Manuelle D'atelier KOMATSU D275A-5R

SEN02158-04
BULLDOZER D275A -5R

SERIAL NUMBERS 35001 and up
SEN02160-04
BULLDOZER 1SHOP MANUAL
D275A-5R
Machine model Serial number

D275A-5R 35001 and up
00 Index and foreword 1

Index
Composition of shop manual .......................................................................................................................... 2
Table of contents ............................................................................................................................................. 4
D275A-5R 1
SEN02160-04 00 Index and foreword
Composition of shop manual 1

The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs SEN02158-04
00 Index and foreword SEN02159-04

Index SEN02160-04 q
Foreword and general information SEN02161-02 q
01 Specification SEN02162-00
Specification and technical data SEN02163-00
10 Structure, function and maintenance standard SEN02164-01

Engine and cooling system SEN02165-00
Power train system, Part 1 SEN02166-00
Undercarriage and frame SEN02168-00
Hydraulic system, Part 1 SEN02169-00
Work equipment SEN02172-01
Cab and its attachments SEN02173-00
Electrical system SEN02174-01
20 Standard value table SEN02175-01

Standard service value table SEN02751-01 q
30 Testing and adjusting SEN02176-01

Testing and adjusting, Part 1 SEN02752-01 q
40 Troubleshooting SEN02177-01
Failure code table and fuse locations SEN02756-01 q
General information on troubleshooting SEN02757-01 q
Troubleshooting by failure and error codes, Part 1 SEN02758-01 q
Troubleshooting by failure and error codes, Part 3 SEN02760-00
2 D275A-5R

Troubleshooting of electrical system (E-mode) SEN02764-01 q
Troubleshooting of hydraulic and mechanical system (H-mode) SEN02765-00
Troubleshooting of engine (S-mode) SEN02766-01 q
50 Disassembly and assembly SEN02178-01

General information on disassembly and assembly SEN03240-01 q
Engine and cooling system SEN03241-01 q
Power train, Part 1 SEN03242-00
Undercarriage and frame, Part 1 SEN03244-01 q
Undercarriage and frame, Part 2 SEN03245-00
Hydraulic system SEN03246-00
Work equipment SEN03247-01 q
Cab and its attachments SEN03248-01 q
Electrical system SEN03249-01 q
90 Diagrams and drawings SEN02179-01

Hydraulic diagrams and drawings SEN02180-00
Electrical diagrams and drawings SEN02181-01
D275A-5R 3
Table of contents 1
00 Index and foreword
Index SEN02160-04
Composition of shop manual....................................................................................................... 2
Table of contents ......................................................................................................................... 4
Foreword and general information SEN02161-02

Safety notice................................................................................................................................ 2
How to read the shop manual ..................................................................................................... 7
Explanation of terms for maintenance standard.......................................................................... 9
Handling of electric equipment and hydraulic component........................................................... 11
Handling of connectors newly used for engines.......................................................................... 20
How to read electric wire code .................................................................................................... 23
Precautions when carrying out operation .................................................................................... 26
Method of disassembling and connecting push-pull type coupler ............................................... 29
Standard tightening torque table ................................................................................................. 32
Conversion table ......................................................................................................................... 36
01 Specification
Specification and technical data SEN02163-00
Specefication dimension drawings .............................................................................................. 2
Specifications .............................................................................................................................. 3
Weight table ................................................................................................................................ 9
Table of fuel, coolant and lubricants ............................................................................................ 11
10 Structure, function and maintenance standard

Engine mount .............................................................................................................................. 2
Cooling system............................................................................................................................ 4
Cooling fan pump ........................................................................................................................ 6
Cooling fan motor ........................................................................................................................ 14
Power train .................................................................................................................................. 2
Overall drawing of power train unit.............................................................................................. 4
Power train hydraulic piping drawing........................................................................................... 8
Damper, universal joint................................................................................................................ 10
Torque converter, PTO ................................................................................................................ 12
Torque converter ......................................................................................................................... 16
Scavenging pump........................................................................................................................ 19
Transmission control ................................................................................................................... 20
Transmission ............................................................................................................................... 22
Tranmission ECMV...................................................................................................................... 36
Main relief valve and torque convertor relif valve ........................................................................ 42
Power train pump, steering lubrication pump .............................................................................. 45
Lubrication relief valve................................................................................................................. 46
Steering, brake control ................................................................................................................ 2
Bevel gear shaft, steering clutch and brake ................................................................................ 4
Steering control valve .................................................................................................................. 14
Steering clutch ECMV ................................................................................................................. 16
Steering brake ECMV.................................................................................................................. 17
Parking brake valve..................................................................................................................... 24
Sudden brake prevention valve................................................................................................... 25
Final drive.................................................................................................................................... 26
Sprocket ...................................................................................................................................... 32
4 D275A-5R
Undercarriage and frame SEN02168-00

Track frame ................................................................................................................................. 2
Recoil spring ............................................................................................................................... 4
Idler ............................................................................................................................................. 6
Track roller .................................................................................................................................. 8
Track roller bogie......................................................................................................................... 10
Carrier roller ................................................................................................................................ 12
Track shoe................................................................................................................................... 14
Main frame .................................................................................................................................. 16
Suspension ................................................................................................................................. 18
Work equipment hydraulic piping diagram .................................................................................. 2
PPC control piping diagram ........................................................................................................ 6
Work equipment control .............................................................................................................. 8
Hydraulic tank ............................................................................................................................. 10
Work equipment pump ................................................................................................................ 12
Control valve ............................................................................................................................... 2
Operation of control valve ........................................................................................................... 12
Self pressure reducing valve....................................................................................................... 29
PPC valve ................................................................................................................................... 2
PCCS lever ................................................................................................................................. 14
PPC lock valve ............................................................................................................................ 17
Work equipment cylinder............................................................................................................. 18
Piston valve................................................................................................................................. 21
Quick drop valve ......................................................................................................................... 22
Pin puller switch .......................................................................................................................... 23
Pin puller solenoid valve ............................................................................................................. 24
Blade control knob ...................................................................................................................... 26
Pitch, dual tilt solenoid valve ....................................................................................................... 27
Accumulator ................................................................................................................................ 28
Cylinder stay ............................................................................................................................... 2
Blade ........................................................................................................................................... 4
Ripper.......................................................................................................................................... 10
Cab mount................................................................................................................................... 2
Cab.............................................................................................................................................. 3
Air conditioner ............................................................................................................................. 5
Engine control system................................................................................................................. 2
CRI engine control system .......................................................................................................... 12
Monitor system............................................................................................................................ 14
Machine monitor.......................................................................................................................... 16
Mode selection system................................................................................................................ 32
Electrical equipment.................................................................................................................... 36
Palm command control system ................................................................................................... 38
Sensors ....................................................................................................................................... 40
KOMTRAX terminal system ........................................................................................................ 44
20 Standard value table

Standard service value table SEN02751-01
Standard value table for engine .................................................................................................. 2
Standard value table for machine................................................................................................ 3
D275A-5R 5
30 Testing and adjusting

Testing and adjusting, Part 1 SEN02752-01
Tools for testing, adjusting, and troubleshooting ......................................................................... 3
Testing engine speed .................................................................................................................. 7
Testing intake air pressure (Boost pressure) ............................................................................... 10
Testing exhaust temperature ....................................................................................................... 12
Testing exhaust gas color............................................................................................................ 14
Adjusting valve clearance............................................................................................................ 16
Testing compression pressure..................................................................................................... 18
Testing blow-by pressure............................................................................................................. 20
Testing engine oil pressure.......................................................................................................... 21
Handling of fuel system devices.................................................................................................. 22
Releasing residual pressure from fuel system ............................................................................ 22
Testing fuel pressure ................................................................................................................... 23
Testing fuel return rate and fuel leakage ..................................................................................... 24
Bleeding air from fuel circuit ........................................................................................................ 28
Testing fuel circuit for leakage ..................................................................................................... 30
Testing and adjusting alternator belt tension ............................................................................... 31
Testing and adjusting air conditioner compressor belt ................................................................ 32
Testing fan speed ........................................................................................................................ 33
Testing fan circuit oil pressure ..................................................................................................... 34
Bleeding air from fan pump ......................................................................................................... 35
Adjusting fuel control dial and decelerator pedal......................................................................... 36
Testing power train oil pressure................................................................................................... 3
Adjusting transmission speed sensor.......................................................................................... 12
Simple method of testing brake performance.............................................................................. 13
Adjusting brake pedal and parking brake lever ........................................................................... 14
Adjusting PCCS lever console position ....................................................................................... 17
Emergency escape method when power train has trouble ......................................................... 18
Adjusting clearance of idler ......................................................................................................... 21
Inspecting wear of sprocket......................................................................................................... 21
Testing and adjusting track shoe tension .................................................................................... 22
Testing and adjusting work equipment oil pressure..................................................................... 23
Testing control circuit main pressure ........................................................................................... 27
Testing PPC valve output pressure ............................................................................................. 28
Adjusting play of PPC valve ........................................................................................................ 30
Testing outlet pressure of ripper pin puller solenoid valve........................................................... 31
Testing parts which cause hydraulic drift of blade and ripper ...................................................... 32
Testing internal leakage of work equipment cylinder................................................................... 33
Releasing residual pressure from work equipment cylinder........................................................ 34
Bleeding air from work equipment cylinder ................................................................................. 34
Adjusting ripper lever position ..................................................................................................... 35
Adjusting work equipment lock lever ........................................................................................... 36
Adjusting blade............................................................................................................................ 37
Testing and adjusting operator's cab ........................................................................................... 41
Special functions of machine monitor (EMMS)............................................................................ 2
Adjustment method when controller has been replaced ............................................................. 2
Method of starting use of KOMTRAX terminal ............................................................................ 4
Indication by KOMTRAX terminal lamps ..................................................................................... 7
Preparation work for troubleshooting for electric system ............................................................ 10
Handling of optional devices ....................................................................................................... 13
Pm Clinic ..................................................................................................................................... 14
6 D275A-5R
40 Troubleshooting
Failure code table and fuse locations SEN02756-01
Failure codes table ...................................................................................................................... 2
Fuse locations ............................................................................................................................. 10
General information on troubleshooting SEN02757-01
Points to remember when troubleshooting.................................................................................. 2
Sequence of events in troubleshooting ....................................................................................... 3
Check before troubleshooting ..................................................................................................... 4
Classification and procedures for troubleshooting ...................................................................... 5
Contents of troubleshooting table................................................................................................ 8
Connection table for connector pin numbers .............................................................................. 10
T-branch box and T-branch adapter table ................................................................................... 46
Failure code [1500L0] Transmission clutch dual engagement .................................................... 3
Failure code [15SAL1] Forward clutch oil pressure 1 ................................................................. 4
Failure code [15SALH] Forward clutch oil pressure 2................................................................. 6
Failure code [15SBL1] Reverse clutch oil pressure 1 ................................................................. 8
Failure code [15SBLH] Reverse clutch oil pressure 2................................................................. 10
Failure code [15SEL1] 1st clutch oil pressure 1.......................................................................... 12
Failure code [15SELH] 1st clutch oil pressure 2 ......................................................................... 13
Failure code [15SFL1] 2nd clutch oil pressure 1......................................................................... 14
Failure code [15SFLH] 2nd clutch oil pressure 2 ........................................................................ 15
Failure code [15SGL1] 3rd clutch oil pressure 1 ......................................................................... 16
Failure code [15SGLH] 3rd clutch oil pressure 2 ........................................................................ 17
Failure code [2201L1] Right steering clutch oil pressure 1 ......................................................... 18
Failure code [2201LH] Right steering clutch oil pressure 2......................................................... 20
Failure code [2202L1] Left steering clutch oil pressure 1............................................................ 22
Failure code [2202LH] Left steering clutch oil pressure 2 ........................................................... 24
Failure code [2300NR] Brake thermal load ................................................................................. 26
Failure code [2301L1] Right steering brake oil pressure 1.......................................................... 28
Failure code [2301LH] Right steering brake oil pressure 2 ......................................................... 30
Failure code [2301NR] Right steering brake thermal load .......................................................... 32
Failure code [2302L1] Left steering brake oil pressure 1 ............................................................ 34
Failure code [2302LH] Left steering brake oil pressure 2 ........................................................... 36
Failure code [2302NR] Left steering brake thermal load............................................................. 38
Failure code [6001ZK] Failure code for design ........................................................................... 38
Failure code [A000NS] Engine overheat..................................................................................... 39
Failure code [AA10NX] Air cleaner clogging ............................................................................... 40
Failure code [AB00MA] Battery charge abnormal....................................................................... 42
Failure code [B@BAZG] Eng oil press low ................................................................................. 44
Failure code [B@BAZK] Eng oil level low ................................................................................... 45
Failure code [B@BCNS] Eng coolant overheat .......................................................................... 46
Failure code [B@BCZK] Radiator coolant level low.................................................................... 46
Failure code [B@BEBF] Water gets mixed with fuel ................................................................... 47
Failure code [B@BFZK] Fuel level abnormal reduction .............................................................. 47
Failure code [B@CENS] Torque converter oil overheat.............................................................. 48
Failure code [B@CHZG] HSS charge oil pressure reduction ..................................................... 49
Failure code [B@CHZK] Power train oil level reduction.............................................................. 49
Failure code [B@GAZK] Battery electrolyte level reduction........................................................ 50
Failure code [B@HANS] Hyd oil overheat .................................................................................. 50
Failure code [B@HAZK] Hydraulic oil level reduction ................................................................. 51
Failure code [CA111] EMC critical internal failure ....................................................................... 4
Failure code [CA115] Eng Ne and Bkup speed sens error ......................................................... 6
Failure code [CA122] Chg air (boost) press sensor high error.................................................... 8
Failure code [CA123] Chg air (boost) press sensor low error ..................................................... 10
Failure code [CA131] Throttle sensor high error ......................................................................... 12
D275A-5R 7
Failure code [CA132] Throttle sensor low error........................................................................... 14

Failure code [CA135] End oil press sensor high error................................................................. 16
Failure code [CA141] Eng oil press sensor low error .................................................................. 18
Failure code [CA144] Coolant temp sens high error ................................................................... 20
Failure code [CA145] Coolant temp sens low error..................................................................... 22
Failure code [CA153] Chg air (boost) temp sensor high error..................................................... 24
Failure code [CA154] Chg air (boost) temp sensor low error ...................................................... 26
Failure code [CA187] Sens supply 2 volt low error ..................................................................... 26
Failure code [CA221] Ambient press sens high error.................................................................. 28
Failure code [CA222] Ambient press sens low error ................................................................... 30
Failure code [CA227] Sens supply 2 volt high error .................................................................... 32
Failure code [CA234] Eng overspeed ......................................................................................... 34
Failure code [CA238] Ne speed sens supply volt error ............................................................... 36
Failure code [CA263] Fuel temp sensor high error ..................................................................... 38
Failure code [CA265] Fuel temp sensor low error....................................................................... 40
Failure code [CA271] PCV1 short error....................................................................................... 41
Failure code [CA272] PCV1 open error....................................................................................... 42
Failure code [CA273] PCV2 short error....................................................................................... 43
Failure code [CA274] PCV2 open error....................................................................................... 44
Failure code [CA322] Inj #1 open/short error .............................................................................. 45
Failure code [CA342] Calibration code incompatibility ................................................................ 51
Failure code [CA351] Injectors drive circuit error ........................................................................ 52
Failure code [CA352] Sens supply 1 volt low error ..................................................................... 54
Failure code [CA386] Sens supply 1 volt high error .................................................................... 56
Failure code [CA441] Battery voltage low error........................................................................... 58
Failure code [CA442] Battery voltage high error ......................................................................... 58
Failure code [CA449] Rail press very high error ......................................................................... 59
Failure code [CA451] Rail press sensor high error ..................................................................... 60
Failure code [CA452] Rail press sensor low error....................................................................... 62
Failure code [CA553] Rail press high error ................................................................................. 62
Failure code [CA554] Rail press sensor in range error ............................................................... 63
Failure code [CA559] No-pressure feed by supply pump 1......................................................... 64
Failure code [CA689] Eng Ne speed sensor error ...................................................................... 68
Failure code [CA731] Eng Bkup speed sens phase error ........................................................... 3
Failure code [CA757] All continuous data lost error .................................................................... 3
Failure code [CA778] Eng Bkup speed sensor error................................................................... 4
Failure code [CA1633] KOMNET datalink timeout error ............................................................. 6
Failure code [CA2185] Throt sens sup volt high error................................................................. 8
Failure code [CA2186] Throt sens sup volt low error .................................................................. 10
Failure code [CA2249] No-pressure feed by supply pump 2....................................................... 10
Failure code [CA2555] Intake air heater relay open error ........................................................... 11
Failure code [CA2556] Intake air heater relay short error ........................................................... 12
Failure code [D110KA] Battery relay holding disconnection........................................................ 14
Failure code [D110KB] Battery relay drive short circuit ............................................................... 16
Failure code [D130KA] Neutral safety relay disconnection ......................................................... 18
Failure code [D130KB] Neutral safety relay short circuit............................................................. 20
Failure code [D161KA] Back-up alarm relay disconnection ........................................................ 22
Failure code [D161KB] Back-up alarm relay short circuit............................................................ 24
Failure code [D190KA] Engine controller ACC signal cut relay................................................... 26
Failure code [D190KB] Engine controller ACC signal cut relay short.......................................... 28
Failure code [D811KR] KOMTRAX controller CAN defective communication ............................ 30
Failure code [DAFRKR] Machine monitor CAN communication defective communication......... 32
8 D275A-5R

Failure code [DAQ0KT] Transmission controller internal abnormality......................................... 3
Failure code [DAQ1KK] Transmission controller main source voltage reduction ........................ 4
Failure code [DAQ2KK] Transmission controller load voltage reduction..................................... 6
Failure code [DAQ5KK] Transmission controller sensor 5 V power source (1)
power supply source voltage reduction................................................................................ 8
Failure code [DAQ6KK] Transmission controller sensor 24 V power supply source
voltage reduction.................................................................................................................. 10
Failure code [DAQ7KK] Transmission controller sensor 5 V power supply source (2)
power source voltage reduction ........................................................................................... 11
Failure code [DAQ9KQ] Transmission controller type collation
(Type select signal inconsistency) ....................................................................................... 12
Failure code [DAQRKR] Transmission controller CAN defective communication
(Abnormality in objective component system) ..................................................................... 14
Failure code [DAQSKR] Transmission controller S-NET defective communication
Failure code [DB2RKR] Engine controller CAN defective communication.................................. 18
Failure code [DB30KT] Steering controller abnormality in controller........................................... 20
Failure code [DB31KK] Steering controller main power supply source voltage reduction .......... 22
Failure code [DB32KK] Load power source of steering controller power source
voltage drop ......................................................................................................................... 24
Failure code [DB35KK] Steering controller sensor 5 V power source (1)
power source voltage drop................................................................................................... 26
Failure code [DB36KK] Steering controller sensor 24 V power supply source
voltage reduction.................................................................................................................. 28
power source voltage drop................................................................................................... 30
Failure code [DB39KQ] Steering controller type collation
(Type select signal inconsistency) ....................................................................................... 32
Failure code [DB3RKR] Steering controller CAN defective communication
Failure code [DB3SKR] Steering controller S-NET defective communication
Failure code [DD12KA] Shift up switch disconnection ................................................................ 38
Failure code [DD12KB] Shift up switch short circuit .................................................................... 40
Failure code [DD13KA] Shift down switch disconnection............................................................ 42
Failure code [DD13KB] Shift down switch short circuit ............................................................... 44
Failure code [DD14KA] Parking brake lever switch disconnection ............................................. 46
Failure code [DD14KB] Parking brake lever switch short circuit ................................................. 48
Failure code [DDB9L4] Reverse switch disagreement................................................................ 50
Failure code [DDK3L4] Forward switch disagreement................................................................ 51
Failure code [DDK5KA] Gearshift switch disconnection ............................................................. 52
Failure code [DDK5KB] Gearshift switch short circuit ................................................................. 53
Failure code [DDN7KA] Blade pitch switch disconnection .......................................................... 54
Failure code [DDN7KB] Blade pitch switch short circuit.............................................................. 56
Failure code [DDN9KA] Blade tilt switch disconnection .............................................................. 58
Failure code [DDN9KB] Blade tilt switch short circuit.................................................................. 60
Failure code [DDNBLD] Ripper lift raise oil pressure switch is kept ON for long time................. 62
Failure code [DDNCLD] Ripper lift lower oil pressure switch is kept ON for long time................ 63
Failure code [DDNDLD] Ripper lift tilt-in oil pressure switch is kept ON for long time................. 64
Failure code [DDQ2KA] Parking brake lever switch disconnection............................................. 66
Failure code [DDQ2KB] Parking brake lever switch short circuit ................................................ 68
Failure code [DDQ2L4] Parking brake lever switch disagreement.............................................. 70
Failure code [DDT5KA] Neutral switch disconnection................................................................. 71
Failure code [DDT5KB] Neutral switch short circuit .................................................................... 72
Failure code [DDT5KQ] Lever specification selection (Model selection signal disagreement) ... 73
Failure code [DGS1KX] Hydraulic oil temperature sensor input signal is out of normal range ... 74
D275A-5R 9

Failure code [DGT1KA] Power train oil temp sensor disconnection ............................................ 4
Failure code [DGT1KX] Power train oil temp sensor out of input signal range ........................... 6
Failure code [DH21KB] Work equipment pump oil pressure sensor short circuit........................ 8
Failure code [DH22KA] Work equipment pump oil pressure sensor disconnection .................... 10
Failure code [DH22KB] Work equipment pump oil pressure sensor short circuit........................ 12
Failure code [DK10KA] Fuel control dial disconnection .............................................................. 14
Failure code [DK10KB] Fuel control dial short circuit .................................................................. 16
Failure code [DK30KA] Steering potentiometer (1) disconnection .............................................. 18
Failure code [DK30KB] Steering potentiometer (1) short circuit.................................................. 20
Failure code [DK30KX] Steering potentiometer (1) out of input signal range.............................. 22
Failure code [DK30KZ] Steering potentiometer (1) disconnection or short circuit....................... 23
Failure code [DK30L8] Steering potentiometer (1) analog signals do not agree......................... 24
Failure code [DK31KA] Steering potentiometer (2) disconnection .............................................. 26
Failure code [DK31KB] Steering potentiometer (2) short circuit.................................................. 28
Failure code [DK40KA] Brake potentiometer disconnection ....................................................... 30
Failure code [DK40KB] Brake potentiometer short circuit ........................................................... 32
Failure code [DK55KX] Directional potentiometer out of input signal range ............................... 34
Failure code [DK55KZ] Directional potentiometer disconnection or short circuit ........................ 35
Failure code [DK55L8] Directional potentiometer analog signals do not agree .......................... 36
Failure code [DK56KA] F-R potentiometer (1) disconnection ..................................................... 38
Failure code [DK56KB] F-R potentiometer (1) short circuit ......................................................... 40
Failure code [DK57KA] F-R potentiometer (2) disconnection ..................................................... 42
Failure code [DK57KB] F-R potentiometer (2) short circuit ......................................................... 44
Failure code [DK60KA] Acceleration sensor disconnection ........................................................ 46
Failure code [DK60KB] Acceleration sensor short circuit............................................................ 48
Failure code [DKH1KA] Pitch angle sensor disconnection.......................................................... 50
Failure code [DKH1KB] Pitch angle sensor short circuit ............................................................. 52
Failure code [DKH1KX] Pitch angle sensor out of input signal range ......................................... 54
Failure code [DLT3KA] Transmission out-speed sensor disconnection ...................................... 56
Failure code [DLT3KB] Transmission out-speed sensor abnormal ............................................. 58
Failure code [DV00KB] Caution buzzer short circuit ................................................................... 59
Failure code [DW59KA] Blade dual selector solenoid disconnection.......................................... 60
Failure code [DW59KB] Blade dual selector solenoid short circuit ............................................. 62
Failure code [DW59KY] Blade dual selector solenoid hot short.................................................. 64
Failure code [DW5AKA] Blade pitch selector solenoid disconnection......................................... 65
Failure code [DW5AKB] Blade pitch selector solenoid short circuit ............................................ 66
Failure code [DW5AKY] Blade pitch selection solenoid hot short circuit..................................... 68
Failure code [DW7BKA] Fan rev EPC disconnection.................................................................. 3
Failure code [DW7BKB] Fan rev EPC short circuit ..................................................................... 4
Failure code [DW7BKY] Fan reverse solenoid hot short circuit .................................................. 5
Failure code [DWN3KA] Sudden stop prevention solenoid disconnection.................................. 6
Failure code [DWN3KB] Sudden stop prevention solenoid short circuit ..................................... 8
Failure code [DWN3KY] Sudden stop prevention solenoid hot short circuit ............................... 10
Failure code [DWN5KA] Fan pump solenoid disconnection........................................................ 12
Failure code [DWN5KB] Fan pump solenoid short circuit ........................................................... 14
Failure code [DWN5KY] Fan pump solenoid hot short circuit ..................................................... 16
Failure code [DXH4KA] 1st clutch ECMV disconnection............................................................. 18
Failure code [DXH4KB] 1st clutch ECMV short circuit ................................................................ 20
Failure code [DXH4KY] 1st clutch ECMV hot short circuit .......................................................... 22
Failure code [DXH5KA] 2nd clutch ECMV disconnection ........................................................... 24
Failure code [DXH5KB] 2nd clutch ECMV short circuit ............................................................... 26
Failure code [DXH5KY] 2nd clutch ECMV hot short circuit ......................................................... 28
Failure code [DXH6KA] 3rd clutch ECMV disconnection ............................................................ 30
Failure code [DXH6KB] 3rd clutch ECMV short circuit................................................................ 32
Failure code [DXH6KY] 3rd clutch ECMV hot short circuit.......................................................... 34
Failure code [DXH7KA] Reverse clutch ECMV disconnection .................................................... 36
10 D275A-5R
Failure code [DXH7KB] Reverse clutch ECMV short circuit ....................................................... 38

Failure code [DXH7KY] R clutch ECMV hot short circuit ............................................................ 40
Failure code [DXH8KA] Forward clutch ECMV disconnection .................................................... 42
Failure code [DXH8KB] Forward clutch ECMV short circuit........................................................ 44
Failure code [DXH8KY] F clutch ECMV hot short circuit............................................................. 46
Failure code [DXH9KA] Right steering clutch ECMV disconnection ........................................... 48
Failure code [DXH9KB] Right steering clutch ECMV short circuit............................................... 50
Failure code [DXH9KY] Right steering clutch ECMV hot short ................................................... 52
Failure code [DXHAKA] Left steering clutch ECMV disconnection ............................................. 54
Failure code [DXHAKB] Left steering clutch ECMV short circuit................................................. 56
Failure code [DXHAKY] Left steering clutch ECMV hot short ..................................................... 58
Failure code [DXHBKA] Right brake ECMV disconnection......................................................... 60
Failure code [DXHBKB] Right brake ECMV short circuit ............................................................ 62
Failure code [DXHBKY] Right brake ECMV hot short circuit ...................................................... 64
Failure code [DXHCKA] Left brake ECMV disconnection ........................................................... 66
Failure code [DXHCKB] Left brake ECMV short circuit............................................................... 68
Failure code [DXHCKY] Left brake ECMV hot short circuit......................................................... 70
Troubleshooting of electrical system (E-mode) SEN02764-01
Information in troubleshooting table ............................................................................................ 3
E-1 The engine does not start ..................................................................................................... 4
E-2 The preheater does not operate (Manual preheating function) ............................................ 7
E-3 The ripper pin puller cylinder does not operate .................................................................... 10
E-4 The machine monitor does not come on at all when the starting switch is turned ON ......... 12
E-5 When the starting switch is turned ON, the machine monitor completely remains lighted
and does not go out ............................................................................................................. 14
E-6 When the starting switch is turned ON, the basic check items flash .................................... 15
E-7 While the engine is operating, any caution item flashes....................................................... 16
E-8 While the engine is operating, the emergency warning item flashes.................................... 19
E-9 While the preheater is operating, the preheating pilot lamp does not come on.................... 24
E-10 At the selecting time of dual tilt, the dual/single tilt selector lamp does not come on
(Dual tilt-mounted machine)................................................................................................. 26
E-11 The engine coolant temperature gauge does not indicate normally ................................... 27
E-12 Indication of the power train (torque converter) temperature gauge is abnormal............... 28
E-13 The hydraulic oil temperature gauge does not indicate normally ....................................... 30
E-14 Indication of the fuel gauge is abnormal............................................................................. 31
E-15 Indications of gear speed and engine speed are abnormal................................................ 32
E-16 Indication of the shift mode service meter is abnormal ...................................................... 32
E-17 The switch module cannot be operated.............................................................................. 33
E-18 The warning lamp does not flash or does not go out.......................................................... 34
E-19 The alarm buzzer does not sound or does not stop ........................................................... 35
E-20 Auto shift down is not possible or is not released............................................................... 36
E-21 The alarm buzzer cannot be cancelled............................................................................... 37
E-22 The operator mode cannot be operated ............................................................................. 38
E-23 The service mode cannot be operated ............................................................................... 40
E-24 The back-up alarm does not sound .................................................................................... 42
E-25 The night light, the headlamp, the working lamp and the rear lamp on the panel
do not come on .................................................................................................................... 44
E-26 The air conditioner does not operate.................................................................................. 50
E-27 KOMTRAX system does not operate normally................................................................... 56
E-28 Fan does not reverse.......................................................................................................... 58
E-29 Gear cannot be shifted ....................................................................................................... 60
E-30 Electric priming pump does not operate or does not stop automatically ............................ 62
Troubleshooting of hydraulic and mechanical system (H-mode) SEN02765-00
Information in troubleshooting table ............................................................................................ 3
H-1 No travel power (No drawbar pull)........................................................................................ 4
H-2 Machine does not move (At 2nd or 3rd speed) .................................................................... 5
H-3 Machine does not move in any speed range........................................................................ 6
D275A-5R 11
H-4 Machine travels only in one direction forward or in reverse ................................................. 7

H-5 When gear is shifted or travel direction is changed, large time lag is made......................... 8
H-6 Steering is not possible......................................................................................................... 9
H-7 Steering is possible only on one side ................................................................................... 10
H-8 Steering overrun occurs........................................................................................................ 11
H-9 Brake does not work............................................................................................................. 12
H-10 Overheat of power train oil temperature ............................................................................. 13
H-11 All work equipment speeds are slow .................................................................................. 14
H-12 Work equipment does not move......................................................................................... 15
H-13 Blade lift speed is slow or lacks power ............................................................................... 16
H-14 Blade tilt speed is slow or lacks power ............................................................................... 17
H-15 Ripper lift speed is slow or lacks power.............................................................................. 18
H-16 Ripper tilt speed is slow or lacks power.............................................................................. 19
H-17 Excessive hydraulic drift of blade lift................................................................................... 20
H-18 Excessive hydraulic drift of blade tilt................................................................................... 21
H-19 Excessive hydraulic drift of ripper lift .................................................................................. 22
H-20 Ripper pin puller cylinder does not work (Giant ripper attachment machine) ..................... 23
H-21 Blade pitch does not work (Dual tilt attachment machine).................................................. 24
H-22 Abnormal sound comes out from around work equipment pump ....................................... 25
H-23 Fan speed is abnormal
(Sound and/or vibration of fan are/is abnormally large or engine overheats) ...................... 26
Troubleshooting of engine (S-mode) SEN02766-01
Method of using troubleshooting chart ........................................................................................ 3
S-1 Starting performance of engine is poor................................................................................. 6
S-2 Engine does not start............................................................................................................ 7
S-3 Engine does not pick up smoothly ........................................................................................ 10
S-4 Engine stops during operation .............................................................................................. 11
S-5 Engine does not rotate smoothly .......................................................................................... 12
S-6 Engine lack output (or lacks power)...................................................................................... 13
S-7 Exhaust gas is black (incomplete combustion)..................................................................... 14
S-8 Oil consumption is excessive (or exhaust gas is blue) ......................................................... 15
S-9 Oil becomes dirty quickly ...................................................................................................... 16
S-10 Fuel consumption is excessive ........................................................................................... 17
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).................................. 18
S-12 Oil pressure drops .............................................................................................................. 19
S-13 Oil level rises (Entry of coolant or fuel) ............................................................................... 20
S-14 Coolant temperature becomes too high (Overheating)....................................................... 21
S-15 Abnormal noise is made ..................................................................................................... 22
S-16 Vibration is excessive ......................................................................................................... 23
S-17 Air cannot be bled from fuel circuit ..................................................................................... 24
50 Disassembly and assembly

General information on disassembly and assembly SEN03240-01
How to read this manual.............................................................................................................. 2
Coating materials list ................................................................................................................... 4
Special tool list............................................................................................................................. 7
Sketchs of special tools............................................................................................................... 15
Removal and installation of fuel supply pump assembly ............................................................. 2
Removal and installation of fuel injector assembly...................................................................... 7
Removal and installation of cylinder head assembly................................................................... 12
Removal and installation of engine front seal.............................................................................. 23
Removal and installation of engine rear seal .............................................................................. 27
Removal and installation of engine assembly ............................................................................. 31
Removal and installation of radiator assembly
(including hydraulic oil cooler assembly and aftercooler assembly) .................................... 36
Removal and installation of hydraulic oil cooler assembly .......................................................... 39
12 D275A-5R
Removal and installation of aftercooler assembly ....................................................................... 41

Removal and installation of radiator guard assembly ................................................................. 44
Removal and installation of fuel tank assembly .......................................................................... 49
Removal and installation of engine hood assembly .................................................................... 51
Removal and installation of fan drive assembly .......................................................................... 53
Removal and installation of fan motor assembly......................................................................... 55
Removal and installation of damper assembly............................................................................ 2
Disassembly and assembly of damper assembly ....................................................................... 5
Removal and installation of power train unit assembly ............................................................... 10
Disconnection and connection of power train unit assembly ...................................................... 14
Disassembly and assembly of PTO assembly ............................................................................ 24
Disassembly and assembly of torque converter assembly ......................................................... 31
Disassembly and assembly of torqflow transmission assembly.................................................. 36
Removal and installation of scavenging pump............................................................................ 2
Disassembly and assembly of steering case assembly .............................................................. 3
Removal and installation of final drive assembly ........................................................................ 18
Disassembly and assembly of final drive assembly .................................................................... 20
Removal and installation of track frame assembly ...................................................................... 2
Removal and installation of recoil spring assembly .................................................................... 6
Disassembly and assembly of recoil spring assembly ................................................................ 10
Removal and installation of idler assembly ................................................................................. 12
Disassembly and assembly of idler assembly............................................................................. 13
Removal and installation of track roller assembly ....................................................................... 16
Disassembly and assembly of track roller assembly................................................................... 18
Removal and installation of carrier roller assembly..................................................................... 21
Disassembly and assembly of carrier roller assembly ................................................................ 22
Removal and installation of 1st bogie assembly ......................................................................... 25
Removal and installation of 2nd, 3rd and 4th bogie assembly .................................................... 31
Disassembly and assembly of bogie assembly........................................................................... 37
Expanding and installing track shoe assembly............................................................................ 2
Whole disassembly and whole assembly of track shoe assembly.............................................. 5
Removal and installation of pivot shaft assembly........................................................................ 27
Removal and installation of equalizer bar assembly ................................................................... 28
Disassembly and assembly of equalizer bar bushing ................................................................. 31
Hydraulic system SEN03246-00
Removal and installation of work equipment pump assembly .................................................... 2
Removal and installation of power train and steering lubricating oil pump assembly ................. 4
Removal and installation of fan pump assembly ......................................................................... 6
Removal and installation of control valve assembly.................................................................... 8
Disassembly and assembly of work equipment control valve assembly ..................................... 12
Disassembly and assembly of hydraulic cylinder assembly........................................................ 13
Removal and installation of blade assembly ............................................................................... 2
Disassembly and assembly of ripper assembly .......................................................................... 4
Removal and installation of ROPS guard.................................................................................... 2
Removal and installation of operator's cab assembly ................................................................. 3
Removal and installation of operator's cab glass (Stuck glass) .................................................. 5
Removal and installation of air conditioner unit assembly .......................................................... 14
Removal and installation of floor frame assembly....................................................................... 17
D275A-5R 13

Removal and installation of transmission controller assembly .................................................... 2
Removal and installation of steering controller assembly ........................................................... 3
Removal and installation of engine controller assembly ............................................................. 4
Removal and installation of monitor panel assembly .................................................................. 5
90 Diagrams and drawings

Hydraulic diagrams and drawings SEN02180-00
Hydraulic circuit diagram ............................................................................................................. 3
Power train hydraulic circuit diagram .......................................................................................... 5
Electrical diagrams and drawings SEN02181-01
Electrical circuit diagram (1/13) ................................................................................................... 3
Electrical circuit diagram (10/13) ................................................................................................. 21
Electrical circuit diagram for inside cab ...................................................................................... 29
Air conditioner unit electrical circuit diagram ............................................................................... 31
Connectors table and arrangement drawing ............................................................................... 33
14 D275A-5R
D275A-5R 15
D275A-5R Bulldozer
Form No. SEN02160-04
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 06-08 (02)
16 D275A-5R
SEN02161-02
D275A-5R

D275A-5R 35001 and up
00 Index and foreword 1

Foreword and general information
Safety notice ................................................................................................................................................... 2
How to read the shop manual ......................................................................................................................... 7
Explanation of terms for maintenance standard ............................................................................................. 9
Handling of electric equipment and hydraulic component .............................................................................11
Handling of connectors newly used for engines ........................................................................................... 20
How to read electric wire code...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36
D275A-5R 1
Safety notice 1
(Rev. 2008/02)
Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1. General precautions 7) If welding repairs are needed, always

k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before weld in g wo rk , al way s wear wel din g
operating the machine. In addition, gloves, apron, shielding goggles, cap and
read this manual and understand its other clothes suited for welding work.
contents before starting the work. 8) Before starting work, warm up your body
1) Before carrying out any greasing or thoroughly to start work under good condi-
repairs, read all the safety plates stuck to tion.
the machine. For the locations of the 9) Avoid continuing work for long hours and
safety plates and detailed explanation of take rests at proper intervals to keep your
precautions, see the Operation and Main- body in good condition. Take rests in
tenance Manual. specified safe places.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always Safety points
keep the tools and parts in their correct
places. Always keep the work area clean 1 Good arrangement
and make sure that there is no dirt, water, 2 Correct work clothes
or oil on the floor. Smoke only in the areas 3 Following work standard
provided for smoking. Never smoke while
working. 4 Making and checking signs
3) When carrying out any operation, always Prohibition of operation and handling by
5
wear safety shoes and helmet. Do not unlicensed workers
wear loose work clothes, or clothes with 6 Safety check before starting work
buttons missing.
Wearing protective goggles
q Always wear safety glasses when hit- 7
(for cleaning or grinding work)
ting parts with a hammer.
q Always wear safety glasses when Wearing shielding goggles and protectors
8
grinding parts with a grinder, etc. (for welding work)
4) When carrying out any operation with 2 or 9 Good physical condition and preparation
more workers, always agree on the oper- Precautions against work which you are
ating procedure before starting. Always 10
not used to or you are used to too much
inform your fellow workers before starting
any step of the operation. Before starting
work, hang UNDER REPAIR warning
signs in the operator's compartment.
5) Only qualified workers must carry out work
and operation which require license or
qualification.
6) Keep all tools in good condition, learn the
correct way to use them, and use the
proper ones of them. Before starting work,
thoroughly check the tools, machine, fork-
lift, service car, etc.
2 D275A-5R
2. Preparations for work 6) When removing a cover which is under

1) Before adding oil or making any repairs, internal pressure or under pressure from a
park the machine on a hard and level spring, always leave 2 bolts in diagonal
ground, and apply the parking brake and positions. Loosen those bolts gradually
block the wheels or tracks to prevent the and alternately to release the pressure,
machine from moving. and then remove the cover.
2) Before starting work, lower the work 7) When removing components, be careful
equipment (blade, ripper, bucket, etc.) to not to break or damage the electrical wir-
the ground. If this is not possible, insert ing. Damaged wiring may cause electrical
the lock pin or use blocks to prevent the fires.
work equipment from falling. In addition, 8) When removing piping, stop the fuel or oil
be sure to lock all the control levers and from spilling out. If any fuel or oil drips
hang warning signs on them. onto the floor, wipe it up immediately. Fuel
3) When disassembling or assembling, sup- or oil on the floor can cause you to slip
port the machine with blocks, jacks, or and can even start fires.
stands before starting work. 9) As a general rule, do not use gasoline to
4) Remove all mud and oil from the steps or wash parts. Do not use it to clean electri-
other places used to get on and off the cal parts, in particular.
machine. Always use the handrails, lad- 10) Be sure to assemble all parts again in their
ders or steps when getting on or off the original places. Replace any damaged
m a c h i n e . N e v e r j u m p o n o r o ff t h e parts and parts which must not be reused
machine. If it is impossible to use the with new parts. When installing hoses and
handrails, ladders or steps, use a stand to wires, be sure that they will not be dam-
provide safe footing. aged by contact with other parts when the
machine is operated.
3. Precautions during work 11) When installing high pressure hoses,
1) Before disconnecting or removing compo- make sure that they are not twisted. Dam-
nents of the oil, water, or air circuits, first aged tubes are dangerous, so be
release the pressure completely from the extremely careful when installing tubes for
circuit. When removing the oil filler cap, a high pressure circuits. In addition, check
drain plug, or an oil pressure pickup plug, t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
loosen it slowly to prevent the oil from installed.
spurting out. 12) When assembling or installing parts,
2) The coolant and oil in the circuits are hot always tighten them to the specified
when the engine is stopped, so be careful torques. When installing protective parts
not to get scalded. Wait for the oil and such as guards, or parts which vibrate vio-
coolant to cool before carrying out any lently or rotate at high speed, be particu-
work on the oil or water circuits. l a r ly c a r e fu l t o c he c k t h a t t h e y ar e
3) Before starting work, stop the engine. installed correctly.
When working on or around a rotating 13) When aligning 2 holes, never insert your
part, in particular, stop the engine. When fingers or hand. Be careful not to get your
checking the machine without stopping fingers caught in a hole.
the engine (measuring oil pressure, 14) When measuring hydraulic pressure,
revolving speed, temperature, etc.), take check that the measuring tools are cor-
extreme care not to get rolled or caught in rectly assembled.
rotating parts or moving parts. 15) Take care when removing or installing the
4) Before starting work, remove the leads tracks of track-type machines. When
from the battery. Always remove the lead removing the track, the track separates
from the negative (–) terminal first. suddenly, so never let anyone stand at
5) When raising a heavy component (heavier either end of the track.
than 25 kg), use a hoist or crane. Before 16) If the engine is operated for a long time in
starting work, check that the slings (wire a place which is not ventilated well, you
ropes, chains, and hooks) are free from may suffer from gas poisoning. Accord-
damage. Always use slings which have ingly, open the windows and doors to ven-
ample capacity and install them to proper tilate well.
places. Operate the hoist or crane slowly
to prevent the component from hitting any
other part. Do not work with any part still
raised by the hoist or crane.
D275A-5R 3
4. Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is well seen
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling
work.
8) When installing wire ropes to an angular
3) Keep putting on gloves during sling work.
load, apply pads to protect the wire ropes.
(Put on leather gloves, if available.)
If the load is slippery, apply proper mate-
4) Measure the weight of the load by the eye
rial to prevent the wire rope from slipping.
and check its center of gravity.
9) Use the specified eyebolts and fix wire
5) Use proper sling according to the weight
ropes, chains, etc. to them with shackles,
of the load and method of slinging. If too
etc.
thick wire ropes are used to sling a light
10) Apply wire ropes to the middle portion of
load, the load may slip and fall.
the hook.
6) Do not sling a load with 1 wire rope alone.
q Slinging near the tip of the hook may
If it is slung so, it may rotate and may slip
cause the rope to slip off the hook
out of the rope. Install 2 or more wire
during hoisting. The hook has the
ropes symmetrically.
k Slinging with 1 rope may cause
maximum strength at the middle por-
tion.
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60°, as a rule.
Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allow-
able load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes 11) Do not use twisted or kinked wire ropes.
sling a load vertically, up to 19.6 kN {2,000 12) When lifting up a load, observe the follow-
kg} of total weight can be suspended. ing.
This weight is reduced to 9.8 kN {1,000 q Wind in the crane slowly until wire
kg} when the 2 ropes make a hanging ropes are stretched. When settling
angle of 120°. If the 2 ropes sling a 19.6 the wire ropes with the hand, do not
kN {2,000 kg} load at a lifting angle of grasp them but press them from
150°, each of them is subjected to a force above. If you grasp them, your fingers
as large as 39.2 kN {4,000 kg}. may be caught.
q After the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.
4 D275A-5R
q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over 16 22.6 2.3
wind stop device, electric shock preven- 18 28.6 2.9
tion earth leakage breaker, crane collision 20 35.3 3.6
prevention device, and power application
25 55.3 5.6
warning lamp, and check safety.
30 79.6 8.1
2) Observe the signs for sling work.
40 141.6 14.4
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
D275A-5R 5
8. Precautions for disconnecting and con- a Example of O-ring (Fitted to every joint of
necting hoses and tubes in air conditioner hoses and tubes)
circuit
1) Disconnection
k For the environment, the air condi-
tioner of this machine uses the
refrigerant (air conditioner gas:
R134a) which has fewer factors of
the depletion of the ozone layer.
However, it does not mean that you
may discharge the refrigerant into
the atmosphere as it is. Be sure to
recover the refrigerant when dis-
connecting the refrigerant gas cir-
cuit and then reuse it.
a Ask professional traders for collecting a For tightening torque, see the precautions for
and filling operation of refrigerant installation in each section of "Disassembly
(R134a). and assembly".
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas gets in your
eyes or contacts your skin, you
may lose your sight and your skin
may be frozen. Accordingly, put
on safety glasses, safety gloves
and safety clothes when recover-
ing or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.
2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
VA L E O T H E R M A L S Y S T E M S :
ZXL100PG (equivalent to PAG46))
to its O-rings.
6 D275A-5R
How to read the shop manual 1
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
1. Composition of shop manual

This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword

This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard

This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for dis-
assembly and service.
20. Standard value table

This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting

This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly

This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
2. Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
D275A-5R 7
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revised edition mark

When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 …)
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol Item Remarks
k Safety Special safety precautions are necessary when performing work.
Special technical precautions or other precautions for preserving stan-

a Caution
dards are necessary when performing work.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
2 Coat Places to be coated with adhesives, etc. during assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
8 D275A-5R
Explanation of terms for maintenance standard 1

The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the
machine maintenance work. The following terms are used to explain the criteria.
1. Standard size and tolerance

q To be accurate, the finishing size of parts
is a little different from one to another.
q To specify a finishing size of a part, a tem-
porary standard size is set and an allow-
able difference from that size is indicated.
q The above size set temporarily is called
the “standard size” and the range of differ-
ence from the standard size is called the
“tolerance”.
q The tolerance with the symbols of + or – is
indicated on the right side of the standard
size.
Example:
Standard size Tolerance
–0.022
120
–0.126
a The tolerance may be indicated in the text

and a table as [standard size (upper limit
of tolerance/lower limit of tolerance)].
Example) 120 (–0.022/–0.126)
q Usually, the size of a hole and the size of

the shaft to be fitted to that hole are indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
q Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
D275A-5R 9
2. Standard clearance and standard value 5. Clearance limit

q The clearance made when new parts are q Parts can be used until the clearance
assembled is called the “standard clear- between them is increased to a certain
ance“, which is indicated by the range limit. The limit at which those parts cannot
from the minimum clearance to the maxi- be used is called the “clearance limit”.
mum clearance. q If the clearance between the parts
q When some parts are repaired, the clear- exceeds the clearance limit, they must be
ance is generally adjusted to the standard replaced or repaired.
clearance.
q A value of performance and function of 6. Interference limit
new products or equivalent is called the q The allowable maximum interference
“standard value“, which is indicated by a between the hole of a part and the shaft of
range or a target value. another part to be assembled is called the
q When some parts are repaired, the value “interference limit”.
of performance/function is set to the stan- q The interference limit shows the repair
dard value. limit of the part of smaller tolerance.
q If the interference between the parts
3. Standard interference exceeds the interference limit, they must
q When the diameter of a hole of a part be replaced or repaired.
shown in the given standard size and tol-
erance table is smaller than that of the
mating shaft, the difference between those
diameters is called the “interference”.
q The range (A – B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the hole to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the “standard interference”.
q After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.
4. Repair limit and allowable value or allow-

able dimension
q The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the “repair
limit”.
q If a part is worn to the repair limit, it must
be replaced or repaired.
q The performance and function of a prod-
uct lowers while it is used. A value which
the product can be used without causing a
problem is called the “allowable value” or
“allowable dimension”.
q If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.
10 D275A-5R
Handling of electric equipment and hydraulic component 1

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

equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, con-
nectors 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 frequently removed and installed again, so
they are likely to suffer deformation or damage.
For this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2. Main failures occurring in wiring harness

1) Defective contact of connectors (defec-
tive contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female con-
nector, or because one or both of the con-
nectors is deformed or the position is not
correctly aligned, or because there is cor-
rosion or oxidization of the contact sur-
faces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connect-
ing and disconnecting the connector about
10 times.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
D275A-5R 11
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 sol-
dering may be damaged, or the wiring
may be broken.
4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof struc-
ture), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
to splash water over the connector. The
connector is designed to prevent water
from entering, but at the same time, if
water does enter, it is difficult for it to be
drained. Therefore, if water should get into
the connector, the pins will be short-cir-
cuited by the water, so if any water gets in,
immediately dry the connector or take
other appropriate action before passing
electricity through it.
5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating 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 connector, wipe it
off with a dry cloth or blow it dry with com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
12 D275A-5R
3. Removing, installing, and drying connec-

tors and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when discon-
necting.
When disconnecting the connectors,
hold the connectors. For connectors
held by a screw, loosen the screw
fully, then hold the male and female
connectors in each hand and pull
apart. For connectors which have a
lock stopper, press down the stopper
with your thumb and pull the connec-
tors apart.
a Never pull with one hand.
2] When removing from clips

q Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is
installed.
q When removing a connector from a

clip, pull the connector in a parallel
direction to the clip for removing stop-
pers.
a If the connector is twisted up and
down or to the left or right, the
housing may break.
3] Action to take after removing connec-

tors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.
D275A-5R 13
2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
14 D275A-5R
3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
D275A-5R 15
4) Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do
not use high-pressure water or steam
directly on the wiring harness. If water
gets directly on the connector, do as fol-
lows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
oi l a nd wa ter fr om t he c om -
pressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
16 D275A-5R
4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
5. Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.
D275A-5R 17
Points to remember when handling hydraulic equipment

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling
hydraulic equipment, it is necessary to be particularly careful.
1. Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2. Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be checked with special test
equipment.
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4. Do not let any dirt or dust get in during

refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
18 D275A-5R
5. Change hydraulic oil when the temperature

is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.
6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
D275A-5R 19
Handling of connectors newly used for engines 1

a Mainly, following engines are object for follow- 2. Pull lock type (PACKARD-2)
ing connectors. q 95 – 170, 12V140 engine
q 95E-5 q Various temperature sensors
q 107E-1 Example)
q 114E-3 Intake air temperature sensor in
q 125E-5 intake manifold: TIM
q 140E-5 Fuel temperature sensor: TFUEL
q 170E-5 Oil temperature sensor: TOIL
q 12V140E-3 Coolant temperature sensor: TWTR,
etc.
1. Slide lock type Disconnect the connector by pulling lock
(FRAMATOME-3, FRAMATOME-2) (B) (on the wiring harness side) of connec-
q 95 – 170, 12V140 engines tor (2) outward.
q Various pressure sensors and NE
speed sensor
Examples)
Intake air pressure in intake manifold:
PIM (125, 170, 12V140 engines)
Oil pressure sensor: POIL
(125, 170, 12V140 engines)
Oil pressure switch
(95, 107, 114 engines)
Ne speed sensor of flywheel housing:
NE (95 – 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)
Disconnect connector (1) according to the fol-

lowing procedure.
1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connec-
tor (1) toward you.
a Even if lock (L2) is pressed, connec-
tor (1) cannot be pulled out toward
you, if part A does not float. In this
case, float part A with a small screw-
driver while press lock (L2), and then
pull out connector (1) toward you.
20 D275A-5R
3. Push lock type

q 95, 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)
Disconnect connector (3) according to the fol-

lowing procedure.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q 114 engine
q 107, 114 engine

Example)
Intake air pressure/temperature sensor in
intake manifold
(SUMITOMO-04)
3) While pressing lock (D), pull out connector

(4) in the direction of the arrow.
q 107 engine
a If the lock is on the underside, use

flat-head screwdriver [1] since you
cannot insert your fingers.
2) While pressing up lock (C) of the connec-
tor with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
D275A-5R 21
q 95, 125 – 170, 12V140 engine 4. Turn-housing type (Round green connector)
4) While pressing lock (E) of the connector, q 140 engine
pull out connector (5) in the direction of Example)
the arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure in common rail: PFUEL etc. 1) Disconnect connector (6) according to the
(AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
2) Connect the connector according to the

following procedure.
1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of
the arrow until it “clicks”.
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
22 D275A-5R
How to read electric wire code 1

a The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.

Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indi-
cated.)
1. Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
General wiring
wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
automobile Insulator Soft polyvinyl chloride
Heat-resis- Conduc- Annealed copper for elec-
General wiring in extremely
tant low-volt- tor tric appliance
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
D275A-5R 23
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
“f” of nominal No. denotes flexible”.
24 D275A-5R
3. Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
4. Types of circuits and color codes
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
D275A-5R 25
Precautions when carrying out operation 1

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work

q If the coolant contains antifreeze, dispose of it correctly.
q After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
q When draining oil, prepare a container of adequate size to catch the oil.
q Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
q To prevent any excessive force from being applied to the wiring, always hold the connectors when dis-
connecting the connectors. Do not pull the wires.
q Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
q Check the number and thickness of the shims, and keep in a safe place.
q When raising components, be sure to use lifting equipment of ample strength.
q When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
q Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
a Precautions when handling piping during disassembly
Fit the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
Plug (nut end) Sleeve nut (elbow end)
number
02 07376-70210 02789-20210
03 07376-70315 02789-20315
04 07376-70422 02789-20422
05 07376-70522 02789-20522
06 07376-70628 02789-20628
10 07376-71034 07221-21034
12 07376-71234 07221-21234
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
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
26 D275A-5R
2. Precautions when carrying out installation work

q Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 – 3 drops of adhesive.
q 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.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with anti-friction compound (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation

1) Refilling with coolant, oil and grease
q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level.
Run the engine to circulate the coolant through the system. Then check the coolant level
again.
q If the hydraulic equipment has been removed and installed again, add engine oil to the speci-
fied level. Run the engine to circulate the oil through the system. Then check the oil level
again.
q If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
a For details, see Testing and adjusting, “Bleeding air”.
q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
2) Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q For the tightening torque, see “Disassembly and assembly”.
3) Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air
suction and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for
coolant leakage.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
D275A-5R 27
4) Checking muffler and exhaust pipe for damage and looseness

1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for
looseness.
If any bolt or nut is loosened, retighten it.
5) Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly
and assembly”.
28 D275A-5R
Method of disassembling and connecting push-pull type coupler 1

k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
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.
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
D275A-5R 29
Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
contacts contact surface (a) of the hexag-
30 D275A-5R
Type 3
1. Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexag-
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
D275A-5R 31
Standard tightening torque table 1

1. Table of tightening torques for bolts and nuts
a Unless there are special instructions, tighten metric nuts and bolts to the torque below.
a The following table corresponds to the bolts in Fig. A.
Thread diameter of bolt Width across flats Tightening torque

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 6.0 – 7.5
12 19 98 – 123 10.0 – 12.5
14 22 157 – 196 16 – 20
16 24 245 – 309 25 – 31.5
18 27 343 – 427 35 – 43.5
20 30 490 – 608 50 – 62
22 32 662 – 829 67.5 – 84.5
24 36 824 – 1,030 84 – 105
27 41 1,180 – 1,470 120 – 150
30 46 1,520 – 1,910 155 – 195
33 50 1,960 – 2,450 200 – 250
36 55 2,450 – 3,040 250 – 310
39 60 2,890 – 3,630 295 – 370
a The following table corresponds to the bolts in Fig. B.

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
a Fig. A a Fig. B
32 D275A-5R
2. Table of tightening torques for split flange bolts

a Unless there are special instructions, tighten split flange bolts to the torque below.

mm mm Nm kgm
10 14 59 – 74 6.0 – 7.5
12 17 98 – 123 10.0 – 12.5
16 22 235 – 285 23.5 – 29.5
3. Table of tightening torques for O-ring boss piping joints

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

Nominal 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 connec- 128 – 186 {13.0 – 19.0} 157 {16.0}
10,12 33 tor. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1,010 {76.0 – 103} 883 {90.0}
4. Table of tightening torques for O-ring boss plugs

a Unless there are special instructions, tighten O-ring boss plugs to the torque below.
Nominal Thread diameter Width across flats Tightening torque Nm {kgm}

No. mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.81 – 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} 127.4 {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}
D275A-5R 33
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque Nm {kgm} Taper seal Face seal

Nominal Width Nominal No. –
No. of across Thread
Thread size Number of
hose flats Range Target diameter (mm)
(mm) threads, type of
(Reference)
thread
34 – 54 { 3.5 – 5.5} – 9/16-18UN 14.3
02 19 44 { 4.5}
34 – 63 { 3.5 – 6.5} 14 – –
22 54 – 93 { 5.5 – 9.5} 74 { 7.5} – 11/16-16UN 17.5
03
24 59 – 98 { 6.0 – 10.0} 78 { 8.0} 18 – –
04 27 84 – 132 { 8.5 – 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(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 – –
6. Table of tightening torques for face seal joints

a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to
be used for engines etc. to the torque shown in the following table.
a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil
(wetted).
Outer Width Tightening torque Nm {kgm} Face seal

diameter across Nominal No. – Thread diameter
of pipe flats Range Target Number of threads, (mm)
(mm) (mm) type of thread (Reference)
8 19 14 – 16 {1.4 – 1.6} 15 {1.5} 9/16-18UN 14.3
10 22 24 – 27 {2.4 – 2.7} 25.5 {2.6} 11/16-16UN 17.5
12 24 (27) 43 – 47 {4.4 – 4.8} 45 {4.6} 13/16-16UN 20.6
15 (16) 30 (32) 60 – 68 {6.1 – 6.8} 64 {6.5} 1-14UN 25.4
22 (20) 36 90 – 95 {9.2 – 9.7} 92.5 {9.4} 1-3/16-12UN 30.2
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.
7. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —
34 D275A-5R
8. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
Thread size Tightening torque

mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
9. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Thread size Tightening torque

inch Nm kgm
1/16 3±1 0.31 ± 0.10
1/8 8±2 0.81 ± 0.20
1/4 12 ± 2 1.22 ± 0.20
3/8 15 ± 2 1.53 ± 0.20
1/2 24 ± 4 2.45 ± 0.41
3/4 36 ± 5 3.67 ± 0.51
1 60 ± 9 6.12 ± 0.92
D275A-5R 35
Conversion table 1
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
1. Convert 55 mm into inches.

1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a hori-
zontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches (B)

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
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
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
36 D275A-5R
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
Liters to U.S. Gallons

1 l = 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
D275A-5R 37
Liters to U.K. Gallons

1 l = 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 7.699 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
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
38 D275A-5R
kg/cm2 to lb/in2
1 kg/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 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
D275A-5R 39
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade 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 81 177.8
–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 60 140.0 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
40 D275A-5R
D275A-5R 41
D275A-5R Bulldozer
© 2008 KOMATSU
All Rights Reserved
42 D275A-5R
SEN02163-00
D275A-5R

D275A-5R 35001 and up
01 Specification 1
Specification and technical data
Specefication dimension drawings.................................................................................................................. 2
Specifications .................................................................................................................................................. 3
Weight table .................................................................................................................................................... 9
Table of fuel, coolant and lubricants...............................................................................................................11
D275A-5R 1
SEN02163-00 01 Specification
Specefication dimension drawings
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
A mm 9,290 9,625 8,905 9,245
length
Overall 3,915 3,915 3,915 3,915

B height mm
(3,990) (3,990) (3,990) (3,990)
(with ROPS)
Overall 4,300 4,615 4,300 4,615

C mm
width
2 D275A-5R
Specifications
Machine model D275A-5R
Serial number 35001 and up
Machine weight
• Bare tractor 38,180
Weight
kg
• Above with semi U-dozer + variable multi- 50,550
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
Transmission speed ranges
1st speed 3.7

Forward
2nd speed km/h 7.1

3rd speed 11.5
Performance
1st speed 5.2

Reverse
2nd speed km/h 9.4

3rd speed 15.3
Bare tractor
With semi U-dozer + variable multi- 88.26 {0.90}
Ground pressure
shank ripper
With ROPS + cab + air conditioner + 116.70 {1.19}
kPa {kg/cm2}
side cover
With U-dozer + variable multi-shank 118.66 {1.21}
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- 8,905

shank ripper mm
With U-dozer + variable multi-shank 9,245
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 4,615
ripper
To top of exhaust pipe 3,915

To top of air intake duct mm 3,153
(To top of control lever)
D275A-5R 3

Overall height
With cab 3,915

With ROPS canopy mm 3,990
With canopy 3,985
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 SAA6D140E-5
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 x 165

Piston displacement l {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} 204 {150}
Starting motor 24V, 11kW

Alternator 24V, 75A
Battery 12V, 170Ah x 2
Radiator core type Rectangle wave fin
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
4 D275A-5R
Wet, multiple disc clutch type, hydraulic drive type,

Steering clutch hand operated type, interconnected with steering
brake
Power train system
Wet multi-disc type, spring boosted type, hydraulic

Steering brake drive type, foot and hand operation type, clutch link-
age type
Bevel gear shaft Spiral bevel gear type, splash type lubrication
Spur gear 1-stage, planetary gear 1-stage type, spiral

Final drive
bevel gear type, 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 (BAR(3)160)

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

{kg/cm2} Max. discharge pressure: 27.4 {280}
Work equipment pump
l/min/rpm Logical discharge pressure: 256/2,286
Variable in-line pump type
MPa Variable swash plate type: (LPV64)

{kg/cm2} Max. discharge pressure: 18.6 {190}
Cooling fan pump
l/min/rpm Logical discharge pressure: 146/2,286
MPa Fixed swash plate type (LMF110)

Cooling fan motor
{kg/cm2}
Max. allowable working pressure: 18.6 {190}
D275A-5R 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)
6 D275A-5R
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

(from ground level)
Performance
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

(from ground level)
Performance
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 4,615

Blade height mm 1,973
Blade cutting angle deg. 52
Semi U-dozer
Max. tilt mm 1,140

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

U-dozer
Max. pitch angle deg. 6

Max. pitch-back angle deg. 6
D275A-5R 7
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
Weight kg 3,640
Variable giant ripper
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 – Four Switch-Selectable
Max. digging depth mm 1,420
Max. lifting height mm 1,195
8 D275A-5R
Weight table
a This weight table is for reference in handling or transporting components.
Unit: kg
Engine
• Engine assembly 1,850
• Damper assembly 135
• Universal joint 25
• Engine mounting parts (Wiring) 5
Radiator assembly 451

(Including built-in oil cooler)
Aftercooler assembly 49
Hydraulic cooler 25
Fuel tank assembly (When empty) 385
Fuel tank assembly (When full) 1,090
Power train unit assembly 2,290

• Torque converter, PTO assembly 544
• Transmission assembly 645
• Steering clutch and brake assembly 1,015
• Brake valve assembly 70
• Power train filter assembly 23 x 2
• Scavenging pump 19
• Power train, lubricating pump 27
• Work equipment pump 63
• Cooling fan pump 40
• Cooling fan motor 25
Final drive assembly 1,720 x 2

Sprocket teeth (25 x 5) x 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 x 3
• Track roller assembly (Single flange x 1) 149 x 2
• Track roller assembly (Double flange x 1) 161 x 5
• Carrier roller assembly 58 x 2
D275A-5R 9
Unit: kg
Track shoe assembly (610mm width, wet type) 3,405 x 2

Pivot shaft assembly 142 x 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 x 2
• Tilt brace 153 x 1
• Center brace 141 x 2
• Tilt cylinder assembly 230
Semi U-tilt + pitch dozer assembly 6,827

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

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

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

• Shank 500 x 1
• Lift cylinder assembly 184 x 2
• Tilt cylinder assembly 155 x 2
• Pin puller cylinder assembly 7
ROPS assembly (Specification with cab) 605

Cab assembly 455
ROPS canopy 650
Dash board 83
Floor frame assembly 591
Air conditioner assembly (Including air conditioner unit assembly) 87
Operator seat assembly 64
10 D275A-5R
Table of fuel, coolant and lubricants

a For details of the notes (Note 1, Note 2 - - -) in the table, see Operation and Maintenance Manual.
D275A-5R 11
Unit: l
D275A-5R
Refilling points
Specified capacity Refill capacity
Engine oil pan 55 50
Damper case 1.5 1.5
Power train case 150 90
Fainal drive case (each) 40 40
Hydraulic system
270 130
(with blade, without ripper)
Cooling system
110 —
(including reservoir tank)
Fuel tank 840 —
12 D275A-5R
D275A-5R 13
D275A-5R Bulldozer
© 2007 KOMATSU
All Rights Reserved
14 D275A-5R
SEN02165-00
D275A-5R

D275A-5R 35001 and up
10 Structure, function and

maintenance standard 1
Engine and cooling system
Engine mount.................................................................................................................................................. 2
Cooling system ............................................................................................................................................... 4
Cooling fan pump............................................................................................................................................ 6
Cooling fan motor.......................................................................................................................................... 14
D275A-5R 1
SEN02165-00 10 Structure, function and maintenance standard
Engine mount 1
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between bracket size Shaft Hole clearance limit
1
and cushion
–0.100 +0.046 0.100 –
60 0.4 Replace
–0.300 +0.046 0.346
Standard clearance Repair limit
2 Free height of mount rubber
90 84
2 D275A-5R
D275A-5R 3
Cooling system 1
4 D275A-5R
A: Power train oil cooler outlet

B: Power train oil cooler inlet
C: Hydraulic oil cooler inlet
D: Hydraulic oil cooler outlet
1. Hydraulic oil cooler

2. Radiator cap
3. Aftercooler outlet hose
4. Radiator inlet hose
5. Aftercooler inlet hose
6. Radiator
7. Aftercooler
8. Power train oil cooler
9. Radiator outlet hose
10. Drain plug
11. Cooling fan motor
12. Cooling fan
13. Reservoir tank
Specifications
Power train
Radiator Hydraulic oil cooler Aftercooler
oil cooler
Core type Rectangle wave fin PTO-OL J4 Rectangle straight fin
Fin pitch (mm) 8.0/2 — 4.0 8.0/2
Total heat dissipation sur-
41.99 x 3 3.741 8.52 25.82
face (m2)
Cracking pressure of pres- 88.3 ± 14.7
— — —
sure valve (kPa{kg/cm2}) {0.9 ± 0.15}
Cracking pressure of vac- 0 – 4.9
— — —
uum valve (kPa {kg/cm2}) {0 – 0.05}
D275A-5R 5
Cooling fan pump 1

LPV71
P1: Pump discharge port P1C: Pump pressure detection port

PS: Pump suction port PEN: Pump control pressure detection port
PA: Pump control basic pressure PD: Pump drain port
PE: Pump control pressure PD2: Pump drain port
6 D275A-5R
1. Shaft 7. Cylinder block

2. Oil seal 8. Valve plate
3. Case 9. Spring
4. Rocker cam 10. Servo piston
5. Shoe 11. Ball
6. Piston 12. End cap
D275A-5R 7
Function Structure
q The rotation and torque of the engine are q Cylinder block (7) is supported on shaft (1)
transmitted to the shaft of this pump and con- through spline (B). Shaft (1) is supported by
verted into hydraulic energy in this pump. This the front and rear bearings.
pump discharges the pressurized oil according q The end of piston (6) has a spherical hollow
to the load. which is combined with shoe (5). Piston (6)
q The discharge of this pump can be changed by and shoe (5) form a spherical bearing.
changing the swash plate angle in it. q Rocker cam (4) has plane (A). Shoe (5) is kept
pressed against plane (A) and slid circularly.
Rocker cam (4) slides around ball (11).
q Piston (6) in each cylinder of cylinder block (7)
moves relatively in the axial direction.
q Cylinder block (7) rotates relatively against
valve plate (8), sealing the pressurized oil, and
the hydraulic balance is maintained properly.
q The oil in each cylinder of cylinder block (7)
can be sucked and discharged through valve
plate (8).
8 D275A-5R
Operation
1. Operation of pump
q 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 (a) between center line (X) of
rocker cam (4) and the axis of cylinder block
(7) changes. Angle (a) is called the swash
plate angle.
q If angle (a) is made between center line (X) of
rocker cam (7) and the axis of cylinder block
(7), plane (A) works as a cam for shoe (5).
q Accordingly, piston (6) slides inside cylinder
block (7) and a difference is made between
volumes (E) and (F) in cylinder block (7). As a
resurlt, each piston (6) sucks and discharges
oil by (F) – (E).
q In other words, if cylinder block (7) rotates and
the volume of chamber (E) is decreased, the
oil is discharged from chamber (E). On the
other hand, the volume of chamber (F) is
increased and the oil is sucked in chamber (F).
(In the figure, chamber (F) is at the end of the
suction stroke and chamber (E) is at the end of
the discharge stroke.)
q If center line (X) of rocker cam (4) is equal to
the axis 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.)
q In short, swash plate angle (a) is in proportion
to the pump discharge.
D275A-5R 9
2. Control of discharge
q If swash plate angle (a) is increased, the differ-
ence between volumes (E) and (F) is
increased, and so discharge (Q) is increased.
Swash plate angle (a) is changed with servo
piston (10).
q Servo piston (10) reciprocates straight accord-
ing 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 D275A-5R
Servo valve
P: EPC valve basic 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
D275A-5R 11
Function
q The servo valve controls the current (i) input to q The relationship between the input current (i)
the EPC valve and the swash plate angle (a) of to the EPC valve and the output pressure of
the pump so that they will be related as shown EPC valve (F) is as follows.
in the figure below.
12 D275A-5R
Operation
q The output pressure of the EPC valve is
applied to the piston chamber to push piston
(6). Piston (6) pushes spool (5) until it is bal-
anced with the spring.
q Then, the land (PE) of the servo piston pres-
sure passage is connected to the pump dis-
charge passages by the cut of spool (5) and
the discharge pressure is led to the servo pis-
ton.
q The servo piston is raised by the rocker cam.
The position feedback is applied and the lever
moves to compress the spring.
q If spool (5) is pushed back, the pump dis-
charge circuit and the servo piston circuit are
shut off.
q The pressure in the servo piston chamber low-
ers and the rocker cam returns toward the
maximum swash plate angle.
q These processes are repeated until the swash
plate is fixed to a position where the EPC out-
put pressure is balanced with the spring force.
q Accordingly as the EPC output pressure is
heightened, the swash plate angle is
decreased.
As the EPC output pressure is lowered, the
swash plate angle is increased.
D275A-5R 13
Cooling fan motor 1

Type: LMF110(65)
P: From fan pump Specifications

T: From cooler to tank Type: LMF110(65)
TC: To tank Capacity: 65.1 cc/rev
Rated speed: 1,300 rpm
Rated flow: 84.6 l/mm
Check valve crack pressure: 78.5 kPa {0.8 kg/cm2}
14 D275A-5R
1. Output shaft 7. End cover

2. Case 8. Center spring
3. Thrust plate 9. Check valve
4. Piston assembly 10. Pilot valve
5. Cylinder block 11. Spool for reversible valve
6. Valve plate 12. Safety valve
Unit: mm
Standard size Repair limit
Free length x Installation Installation Free Installation
13 Spool return spring outer diameter length load length load Replace spring
146 N 117 N if damaged or
62.66 x 19.8 53.5 —
{14.9 kg} {11.9 kg} deformed.
13.7 N 11.0 N
14 Check valve spring 16.4 x 8.9 11.5 —
{1.4 kg} {1.12 kg}
D275A-5R 15
1. Hydraulic motor
Function
q This hydraulic motor is called a swash plate-
type axial piston motor. It converts the energy
of the pressurized oil sent from the hydraulic
pump into rotary motion.
Principle of operation
q The oil sent from the hydraulic pump flows
through valve plate (7) into cylinder block (5).
This oil can flow on only one side of the (Y-Y)
line connecting the top dead center and bottom
dead center of the stroke of piston (4).
q The oil sent to one side of cylinder block (5)
presses piston (4) [4 or 5 pieces], and gener-
ates force (F1)[F1 = P x xD2/4].
q This force is applied to thrust plate (2). Since
thrust plate (2) is fixed to the angle of (a°)
degrees to the output shaft(1), the force is
divided into components (F2) and (F3).
q The radial component (F3) generates torque
[Ti = F3 x ri] against the (Y-Y) line connecting
the top dead center and bottom dead center.
q The result of this torque [T = Ti] rotates cylin-
der block (5) through the piston.
q Since this cylinder block (5) is splined to the
output shaft, the output shaft revolves to trans-
mit the torque.
16 D275A-5R
2. Suction valve 2) When the pump is stopped

q If the engine is stopped and the input revolu-
Function
tion of the fan pump lowers to 0 rpm, the pres-
q If the fan pump stops, the pressurized oil does surized oil from the pump is not supplied to
not flow into the motor. Since the motor contin- port (P) any more. As the pressurized oil is not
ues revolution because of the force of inertia, supplied to the (MA) side of the motor, the
however, the pressure on the outlet side of the motor speed lowers gradually to stop.
motor rises. q If the motor shaft is revolved by the force of
q When the oil stops flowing in from inlet port (P), inertia while the oil flow in the port (P) is reduc-
suction valve (1) sucks in the oil on the outlet ing, the oil in port (T) on the outlet side is sent
side and supplies it to port (MA) where there is by the suction valve (1) to the (MA) side to pre-
not sufficient oil to prevent cavitation. vent cavitation.
Operation
1) When pump is started
q If the pressurized oil from the pump is supplied
to port (P) and the pressure on (MA) side rises
and starting torque is generated in the motor,
the motor starts revolution.The pressurized oil
on the motor outlet (MB) side of the motor
returns through port (T) to the tank.
D275A-5R 17
3. Operation of reversible valve 2) When the ON-OFF solenoid is energized.

q If ON-OFF solenoid (1) is “energized“, ON-
1) When the ON-OFF solenoid is de-energized.
OFF selector valve (2) changes to let the pres-
q If ON-OFF solenoid (1) is “de-energized“, the
surized oil from the pump flow through port (C)
pressurized oil from the pump is blocked by
into spool chamber (D).
ON-OFF selector valve (2), and port (C) opens
q The pressurized oil in chamber (D) pushes
for the tank circuit.
valve spool (3) to the left against spring (4).
q Spool (3) is pushed to the right by spring (4).
q Motor port (MB) opens and pressurized oil
q Motor port (MA) opens and pressurized oil
flows in to revolve the motor in reverse (coun-
flows in to revolve the motor in forward (clock-
terclockwise).
wise).
18 D275A-5R
4. Safety valve
Function
q When the engine is started, the pressure in
port (P) of the fan motor is heightened in some
cases.
q Safety valve (1) is installed to protect the fan
system circuit.
Operation
q If the pressure in port (P) rises above the
cracking pressure of safety valve (1), valve (2)
of safety valve (1) opens to release the pres-
surized oil into port (T).
q By this operation, generation of abnormal pres-
sure in port (P) is prevented.
D275A-5R 19
D275A-5R Bulldozer
© 2007 KOMATSU
All Rights Reserved
20 D275A-5R
SEN02166-00
D275A-5R

D275A-5R 35001 and up

Power train system, Part 1
Power train...................................................................................................................................................... 2
Overall drawing of power train unit ................................................................................................................. 4
Power train hydraulic piping drawing .............................................................................................................. 8
Damper, universal joint ................................................................................................................................. 10
Torque converter, PTO .................................................................................................................................. 12
Torque converter ........................................................................................................................................... 16
Scavenging pump ......................................................................................................................................... 19
Transmission control ..................................................................................................................................... 20
Transmission................................................................................................................................................. 22
Tranmission ECMV ....................................................................................................................................... 36
Main relief valve and torque convertor relif valve.......................................................................................... 42
Power train pump, steering lubrication pump................................................................................................ 45
Lubrication relief valve .................................................................................................................................. 46
D275A-5R 1
Power train 1
Outline
q The power generated by engine (1) has its tor- q Steering brake (13) is disc type similar to the
sional vibration dampened by damper (2), and steering clutch. The power output from the
then passes through universal joint (3), and is steering clutch is slowed down in the final drive
transmitted to torque converter (9). (14) and rotates sprocket (15).
q The power from the engine is transmitted q The final drive consists of a single-stage spur
through the oil by torque converter (9) to the gear system and a single-stage planetary gear
transmission input shaft (turbine shaft) in system. The sprocket drives track shoe (16) to
accordance with the change in load. move the machine. The power output from
q Transmission (10) uses a combination of a steering brake (13) is transmitted to final drive
planetary gear system and hydraulic clutches (14).
to reduce the speed and shift the gears (3 for- q Final drive (14) reduces the speed with the sin-
ward gears and 3 reverse gears). It connects gle-stage spur gear system and single-stage
2 sets of clutches selected according to the planetary gear system to rotate sprocket (15)
change in load, and transmits the power to and drive track shoe (16) and move the
bevel gear (11) from the bevel pinion at the machine. The oil from fan pump (17) driven
rear end of the transmission. with PTO (6) rotates fan motor (18).
q The power divided into right and left portions
by the bevel gear is transmitted to the respec-
tive steering clutches (12). Steering clutches
(12) turn on and off the power transmitted from
the bevel gear shaft to the final drive to control
the travel direction of the machine.
q The travel direction is changed by operating
the steering lever to turn off the power of the
steering clutch on the turning side. The turning
radius is controlled with steering brake (13)
installed to the outside of the steering clutch.
2 D275A-5R
1. Engine (SAA6D140E-5) 7. Power train pump 14. Final drive

2. Damper (SAR(3)-100) 15. Sprocket
3. Universal joint 8. Steering lubricating oil pump 16. Track shoe
4. Scavenging pump (SAR(3)-50) 17. Fan pump (LPV71)
(BAR(3)-160) 9. Torque converter 18. Fan motor (LMF65)
5. Work equipment pump 10. Transmission
(HPV95) 11. Bevel gear
6. PTO 12. Steering clutch
13. Steering brake
D275A-5R 3
Overall drawing of power train unit 1
4 D275A-5R
D275A-5R 5
1. Work equipment pump Outline

2. Torque converter, PTO q The power train unit consists of the main com-
3. Power train pump ponents of torque converter (2), transmission
4. Steering lubricating oil pump (5), and steering unit (13). Accordingly, after
5. Transmission the power train unit is removed, it can be
6. Parking brake valve divided into the torque converter, transmission
7. Right clutch ECMV unit, and steering unit.
8. Left clutch ECMV q The steering unit consists of the bevel pinion
9. Sudden brake prevention valve unit, bevel gear shaft, steering clutch, and
10. Right brake ECMV steering brake.
11. Left brake ECMV
12. Fan pump A. Left clutch oil pressure pick-up port (LC)
13. Steering unit B. Left brake oil pressure pick-up port (LB)
14. Main relief valve, torque converter relief valve C. Rightt clutch oil pressure pick-up port (RC)
15. Power train oil strainer D. Right brake oil pressure pick-up port (RB)
16. Scavenging pump E. Transmission 1st clutch oil pressure pick-up
port (F1)
F. Transmission 2nd clutch oil pressure pick-up
port (2ND)
G. Transmission 3rd clutch oil pressure pick-up
port (3RD)
H. Transmission R clutch oil pressure pick-up port
(R)
J. Transmission F clutch oil pressure pick-up port
(FWD)
K. Torque converter requlator pressure pick-up
port (OUT)
L. Torque converter relief pressure pick-up port
(IN)
6 D275A-5R
D275A-5R 7
Power train hydraulic piping drawing 1
8 D275A-5R
1. Scavenging pump [BAR(3)-160]

2. Power train oil filter
3. Power train lubrication oil filter
4. Work equipment pump (HPV112)
5. Centralized pressure pick-up ports
6. Power train pump [SAR(3)-100]
7. Steering lubricating oil pump [SAR(3)-50]
8. Brake control valve
9. Main relief valve
10. Power train oil cooler
(built in radiator lower tank)
11. Transmission ECMV
A: Left brake oil pressure pick-up port (LB)

B: Right brake oil pressure pick-up port (RB)
C: Transmission 1st clutch oil pressure pick-up
port (1st)
D: Transmission 2nd clutch oil pressure pick-up
port (2ND)
E: Transmission 3rd clutch oil pressure pick-up
port (2RD)
F: Transmission R clutch oil pressure pick-up port
(R)
G: Transmission F clutch oil pressure pick-up port
(FWD)
H: Transmission main relief pressure pick-up port
(TM)
J: Left clutch oil pressure pich-up port (LC)
K: Right clutch oil pressure pich-up port (RC)
L: Torque converter outlet pressure pick-up port
(OUT)
M: Torque converter inlet pressure pick-up port (IN)
D275A-5R 9
Damper, universal joint 1
10 D275A-5R
1. Breather Outline
2. Oil level gauge q 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
5. Flywheel suddenly or when carrying out heavy-duty dig-
6. Outer body ging. In this way it acts to protect the torque
7. Coupling converter, transmission, and other parts of the
8. Universal joint power train.
9. Cover q This damper has few component parts: it uses
10. Rubber coupling a rubber coupling, so the vibration is absorbed
11. Inner body by the damping effect of the rubber material.
Operation
q This motive force from the engine passes
through flywheel (5) and it transmitted to outer
body (6).
q 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
Clearance between flywheel size Shaft Hole clearance limit
12
housing and cover – 0.022 + 0.070 0.022 –
511.18 0.2
– 0.092 + 0.070 0.162
Clearance between flywheel – 0.020 + 0.063 0.020 – Replace
13 466.72 0.2
and damper – 0.083 + 0.063 0.146
Standard size Tolerance Repair limit
Outer circumference of cou-
14 – 0.087
pling oil seal contact surface 90 89.8
– 0.087
D275A-5R 11
Torque converter, PTO 1
12 D275A-5R
D275A-5R 13
1. Work equipment pump mounting port Outline

2. Scavenging pump mounting port q The torque converter is the 3-element, 1-stage,
3. Fan pump mounting port and 1-phase type, which is combined with the
4. PTO lubrication tube transmission into 1 unit.
5. Power train, Steering lubricating oil pump
mounting port Structure
6. Coupling q Pump (15) is combined with coupling (6), input
7. Input shaft [PTO drive gear (56 teeth)] shaft (7), and drive case (11) into 1 unit and
8. Idler gear (77 teeth) rotated by the engine power.
9. Idler gear shaft q Turbine (12) is combined with turbine boss (21)
10. Torque converter case and transmission input shaft (20) into 1 unit
11. Drive case and rotated by the engine power.
12. Turbine q Stator (13) is combined with stator boss (14)
13. Stator and stator shaft (17) into 1 unit and fixed to
14. Stator boss front housing (19) and rear housing (18).
15. Pump q The front hosing and rear housing of the stator
16. Retainer clutch are bolted to the front housing of the
17. Stator shaft transmission R clutch.
18. Stator rear housing q The PTO unit consists of input shaft (7), idler
19. Stator front housing gear (8), scavenging pump drive gear (24),
20. Transmission input shaft work equipment pump and power train pump
21. Turbine boss (90 teeth) drive gear (22), and fan pump drive gear (23).
22. Pump drive gear (49 teeth)
(Work equipment, power train, and steering
lubricating oil pump)
23. Fan pump drive gear (49 teeth)
24. Scavenging pump drive gear (57 teeth)
25. Power train oil strainer
A. To oil cooler
B. Torque converter oil inlet
C. To steering case (From scavenging pump)
D. To transmission case (From torque converter
case)
E. From steering case and transmission case
(Oil pan pass)
14 D275A-5R
D275A-5R 15
Torque converter 1
16 D275A-5R
Unit: mm
Outside diameter of coupling
1 – 0.054 Repair hard
oil seal contact surface 120 119.8
– 0.054 chrome plating
Inside diameter of retainer or replace
+ 0.040
2 150
+ 0.040
150.5
seal ring contact surface
Backlash between PTO drive Standard clearance Clearance limit
3 gear and scavenging pump
drive gear 0.204 – 0.512 —
Backlash between PTO drive
4 0.204 – 0.512 —
gear and driven gear
5 Wear of stator shaft seal ring Width: 4.4 Width: 4.0
Height: 5.5 Height: 5.1
D275A-5R 17
Power train route
Flow of power
q Engine power
O
Coupling (1)
O
Input shaft (2)
O
Drive case (3)
O
Pump (4)
O
Turbine (5)
O
Turbine boss (6)
O
Transmission input shaft (7)
Flow of oil
q The oil is sent through the main relief valve
and its pressure is reduced below the set pres-
sure by the torque converter relief valve.
Then, it flows in inlet port (A) and through the
oil path of stator front housing (1) to pump (2).
The oil is given centrifugal force by pump (2)
and flows in turbine (3) and gives its energy to
turbine (3).
The oil from turbine (3) is sent to stator (4) and
then returned to pump (2). A part of the oil is
sent from stator (4) through outlet port (B) to
the oil cooler, however.
18 D275A-5R
Scavenging pump 1
BAR (3) 160
A. Discharge port
B. Suction port
Unit: mm
1 Spline shaft rotation torque —
Discharge Standard Permissible
Rotating pressure discharge discharge
Delivery Type speed MPa amount amount —
— (rpm)
(Oil: SAE10WCD {kg/cm2} (l/min) (l/min)
Oil temperature: 45 – 55°C) 2.94
BAR160 2,500 — —
{30}
D275A-5R 19
Transmission control 1
a For steering operation concerned to operation a PCCS: Abbreviation for Palm Command Con-
of PCCS lever, see STEERING AND BRAKE trol System
CONTROL.
SWD05824
1. Brake pedal Lever positions Outline

2. Safety lever [1] : Neutral q The transmission is controlled with
3. PCCS lever (Forward-Reverse, [2] : Forward PCCS lever (3).
Gear shift) [3] : Reverse The PCCS lever is used to select the
3A. UP switch [4] : OFF travel direction and shift the gear.
(Gear is shifted up each [5] : Shift UP q Since the safety mechanism is employed,
time this switch is [6] : Shift DOWN transmission neutral safety switch (4)
pressed.) [7] : Free does not work and the engine does not
3B. DOWN switch [8] : Lock start unless safety lever (2) is in the
(Gear is shifted down each LOCK position.
time this switch is pressed.)
4. Transmission neutral safety
switch
5. Cable
6. Transmission control valve
20 D275A-5R
D275A-5R 21
Transmission 1
22 D275A-5R
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
D275A-5R 23
24 D275A-5R
1. Main relief valve Outline

2. Transmission case q The transmission consists of planetary gear
3. Transmission control valve and valve cover systems and disc clutches and has "3 forward
assembly gear speeds and 3 reverse gear speeds".
4. Lubricating oil relief valve q Among the 5 sets of planetary gear system
5. Input shaft and disc clutch of the transmission, 2 clutches
6. Reverse clutch sungear (34 teeth) are fixed hydraulically with control valves to
7. Pinion shaft select 1 rotating direction and rotating speed.
8. Ring gear of reverse travel (86 teeth) q Clutches No. 1, No. 2, No. 3, No. 4, and No. 5
9. Planetary pinion for reverse travel (26 teeth) are fixed respectively when the reverse, for-
10. Disc ward, 3rd, 2nd, and 1st gears are selected.
11. Plate
12. Piston Number of plates and discs
13. Planetary pinion for forward travel (27 teeth)
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 inter-
nal teeth: 91, Number of external teeth: 105) No.1 6 6
16. Sun gear for 2nd gear speed (39 teeth) No.2 8 7
No.3 4 5
17. Planetary pinion for 1st gear speed (21 teeth)
No.4 4 5
18. Sun gear for 1st gear speed (49 teeth)
No.5 3 4
19. Output shaft (Number of teeth of sun gear for
3rd gear speed: 20)
20. Ring gear for 1st gear speed (Number of inter- Gear speeds and operated clutches
nal teeth: 91, Number of external teeth: 105)
21. 1st clutch carrier (90 teeth) Gear speed Operated clutches (Turned ON)
22. Clutch housing for 1st gear speed
23. Clutch housing for 2nd gear speed Forward 1st No.2·No.5
Forward 2nd No.2·No.4
24. Planetary pinion for 2nd gear speed (26 teeth)
Forward 3rd No.2·No.3
25. Ring gear for 2nd gear speed (Number of inter- Neutral *1. No.5 or No. 4
nal teeth: 90, Number of external teeth: 105) Reverse 1st No.1·No.5
26. Clutch housing for 3rd gear speed Reverse 2nd No.1·No.4
27. Carrier for 2nd and 3rd gear speeds Reverse 3rd No.1·No.3
28. Clutch housing for forward travel
29. Sun gear for forward travel (37 teeth) *1: While the transmission is in neutral, the 1st
30. Ring gear for forward travel (Number of inter- clutch or 2nd clutch is filled with low-pressure
nal teeth: 91, Number of external teeth: 105) oil and engaged so that the machine can start
31. Carrier for forward travel (86 teeth) without a time lag.
32. Clutch housing for reverse travel
33. Return spring
34. Ring gear for reverse travel (Number of inter-
nal teeth: 90, Number of external teeth: 105)
35. Pin
36. Carrier for reverse travel (90 teeth)
D275A-5R 25
26 D275A-5R
Unit: mm
Installed Installed Installed
Free length Free length
1 No. 1 clutch spring (12 pcs.) length load load
174.6N 165.7N
91 71.2 88.3
{17.8 kg} {16.9 kg}
52.7N 50.0N
2 No. 2 clutch spring (12 pcs.) 84 79.8 81.5
{5.4 kg} {5.1 kg}
95N 90.2N
3 No. 3 clutch spring (12 pcs.) 68 59.5 66.0
{9.7 kg} {9.2 kg}
93.1N 88.3N
4 No. 4 clutch spring (12 pcs.) 70 51 67.9
{9.5 kg} {9.0 kg}
83.3N 79.4N
5 No. 5 clutch spring (12 pcs.) 70 53 67.9
{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
Thickness of clutch disc
7 5.4 ± 0.1 4.6
(No. 3 – 5 clutches)
Thickness of clutch plate
8 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 62.3 Replace
Backlash between each sun Standard clearance Clearance limit

gear and planetary pinion (For-
14
ward, reverse, 1st – 3rd gear 0.14 – 0.35 —
speeds)
Backlash between each plane-
tary gear and internal teeth of
15 0.15 – 0.38 —
ring gear (Forward, reverse,
1st and 2nd gear speeds)
Backlash between planetary
16 pinion and internal teeth of ring 0.16 – 0.41 —
gear (3rd gear speed)
Backlash between carrier and
17 internal teeth of ring gear 0.18 – 0.54 —
(Reverse)
Backlash between each carrier
18 and internal teeth of ring gear 0.18 – 0.48 —
(Forward, 1st gear speed)
D275A-5R 27
Unit: mm
Inside diameter of seal ring
contact face + 0.052
ø 255 ø 255.1
+ 0.052
+ 0.15
Width of seal ring groove 4.0 4.4
19 + 0.10
– 0.01
Width of seal ring 4.0 3.6
– 0.04
Thickness of seal ring 5.0 ± 0.15 4.5
Inside diameter of seal ring + 0.052

ø 270 ø 270.1
+ 0.15
+ 0.10 Replace
20
– 0.01
– 0.04
Inside diameter of seal ring + 0.046

ø 220 ø 220.1
+ 0.15
+ 0.10
21
– 0.01
– 0.04
28 D275A-5R
Operation
1. Operation of disc clutch
q 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
external 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)

q Oil from the control valve flows under pressure
through the port in housing (32) to the back of
piston (12).
q The piston presses plates (11) and discs (10)
together, 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)

q When the supply of pressure oil from the con-
trol valve is shut off, piston (12) is returned to
its original 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.
D275A-5R 29
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 NEU-
TRAL 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 forward 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.
30 D275A-5R
2. Forward 1st
F ring gear (30) and 1st ring gear (20) are fixed hydraulically.
The power from torque converter

O
Input shaft (5)
O
F sun gear (29)
O
F planet pinion (13)
O
F camier (31)
O
3rd, 2nd camier (27)
O
2nd planet pinion (24)
O
2nd ring gear (25) 2nd sun gear (16)
O
1st camier (21)
O
1st planet pinion (17)
O
1st sun gear (18)
O
Output shaft (19)
D275A-5R 31
3. Forward 2nd
F ring gear (30) and 2nd ring gear (25) are fixed hydraulically.

O
Input shaft (5)
O
F sun gear (29)
O
O
F camier (31)
O
O
O
2nd ring gear (16)
O
Output shaft (19)
32 D275A-5R
4. Forward 3rd
F ring gear (30) and 3rd ring gear (15) are fixed hydraulically.

O
Input shaft (5)
O
F sun gear (29)
O
O
F camier (31)
O
O
3rd planet pinion (14)
O
Output shaft (19)
D275A-5R 33
5. Reverse 1st
R ring gear (34) and 1st ring gear (20) are fixed hydraulically.

O
Input shaft (5)
O
R sun gear (6)
O
R planet pinion (9)
O
R ring gear (8)
O
F camier (31)
O
O
O
2nd ring gear (25) 2nd sun gear (16)
O
1st camier (21)
O
1st planet pinion (17)
O
1st sun gear (18)
O
Output shaft (19)
34 D275A-5R
D275A-5R 35
Tranmission ECMV 1
(Electronic Control Modulation Valve)
36 D275A-5R
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
D275A-5R 37
Outline of ECMV
q The ECMV (Electronic Control Modulation
Valve) consists of the following two units, a
pressure control valve and fill switch.
q Pressure control valve
Converts a current sent from the transmission
controller to the proportional solenoid valve, to
an oil pressure.
q Fill switch
Detects that the clutch is filled with oil. It has
the functions below.
1) It outputs a signal (fill signal) to the con-
troller as soon as the clutch is filled with oil
to report the completion of filling.
2) It outputs a signal (fill signal) to the con-
troller while an oil pressure is applied to
the clutch to report the presence/absence
of oil pressure.
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

q One proportional solenoid is attached to one
ECMV. After receiving the command current
from the controller, it produces thrust in the
right figure.
By making the proportional solenoid-produced

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

q 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.
38 D275A-5R
Operation of ECMV
q The ECMV is controlled by the command cur-
rent sent from the controller to the proportional
solenoid 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
q The clutch is crimped by the piston when shift-

ing the gear with the gear shift switch. If a high
oil pressure is applied suddenly, however, the
piston connects to the clutch suddenly, causing
the machine to make a sudden start and give
an excessive shock to the machine.
To prevent them, it is designed so that if you
connect 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 durability 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 propor-
tional 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.
D275A-5R 39
2. When filling (When inputting the trigger 3. Pressure regulation (D region in the diagram)
command to the pressure control valve) If you flow a current to the proportional sole-
(B and C regions in the diagram) noid (1), the solenoid produces thrust propor-
If you supply a current to the proportional sole- tional to the current. Pressure is regulated by
noid (1) with no oil in the clutch, an oil pressure striking a balance among the thrust of the sole-
proportional to the solenoid force acts on the noid, the thrust of the oil pressure of the clutch
chamber (B), pushing the pressure control port, and reaction force of the pressure control
valve (2) rightward. This operation opens the spring (5).
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.
40 D275A-5R
D275A-5R 41
Main relief valve and torque convertor relif valve 1
1. Body Outline
2. Torque converter relief valve 1. Main relief valve
3. Valve spring Main relief valve (6) sets the set pressure of
4. Piston the oil pressure for the transmission, steering
5. Piston spring clutch, and brake.
6. Main relief valve 2. Torque converter relief valve
7. Valve spring Torque converter relief valve (2) acts to protect
8. Piston spring the torque converter from abnormally high
9. Piston pressure by relieving the circuit if the torque
converter inlet port pressure rises above the
A: Drain port (for torque converter relief) set pressure.
B: Drain port Unit: MPa {kg/cm2}
C: From pump
Set pressure
D: Drain port
E: To torque converter Main relief pressure 3.2 ± 0.1 {32.7 ± 1.0}
P1: Main relief oil pressure detection port Torque converter relief
0.98 ± 0.05 {10.2 ± 0.5}
P8: Torque converter relief oil pressure detection pressure
port
42 D275A-5R
Unit: mm
Clearance between main relief size Shaft Hole clearance limit
10
valve and valve body 0.035 –
– 0.035 + 0.013
28 0.08
– 0.045 + 0.013 0.058
Clearance between main relief – 0.020 + 0.021 0.020 –
11 19 0.07
valve and piston – 0.030 + 0.018 0.051
Clearance between torque 0.035 –
– 0.035 + 0.013
12 converter relief valve and valve 22 0.08
– 0.045 + 0.013 0.068
body
Clearance between torque
– 0.020 + 0.018 0.020 –
13 converter relief valve and pis- 15 0.07
– 0.030 + 0.018 0.048
ton
Standard size Repair limit Replace
Main relief valve spring Free length Free length
14 length load load
(outside)
481 N 457 N
122 78 118.3
{49 kg} {46.6 kg}
Main relief valve spring 368 N 349 N
15 108 78 104.8
(inside) {37.5 kg} {35.6 kg}
7.32 N 6.96 N
16 Main relief valve piston spring 30 25 29.1
{0.746 kg} {0.71 kg}
Torque converter relief valve 182 N 174 N
17 50 40.5 48.5
spring {18.6 kg} {17.7 kg}
Torque converter relief valve 4.87 N 4.61 N
18 26 20 25.2
piston spring {0.497 kg} {0.47 kg}
D275A-5R 43
Operation of main relief valve Operation of torque converter relief valve

q The oil from power train pump passes through q The oil relieved by the main relief valve flows
the filter, enters port (A) of the main relief from port (C) to the torque converter, and at
valve, then passes through orifice (a) and the same time, passes through orifice (b) and
enters port (B). When the oil from the pump enters port (D).
fills the circuit, the oil pressure starts to rise. When the passage to the torque converter is
q As the oil pressure in the circuit rises, the oil filled with oil, the oil pressure starts to rise.
entering port (B) pushes piston (4). The reac- q As the oil pressure to the torque converter
tion compresses spring (7), moves main relief rises, the oil entering port (D) pushes piston
valve (6) to the left in the arrow direction, and (9). The reaction compresses spring (3),
opens ports (A) and (C). moves relief valve (2) to the right in the arrow
Then, the oil from the pump is relieved from direction, and opens ports (C) and (E).
port (A) to port (C), then flows from port (C) to Then, the oil from port (C) is relieved to port (E)
the torque converter. and is drained to the oil tank.
The oil pressure at port (A) at this point is 3.2 ± The oil pressure at port (C) at this point is 1.0 ±
0.1 MPa {32.7 ± 1.0 kg/cm2}. 0.05 MPa {10.2 ± 0.5 kg/cm2}.
44 D275A-5R
Power train pump, steering lubrication pump 1

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 bear- SAR (3) 100
2 ing inner diameter and gear 0.060 – 0.149 0.20
shaft outer diameter SAR (3) 50 Replace
Type Standard size Tolerance
3 Pin driving depth SAR (3) 100 – 0.5
14
SAR (3) 50 – 0.5
4 Spline shaft rotation torque 13.7 – 73.5Nm{1.4 – 2.4kgm}
Delivery
Standard Delivery
Speed pressure
Delivery Type delivery limit
(rpm) MPa
(l/min) (l/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
D275A-5R 45
Lubrication relief valve 1
1. Forward clutch housing q The lubrication relief valve is installed to the

2. Spring right side face of the forward clutch housing.
3. Piston And prevents any abnormal pressure in the
lubrication oil.
A: From oil cooler Unit: MPa {kg/cm2}
B: Drain Set pressure
C: Drain
Pressure when normal 0.14 ± 0.05 {1.4 ± 0.5}
Outline Cracking pressure 0.30 ± 0.03 {3.0 ± 0.3}
q The oil leaving the torque converter passes
through the oil cooler built in the radiator lower
tank. It then goes through the lubrication relief
valve and lubricates the transmission and
PTO.
46 D275A-5R
Unit: mm
4 Lubrication relief valve spring length load load Replace
12.5 N 11.9 N
26 23.6 25.2
{1.27 kg} {1.21 kg}
D275A-5R 47
D275A-5R Bulldozer
© 2007 KOMATSU
All Rights Reserved
48 D275A-5R
SEN02167-00
D275A-5R

D275A-5R 35001 and up

Power train system, Part 2
Steering, brake control ....................................................................................................................................................... 2
Bevel gear shaft, steering clutch and brake ....................................................................................................................... 4
Steering control valve....................................................................................................................................................... 14
Steering clutch ECMV ...................................................................................................................................................... 16
Steering brake ECMV....................................................................................................................................................... 17
Parking brake valve.......................................................................................................................................................... 24
Sudden brake prevention valve........................................................................................................................................ 25
Final drive......................................................................................................................................................................... 26
Sprocket ........................................................................................................................................................................... 32
D275A-5R 1
Steering, brake control 1

q Regarding the transmission-related description
of the operation of the PCCS lever, refer to the
transmission control.
q PCCS: Palm Command Control System
2 D275A-5R
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
[1] [10]: Free
[11]: Lock
Outline
q PCCS lever (3) sends electric signals to steer- q If PCCS lever (3) is tilted fully to the left, the left
ing controller (4). Receiving those signals, steering clutch is “disengaged“ completely. if
steering controller (4) sends proportional cur- the left steering brake is turned ON at this time,
rents to steering ECMV (6) to control the steer- the machine turns sharply to the left.
ing clutches and brakes. q Safety lever (2) is connected to parking brake
q Brake pedal (1) sends electric signals through lever (8) and used to apply the parking brake,
potentiometer (11) to steering controller (4). too.
Receiving this signal, streering controller (4)
sends proportional current to steering ECMV
(6) to operate the brakes. In this case, both
brakes are applied simultaneously to stop the
machine. Rod (10) works as a redundant
device to operate the brake through brake
valve (7) (only in the complete braking mode).
q If PCCS lever (3) is tilted a little to the left, the
left streering clutch is “half disengaged“ and
the machine turns gradually to the left.
D275A-5R 3
Bevel gear shaft, steering clutch and brake 1
4 D275A-5R
D275A-5R 5
6 D275A-5R
1. Cover A. To transmission case (power train pump)

2. Output shaft B. From transmission case (scavenging pump)
3. Cylinder C. To pin puller solenoid valve
4. Spring D. From pin puller solenoid valve
5. Brake piston 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) H. Left clutch oil Pressure pick-up port
9. Brake outer drum (140 teeth) J. Right clutch oil Pressure pick-up port
10. Hub (106 teeth)
11. Bearing cage
12. Shim (For adjustment of bevel gear)
13. Bearing A
14. Bevel gear shaft
15. Bevel gear (46 teeth)
16. Bearing B
17. Hub (84 teeth)
18. Clutch outer drum (115 teeth)
19. Clutch plate (6 pcs. on each side)
20. Clutch disc (7 pcs. on each side)
21. Clutch Piston
22. Hub
23. Shim (For adjustment of bevel pinion)
24. Bearing cage
25. Bearing
26. Nut (For adjustment of preload on bearing)
27. Bevel pinion (19 teeth)
D275A-5R 7
Unit: mm
Replace
28 Brake plate Thickness 2.9 ± 0.1 2.6
Distortion — 0.3 0.4 Repair or replace
Thickness 4.5 ± 0.1 4.0 Replace
29 Brake disc
Total assembly thickness of
30 48.9 — 45.3
brake plate and disc Replace
Thickness 2.6 ± 0.1 2.3
31 Clutch plate
Thickness 4.7 ± 0.15 4.2 Replace
32 Clutch disc
Total assembly thickness of
33 48.5 — 44.8
clutch plate and disc
Backlash between brake disc Standard clearance Clearance limit
34
and hub 0.42 – 0.72 1.00
Backlash between clutch disc
35 0.33 – 0.69 0.96
and hub
Backlash between bevel gear
36 0.25 – 0.33 0.50
and pinion
size Shaft Hole clearance limit
Inside diameter of Large
seal ring contact – 0.5 + 0.081 0.500 –
37 diameter 270 —
face of brake pis- portion – 0.7 + 0.081 0.781
ton
Small
– 0.100 + 0.072 0.100 –
diameter 220 —
– 0.172 + 0.072 0.244 Replace
portion
Large
– 0.5 + 0.081 0.500 –
Inside diameter of diameter 260 —
– 0.7 + 0.081 0.781
seal ring contact portion
38
face of clutch pis- Small
ton – 0.085 + 0.063 0.085 –
diameter 180 —
– 0.148 + 0.063 0.211
portion
Inside diameter of seal ring
ø 125 ø 125.1
+ 0.040
+ 0.070
39 + 0.020
– 0.080
– 0.080
8 D275A-5R
Outline
Bevel gear shaft Steering brakes
q The bevel gear shaft device changes the out- q The steering brakes are connected to the
put power of the transmission by a right angle steering clutches on both sides respectively.
to the lateral directions and reduce the output They control the power transmitted from the
speed by using a bevel pinion and a bevel steering clutches to the final drives to change
gear. the turning direction of the machine and brake
q The bevel gear shaft device has a spiral bevel the machine.
pinion and spiral bevel gear and is lubricated q The steering brakes are wet-type, multiple disc
forcibly with pressurized oil. clutch-type, spring force brakes. They are
q The bevel gear shaft device consists of bevel driven hydraulically together with the clutches
pinion (27) meshed with bevel gear (15), bevel by the steering ECMV valve operated with the
gear shaft (14), and bearings (13) and (16) to PCCS lever.
support the bevel gear shaft. The steering brakes are lubricated forcedly
with oil supplied by the power train lubricating
Steering clutches oil pump and lubricating circuit of the scaveng-
q The steering clutches are connected to both ing pump. The lubricating oil flows through the
bevel gear shafts respectively through the paths in the steering case, cover, cylinder,
splines. They transmit and cut out the power disc, and plate.
of the bevel gear shafts to the final drives to While the engine is stopped, even if the brake
change the turning direction of the machine. pedal is not pressed, the back pressure of the
q The steering clutches are wet-type multiple- steering brake piston lowers and the brake is
disc hydraulic clutches. They are driven "applied". After the engine is started again,
hydraulically together with the brakes by the however, as the hydraulic pressure in the cir-
steering ECMV valve operated with the PCCS cuit rises, the brake is "released". Accordingly,
lever. the parking brake must be kept locked.
The steering clutches are lubricated forcedly q Each steering brake consists of hub (10) con-
with oil supplied by the power train lubricating nected to clutch outer drum (18), disc (8)
oil pump. The lubricating oil from the pump engaged with the hub, plate (7), the periphery
flows through the paths in the steering case, of which is connected to the brake outer drum
cover, cylinder, hub, disc, and plate. (9) by spline, brake outer drum (9), brake pis-
q Each steering clutch consists of hub (17) con- ton (5) to press the disc and plate against each
nected to the bevel gear shaft by spline, disc other, spring (4), and cylinder (3), hub (22),
(20) engaged with the hub, plate (19), the cover (1), and output shaft (2) to support these
periphery of which is connected to the clutch parts.
outer drum by spline, clutch outer drum (18), Brake outer drum (9) and cover (1) are fixed to
clutch piston (21) to press the disc and plate the steering case.
against each other, and hub (10) and bearing Output shaft (2) is connected to hub (22) by
to support these parts. Clutch outer drum (18) spline and fixed by the stopper in the axial
and hub (10) are connected to steering brake direction.
and transmit the power from the bevel gear
shaft through hub (22) to output shaft (2).
D275A-5R 9
Operation of steering clutch

1. When steering clutch is turned "ON"
When the PCCS lever is in the "neutral" posi-
tion, the steering ECMV applies the maximum
hydraulic pressure clutch to piston (1).
The power from transmission
O
Bevel pinion (27)
O
Bevel gear (15)
O
Bevel gear shaft (5)
O
Hub (6)
O
Clutch outer drum (4)
O
Hub (7)
O
Hub (8)
O
Output shaft
O
To final drive
2. When steering clutch is turned "OFF"

If the PCCS lever is operated to right or left,
the steering ECMV opens the drain circuit,
then the hydraulic pressure on the back of
clutch piston (1) starts lowering to 0.
The power from transmission
O
Bevel pinion (27)
O
Bevel gear (15)
O
Bevel gear shaft (5)
O
Hub (6)
O
The power is not transmitted to after parts
If the PCCS lever is released, the steering
ECMV applies the maximum hydraulic pres-
sure to clutch piston (1) to turn "ON" the clutch
as explained in 1 above.
If the left steering clutch is turned "OFF", the
power is transmitted to only the right steering
clutch and the machine turns to the left conse-
quently.
10 D275A-5R
Operation of steering brake

1. When steering brake is "released"
When the PCCS lever is in the "neutral" posi-
tion and the brake pedal is at the "release"
position, the steering ECMV sets both steering
clutch pressure and steering brake pressure to
the maximum. Accordingly, the steering clutch
is turned "ON" and the oil flows in the back
pressure port of piston (1) of the brake.
As the hydraulic pressure rises, the oil pushes
the brake piston to the left to compress spring
(2) to reduce the pressure on disc (3) and plate
(4) to 0. Then, the power transmitted from
bevel gear shaft (5) through the steering clutch
to hub (6) is further transmitted through hub (7)
and output shaft (8) to the final drive.
2. When steering brake is turned "ON" (When

PCCS lever is "operated")
If the PCCS lever is operated to the right or
left, the steering ECMV so changes that the
steering clutch is turned "OFF" and the hydrau-
lic pressure on the back side of brake piston
(1) is released into the drain circuit.
Under this condition, the brake piston is
pushed out to the right by the tension of spring
(2), then disc (3) and plate (4) are pressed
against the stopper of brake outer drum (9).
The brake outer drum is connected to the
steering case and fixed.
Accordingly, even if the steering clutch is
turned "OFF", hub (6), or output shaft (8),
which is revolving inertially stops as the disc
and plate are fixed to each other.
Since the braking force can be adjusted by
controlling the hydraulic pressure on brake pis-
ton (1) with the PCCS lever, the turning radius
and turning time can be controlled.
D275A-5R 11
3. When brake is turned "ON" (When PCCS

lever is in "neutral" position and brake
pedal is "pressed")
If the brake pedal is pressed, the brake ECMV
so changes that the hydraulic pressure on the
back side of brake piston (1) is released into
the drain circuit, then only the brake operates
with the steering clutch kept turned "ON" and
output shaft (8) stops.
The braking force can be adjusted by control-
ling the hydraulic pressure applied to brake
piston (1) with the brake pedal.
12 D275A-5R
D275A-5R 13
Steering control valve 1
14 D275A-5R
1. Parking brake valve Outline

2. ECMV (For right clutch) q This machine employs four ECMV (electronic-
3. ECMV (For left clutch) controlled modulation valve) on the steering
4. Sudden braking prevention valve control valve.
5. ECMV (For right brake) q The steering control valve is provided on
6. ECMV (For left brake) respective valve sheets as the assembly.
7. Filter q The steering control valve is situated in the cir-
8. Valve seat cuit between the power train pump via the
main relief valve and the piston of the steering
A. Left clutch operating pressure pick-up port clutch and the brake. It is consisted with two
B. Right clutch operating pressure pick-up port pairs of the steering clutch Brake ECMV (right
C. Left brake operating pressure pick-up port and left) and the brake ECMV (right and left).
D. Right brake operating pressure pick-up port q Shifting the PCCS lever (steering and forward/
E. To left clutch reverse) right or left disconnects the steering
F. To left lubrication clutch. Shifting it further turns “ON“ the brake.
G. To left brake The controller sends the instruction to respec-
H. To right clutch tive ECMV to cause the gradual or sudden turn
J. To right lubrication whichever is designated by the operating posi-
K. To right brake tion of the PCCS lever (steering lever).
L. From steering lubrication pump Depending on depth of the pedal depression,
M. From pump the controller instructs ECMV to apply the right
N. To pin puller solenoid valve and left brakes to stop the machine.
The controller that is electrically connected to
the PCCS lever and pedal performs above
operations by switching the steering control
valves (each ECMV).
The steering control valves feed the oil from
the power train pump to the steering clutch and
brake to operate their disk clutches.
q The sudden stop prevention valve disables
sudden braking that can result when a failure is
detected in the electric systems.
q Shifting the parking brake lever to the “Lock“
position switches the port of the parking brake
valve, thereby draining the oil between the
ECMV for left-and-right brakes. As the result,
the machine brake is turned on.
The parking brake is also connected to the
brake pedal via the linkage.
D275A-5R 15
Steering clutch ECMV 1

(Electronic control modulation valve)
A: To clutch 1. Connector for fill switch

T: Drain 2. Connector for proportional solenoid
Dr: Drain 3. Oil pressure pick-up valve
P: From pump 4. Fill switch
P1: Clutch oil pressure pick-up port 5. Proportional solenoid
P2. Pilot oil pressure pick-up port 6. Pressure control valve
16 D275A-5R
Steering brake ECMV 1

(Electronic control modulation valve)
A: To brake 1. Connector for fill switch

T: Drain 2. Connector for proportional solenoid
Dr: Drain 3. Oil pressure pick-up valve
P: From pump 4. Fill switch
P1: Brake oil pressure pick-up port 5. Proportional solenoid
P2. Pilot oil pressure pick-up port 6. Pressure control valve
D275A-5R 17
Outline of ECMV
q The ECMV (Electronic Control Modulating
valve) consists of a pressure control valve and
a fill switch.
q Pressure control valve
This valve allows a proportional solenoid to
receive a current sent from a steering control-
ler and converts it to oil pressure.
q Fill switch
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 con-
troller and transmits the presence of oil
pressure.
ECMV and Proportional Solenoid

q 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 con-
trol valve is actuated, then a flow of oil and the
oil pressure is controlled.
Operation of ECMV
q The ECMV is controlled using the command
current from the controller to the proportional
solenoid and a fill switch output signal.
Outline
q This valve sets the steering clutch oil pressure
or the steering brake oil pressure to a set pres-
sure and switches a circuit to the clutch cham-
ber and the brake chamber.
18 D275A-5R
Operation
1. When PCCS lever is in "neutral" and brake pedal is "released": Straight travel
(Both clutches are turned "ON", both brakes are "released", and parking brake is turned "OFF".)
q When the PCCS lever is in "neutral" and the of the brake piston. As the back pressure
brake pedal is "released", solenoid (1) of the rises, the brake piston moves to the left and
clutch ECMV is turned ON and ball (2) is compresses the brake spring to "release" the
pressed to the left to close the sealing part. brake.
The oil from the power train pump flows q When the parking brake is turned "OFF", the
through the main relief valve to port Pc of the parking brake valve is closed and the oil in the
clutch ECMV. Then, it flows through orifice "a" brake circuit is not drained.
to port F and pushes valve (3) to the left to
open the path between port Pc and port C and
close the path between port C and port Dr.
The oil in port C flows to the back pressure port
of the clutch piston to turn "ON" the clutch.
q Solenoid (5) of the brake ECMV is also turned
ON and ball (6) is pressed to the left to close
the sealing part. The oil in port Pb flows to port
E and pushes valve (7) to the left to open the
path between port Pb and port B and close the
path between port B and port Dr.
The oil in port B flows to the back pressure port
D275A-5R 19
2. When PCCS lever is operated to left halfway: Gradual turn

(Left clutch is turned "OFF", left brake is "half released", right clutch is turned "ON", right brake
is "released", and parking brake is turned "OFF")
q When the PCCS lever is operated to the left generates thrust proportional to the current.
halfway, solenoid (1) of the left clutch ECMV is The pressure is stabilized at a point where this
turned OFF and the sealing part of ball (2) is thrust is balanced with the sum of the thrust
opened. The oil from the power train pump is caused by the oil pressure in the brake port
drained through port Pc, orifice "a", and seal- and the reaction force of pressure control valve
ing part of ball (2). Accordingly, the path spring (8).
between port Pc and port C is closed and the q Accordingly, if the stroke of the PCCS lever is
path between port C and port Dr is opened. As short, the oil pressure in port B and the circuit
the oil in port C is drained through port Dr, the is controlled high and the brake is "half
clutch is turned "OFF". released". If the stroke is long, the oil pressure
The oil pressure in the charge circuit, etc. is is controlled low and the brake is turned "ON".
secured by orifice "a". q When the parking brake is turned "OFF", the
q Solenoid (5) of the left brake ECMV is turned parking brake valve is closed and the oil in the
ON and ball (6) is pressed to the left to close brake circuit is not drained.
the sealing part. The oil in port Pb flows to port
E and pushes valve (7) to the left. The oil
pressure in port B and the circuit is controlled
by the command current sent from the control-
ler to solenoid (5) according to the operation
stroke of the PCCS lever.
If a current flows into solenoid (5), the solenoid
20 D275A-5R
3. When PCCS lever is operated to left fully: Sharp turn

(Left clutch is turned "OFF", left brake is turned "ON", right clutch is turned "ON", right brake is
"released", and parking brake is turned "OFF")
q If the PCCS lever under the condition in 2

above is operated to the left fully, solenoid (5)
of the left brake ECMV is turned OFF and the
sealing part of ball (6) is opened.
Since the oil in port E is drained through the
sealing part, valve (7) is moved to the right by
the tension of spring (8). At this time, the path
between port Pb and port B is closed and the
path between port B and port Dr is opened.
q The oil from the power train pump is drained
through port Pb, orifice "b", and sealing part of
ball (6).
The oil pressure in the charge circuit, etc. is
secured by orifice "b".
The oil flowing in the back pressure port of the
brake piston is drained through port B into port
Dr and the brake is turned "ON" by the tension
of the brake spring.
q When the parking brake is turned "OFF", the
parking brake valve is closed and the oil in the
brake circuit is not drained.
D275A-5R 21
4. When brake pedal is "pressed"

(Both clutches are turned "ON", both brakes are turned "ON", and parking brake is turned
"OFF")
q If the brake pedal is pressed fully, solenoids (5)

of both brake ECMV’s are turned OFF.
q The controller outputs a command current to
solenoids (5) according to the pressing stroke
of the brake pedal.
If a current flows into solenoids (5), the sole-
noids generate thrust proportional to the cur-
rent. The pressure is stabilized at a point
where this thrust is balanced with the sum of
the thrust caused by the oil pressure in the
brake port and the reaction force of pressure
control valve spring (8), thus the braking force
can be adjusted.
Since the PCCS lever is not operated, sole-
noids (1) of both clutch ECMV’s are turned ON,
thus both clutches are turned ON.
q If the brake pedal is pressed, the parking brake
valve linked with it operates to drain the oil
from the brake circuit.
22 D275A-5R
5. When parking brake is turned "ON"

(Clutch is turned "ON", brake is turned "ON", joystick is in "neutral", and brake pedal is
"released")
q If the safety lever for the PCCS lever is set in

the "LOCK" position, parking brake valve (1)
moves to the left and the path between port A,
port B, and port C is opened. As a result, the
oil in the brake piston port under the back pres-
sure is drained through port A, port B, and port
C. Then, the back pressure in the brake piston
port lowers continuously and the brake is
turned "ON" completely and kept under that
condition.
q When the engine is started again, the path
between port A, port B, and drain port C is kept
open. Accordingly, the brake is kept turned
"ON".
q If the parking brake is turned "OFF", parking
brake valve (1) moves to the right and the path
between port A, port B, and drain port C is
closed. Accordingly, the brake is "released" by
the oil pressure.
D275A-5R 23
Parking brake valve 1
Unit: mm
Clearance between parking size Shaft Hole clearance limit
1 brake valve spool and valve Replace
body – 0.020 + 0.011 0.020 –
14 0.05
– 0.030 + 0.011 0.041
Outside diameter of sliding Tolerance Clearance limit Repair by hard
2 parts fitting to dust seal and V- 14 – 0.020 chromium plat-
packing (Spool) 13.9 ing or replace
– 0.030
Using
Parking brake valve spool Free length Using load Free length Using load
3 length Replace
spring
38.2N 36.3N
65 47.7 63.1
{3.9kg} {3.71kg}
24 D275A-5R
Sudden brake prevention valve 1
Outline
q The sudden brake prevention valve is installed
to p r ev e nt th e br a ke fr om s to pp i ng th e
machine suddenly because of a trouble in the
electric system.
q Sudden brake prevention valve (1) is installed
in the brake ECMV pilot pressure drain circuit.
If brake ECMV solenoid valve (2) is deacti-
vated, the oil is drained from the brake circuit
and the brake is applied suddenly. To prevent
this, if solenoid valve (3) of sudden brake pre-
vention 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.
D275A-5R 25
Final drive 1
Outline
q The final drive is a single stage spur gear, sin-
gle stage planetary gear reduction type. The
lubrication is of splash type using the rotation
of the gears. The final drive can be removed
and installed as a single unit.
q Floating seal (1) is installed to the rotating slid-
ing portion of the sprocket to prevent the entry
of dirt or sand and to prevent leakage of lubri-
cating oil.
26 D275A-5R
D275A-5R 27
28 D275A-5R
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
Backlash between No.1 pinion Standard clearance Clearance limit
22
and No.1 gear 0.28 – 0.93 0.93
Backlash between sun gear Replace
23 0.22 – 0.81 0.81
and planet pinion
Backlash between planet pin-
24 0.25 – 0.90 0.90
ion and ring gear
Outside diameter of No.1 pin- Repair or
25 0
ion oil seal contact surface 95 94.913 replace
– 0.087
Thickness of thrust collar of
26 30 29.95
roller bearing
Clearance between outer diam- Standard Tolerance Standard Clearance

eter of planet gear shaft and in- size Shaft Hole clearance limit
27
ner diameter of carrier hole. – 0.036 – 0.024 – 0.023 –
85 0.034 Replace
(Small diameter) – 0.058 – 0.059 0.034
Clearance between outer diam-
eter of planet gear shaft and in- – 0.036 – 0.072 – 0.071 –
28 105 – 0.014
ner diameter of carrier hole. – 0.058 – 0.107 – 0.014
(Large diameter)
Standard shim thickness for
29 2 Adjust
No.1 pinion bearing cage
Standard size Repair limit Repair or
30 Wear of wear guard
72 18 replace
D275A-5R 29
Path of power transmission
30 D275A-5R
q The power from the bevel gear shaft and steer-

ing clutch is transmitted to 1st pinion (13) to
rotate 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
cover (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).
D275A-5R 31
Sprocket 1
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
32 D275A-5R
Sprocket tooth shape of real dimension
a 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.
D275A-5R 33
D275A-5R Bulldozer
© 2007 KOMATSU
All Rights Reserved
34 D275A-5R
SEN02168-00
D275A-5R

D275A-5R 35001 and up

Undercarriage and frame
Track frame ..................................................................................................................................................... 2
Recoil spring ................................................................................................................................................... 4
Idler ................................................................................................................................................................. 6
Track roller ...................................................................................................................................................... 8
Track roller bogie .......................................................................................................................................... 10
Carrier roller .................................................................................................................................................. 12
Track shoe .................................................................................................................................................... 14
Main frame .................................................................................................................................................... 16
Suspension ................................................................................................................................................... 18
D275A-5R 1
Track frame 1
1. Idler Outline
2. Recoil spring assembly q The track roller uses an K-shape bogie mount
3. Carrier roller to increase the ground contact area between
4. Track frame the track shoe and ground surface on rough
5. Sprocket surfaces, thereby increasing the drawbar pull.
6. Sprocket cover guard q The K-shape bogie is fitted with rubber pads to
7. Track roller bogie absorb the shock from the ground surface.
8. Track roller
9. Track roller support guard Track roller, bogie
10. Pivot shaft
11. Cylinder Track roller flange type and bogie arrangement
12. Guide 1st 2nd 3rd 4th 5th 6th 7th
S D D D D D S
2 D275A-5R
Unit: mm
Item Repair limit
Deformation of track frame out- Curvature 7 (for length of 3,000)
4 Repair or replace
er pipe Twisting 3 (for level length of 300)
Dents (pipe portion) 12
Clearance between inner pipe size clearance limit
Shaft Hole
11 and adjustment cylinder protru- Replace
sion – 0.15 + 0.1
50 0.15 – 0.45 2.0
– 0.35 + 0.1
Clearance between idler bogie Standard clearance Clearance limit
12 Adjust
and guide 0 – 0.5 3.0
13 Press-fitting force for cartridge 275 – 530 kN {28 – 54 ton} —
D275A-5R 3
Recoil spring 1
1. Yoke Outline
2. Nut q Recoil spring (4) is used to adjust the track ten-
3. Retainer sion by pumping in or releasing grease from
4. Recoil spring lubricator (10) to move rod (5) forward or back-
5. Rod ward. The recoil spring (4) also acts to dampen
6. Spring cylinder any sudden shock brought to bear on the idler.
7. Retainer
8. Holder
9. Piston
10. Lubricator (for pumping in and releasing grease)
11. Grease chamber cylinder
4 D275A-5R
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 cylin- size clearance limit
Shaft Hole
13 der and outer cylinder of outer
cylinder 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 + 0.054 0.404
Press-fitting force for outer cyl-
15 inder bushing (outer cylinder 42.1 – 96.1 kN {4.3 – 9.8 ton}
side)
Press-fitting force for outer cyl-
Adjust
16 inder bushing (inner cylinder 44.1 – 228.6 kN {4.5 – 23.3 ton}
side)
Clearance between recoil
17 0 – 1.0
spring mount nut and lock plate
D275A-5R 5
Idler 1
6 D275A-5R
Unit: mm
Outside diameter of protruding Standard size Repair limit
1
part 822 —
Outside diameter of tread sur-
2 780 755
face
3 Width of protruding part 121 — Rebuild or
replace
4 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 – Replace
84 —
+ 0.046 – 0.200 0.246
Standard clearance Clearance limit
10 Play in axial direction of shaft
0.5 – 1.0 —
D275A-5R 7
Track roller 1
8 D275A-5R
Unit: mm
Outside diameter of flange Standard size Repair limit
1
(outside of single flange) 291 —
Outside diameter of flange
2 277 —
(inside of double flange)
Outside diam- single flange 255 185
3
eter double flange 255 195
Thickness of single flange 65 30
4 Rebuild or
tread double flange 65 35 replace
5 Overall width 336 —
6 Width of tread (single flange) 80 —
7 Width of tread (double flange) 80 —
Width of flange (double flange
8 27.5 12.5
of outside)
Width of flange (double flange
9 24 9
of 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 – Replace
65 —
+ 0.046 – 0.200 0.246
0.44 – 0.91 —
D275A-5R 9
Track roller bogie 1
1. Guide Outline
2. Cap q The track roller are installed to small bogie (6).
3. Track roller assembly (double) The track rollers and track shoes are always in
4. Large bogie contact.
5. Rubber mount q The vibration of the machine from the ground
6. Small bogie surface is absorbed by rubber mount (5).
7. Track roller assembly
8. Cover
9. Cartridge pin
10 D275A-5R
D275A-5R 11
Carrier roller 1
12 D275A-5R
Unit: mm
1 Outside diameter of flange
232 —
Outside diameter of carrier roll-
2 200 175 Rebuild or
er tread
replace
3 Thickness of tread 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 – Replace
77 —
+ 0.150 0 0.210
0 – 0.22 —
D275A-5R 13
Track shoe 1
a Portion P shows the link on the side where the bushing is pressed fitted.
14 D275A-5R
Unit: mm
Standard size Repair limit Reverse or
1 Link pitch
260.6 263.6 replace
2 Height of grouser 88 30 Lug welding
3 Thickness of plate 20 — rebuild or replace
4 Link height 166 148 Rebuild or
5 Thickness of link metal 51.7 33.7 replace
82 (Standard ground)
6 Bushing outside diameter 90.5
84.5 (Heavy duty ground)
8.6 (Standard ground)
7 Thickness of bushing metal 17.1
11.1 (Heavy duty ground)
Tolerance Standard
Standard Interfer-
interfer-
Interference between bushing size Shaft Hole ence limit Reverse or
8 ence
and link replace
+ 0.602 + 0.087 0.285 –
90 0.10
+ 0.372 + 0.087 0.602
Interference between pin and + 0.296 – 0.206 0.442 –
55.5 —
link (without wedge ring) + 0.236 – 0.280 0.576
9
Interference between pin and + 0.296 – 0.034 0.270 –
55.5 —
link (with wedge ring) + 0.236 – 0.096 0.392
Clearance between link and
10 Each side Both sides Both sides
link
1.4 2.8 —
Tightening torque for regular Tightening torque Additional tightening Replace
11
bolt 784 ± 78 Nm {80 ± 8 kgm} 120° ± 10°
Tightening torque for master
12 490 ± 49 Nm {50 ± 5 kgm} 180° ± 10°
bolt
D275A-5R 15
Main frame 1
16 D275A-5R
1. Main frame
2. Cage
3. Clamp
4. Cover
5. Seal
6. Clamp
7. Cap
8. Plate
Unit: mm
Clearance between radiator size clearance limit
Shaft Hole
9 guard mounting pin and bush-
ing – 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 guard mounting pin and bush- 80 1.0
– 0.076 + 0.170 0.405
ing Replace
Clearance between ripper – 0.036 + 0.267 0.098 –
11 110 1.5
beam mount pin and bushing – 0.090 + 0.180 0.254
Clearance between ripper cyl- – 0.036 + 0.257 0.064 –
12 90 1.5
inder mounting pin and bushing – 0.090 + 0.170 0.256
Clearance between equalizer – 0.036 – 0.109 –
13 120 1.5
bar shaft and bushing – 0.090 – 0.260
Press-fitting force for radiator
14 6.08 – 138.3 kN {6.2 – 14.1 ton}
guard mount bushing
Press-fitting force for radiator
15 68.7 – 155.0 kN {7.0 – 15.8 ton}
guard mount bushing
Press-fitting force for ripper
16 69.7 – 37.3 kN {7.1 – 14.0 ton} Adjust
beam mount bushing
Press-fitting force for ripper cyl-
17 57.9 – 114.8 kN {5.9 – 11.7 ton}
inder mount bushing
Press-fitting force for equalizer
18 31.4 – 105.9 kN {2 – 13 ton}
bar shaft bushing
D275A-5R 17
Suspension 1
1. Equalizer bar 8. Seal Outline

2. Pivot shaft assembly 9. Bushing q The front of the track frame rocks up and down
3. Cover 10. Side pin using the rear pivot shafts (6) as a fulcrum.
4. Thrust plate 11. Center pin Equalizer bar (1) rocks using center pin (11) as
5. Thrust plate 12. Bushing a fulcrum. The left and right track frames are
6. Pivot shaft connected by side pin (10).
7. Seal cage
18 D275A-5R
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 – 0.030 + 0.046 0.030 –
14 75 1.0 Replace bushing
and bushing – 0.060 + 0.046 0.106
Tolerance Standard Interfer-
Standard
interference
Interference between side pin size Shaft Hole
15 ence limit
boss and bushing
– 0.018 – 0.088 0.098 –
140 —
– 0.018 – 0.098 0.106
Press-fitting force for center pin
16 32.4 – 225.6 kN {3.3 – 23 ton}
bushing
—
Press-fitting force for side pin
17 34.3 – 68.7 kN {3.5 – 7.0 ton}
bushing
D275A-5R 19
*1. Indicates the left of the blade single tilt specifications.

*2. Indicates the right of the blade single tilt specifications.

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 – 0.145 + 0.132 0.204 – Replacing
155 1.0 bushing
– 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
20 D275A-5R
D275A-5R 21
D275A-5R Bulldozer
© 2007 KOMATSU
All Rights Reserved
22 D275A-5R
SEN02169-00
D275A-5R

D275A-5R 35001 and up

Hydraulic system, Part 1
Work equipment hydraulic piping diagram...................................................................................................... 2
PPC control piping diagram ............................................................................................................................ 6
Work equipment control .................................................................................................................................. 8
Hydraulic tank ............................................................................................................................................... 10
Work equipment pump.................................................................................................................................. 12
D275A-5R 1
Work equipment hydraulic piping diagram 1

Semi U-dozer
1. Blade tilt cylinder 6. Oil cooler bypass valve

2. R.H. blade lift cylinder 7. Work equipment pump
3. Control valve 8. L.H. blade lift cylinder
4. Accumulator 9. Oil cooler
5. Hydraulic tank
2 D275A-5R
U-Dozer + dual tilt
1. Blade tilt cylinder 7. Oil cooler bypass valve

2. R.H. blade lift cylinder 8. Work equipment pump
3. Control valve 9. L.H. blade lift cylinder
4. Accumulator 10. Blade pitch cylinder
5. Dual tilt solenoid valve 11. Oil cooler
6. Hydraulic tank
D275A-5R 3
Multi-shank ripper
1. Control valve
2. Divider block
3. Ripper tilt cylinder
4. Ripper lift cylinder
4 D275A-5R
Giant ripper
q The diagram shows a machine equipped with a pin puller cylinder
1. 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. Steering case
5. Pin puller cylinder 10. Brake valve
D275A-5R 5
PPC control piping diagram 1

PPC control piping diagram
1. Blade control PPC valve 5. PPC lock valve

2. Control valve 6. Work equipment lock lever
3. Accumulator 7. Work equipment pump
4. Ripper control PPC valve
6 D275A-5R
D275A-5R 7
Work equipment control 1

q The diagram shows a machine equipped with pitch dozer and pin puller cylinder.
8 D275A-5R
1. Work equipment lock 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

A: Blade HOLD
B: Blade LOWER
C: Blade FLOAT
D: Blade RAISE
E: Blade LEFT TILT/PITCH
F: Blade RIGHT TILT/PITCH
G: Ripper HOLD
H: Ripper RAISE
J: Ripper LOWER
K: Ripper TILT IN
L: Ripper TILT BACK
M: FREE
N: LOCK
P: Single tilt
Q: Dual tilt
R: Pitch OFF
S: Pitch ON
T: Pin puller switch PUSH IN
U: Pin puller switch PUSH OUT
Outline
q The work equipment control employs a PPC
method which uses a PPC valve to move each
control valve spool.
q Work equipment lock lever (1) is intercon-
nected with PPC lock valve (7), and at the
LOCK position, the oil in the PPC circuit is
stopped.
D275A-5R 9
Hydraulic tank 1
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 D275A-5R
Specified value Specified value
Tank capacity (l) 200 Cracking pressure 102.9 ± 19.6

(KPa {kg/cm2}) {1.05 ± 0.2}
Hydraulic Hi (l) 149
Level inside Hydraulic Mesh size (µm) 30/8
tank Center (l) 135
tank filter
Filtering area (cm2) 13,600
Low (l) 117
Filtering oil flow (l/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})
D275A-5R 11
Work equipment pump 1

Type: HPV95 (112-cm3/rev specification)
Outline
This pump consists of a swash plate-type variable-capacity piston pump and an LS valve.
12 D275A-5R
1. Piston pump
2. Control assembly
PA1: Pump discharge port

PD1: Pump drain plug
PD2: Pump drain port
PS1: Pump suction port
PLS1: Load pressure input port
PLS2: Load pressure pick-up plug
PEN12: Control pressure pick-up plug
Specifications
Type: HPV95 (112 cm3/rev)
Theoretical displacement: 112 ±1 cm3/rev
Rated speed: 2,286 rpm
Max. cut-off pressure: 27.5 MPa {280 kg/cm2}
D275A-5R 13
PA: Pump discharge port PD2: Pump drain port

PA1: Pump pressure signal port PS: Pump suction port
PD1: Pump drain plug PEN11:Control pressure port
14 D275A-5R
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
D275A-5R 15
Outline q Rocker cam (4) forms a static bearing sending

q The engine rotation and torque transmitted to high pressure oil at cylindrical surface (B) of
the pump shaft is converted to hydraulic cradle (3), which is fixed to the case, and car-
energy and pressurized oil is discharged ries out a sliding movement.
according to the load. q Piston (8) carries out motion relative to the
q It is possible to change the discharge amount axial direction inside each cylinder chamber of
by changing the swash plate angle. cylinder block (9).
q The cylinder block (9) carries out rotation rela-
Structure tive to valve plate (10) while sealing the pres-
q Cylinder block (9) is supported to shaft (1) by a surized oil, and this surface ensures that the
spline (13), and shaft (1) is supported by the hydraulic balance is maintained correctly.
front and rear bearings. q The oil inside each cylinder chamber of cylin-
q The end of piston (8) has a concave ball shape der block (9) is sucked in and discharged
and shoe (5) is caulked to it to form one unit. through valve plate (10).
Piston (8) and shoe (5) form a spherical bear- q Impeller (12) is fixed to shaft (1), and rotates
ing. together with the shaft, it makes it easier for
q Rocker cam (4) holds plane (A), and shoe (5) the oil sucked in from the suction port to be
is always pressed against this surface as it sucked in and sends it into the cylinder cham-
slides in a circle. ber by centrifugal force.
16 D275A-5R
Operation q When center line (X) of rocker cam (4) is the

1. Operation of pump same as the axial direction of cylinder block (9)
q Cylinder block (9) rotates together with shaft (s wash plate angle = 0) , the differ enc e
(1), and shoe (5) slides on plane (A). When between volumes (E') and (F') inside cylinder
this happens, rocker cam (4) moves along block (9) is 0, so pump does not suction and
cylindrical surface (B), so angle (a) of center discharge, and no pumping's carried out. Actu-
line (X) of rocker cam (4) to the axial direction ally swash plate angle does not become 0.)
of cylinder block (9) changes. This angle (a) is q The swash plate angle (a) is proportional to
called the swash plate angle. pump discharge volume.
q With swash plate angle (a) formed by the angle

between center line (X) of rocker cam (4) to the
axial 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 gener-
ated between volumes (E) and (F) inside the
cylinder block. The amount of suction and dis-
charge is equal to difference (F) – (E).
q In other words, cylinder block (9) rotates, and
the volume pf chamber (E) becomes smaller,
so oil is discharged during this process. At the
s a m e t i m e , t h e v o l u m e o f c h a m b e r ( F)
becomes larger and oil is sucked in this pro-
cess.
D275A-5R 17
2. Control of delivery
q If swash plate angle (a) becomes larger, the
difference between volumes (E) and (F)
becomes larger, and pump delivery (Q) is
increased. Swash plate angle (a) is changed
by servo piston (6).
q Servo Piston (6) carries out reciprocal move-
ment in a straight line according to the com-
mand 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.
q 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
piston end is always connected with main
pump discharge pressure (self pressure) (PP).
q Output pressure (PNC) of the LS valve is
applied to the chamber receiving the pressure
at the large diameter piston end (which
receives pressure of the pump).
q The movement of servo piston (6) is controlled
by the relationship of the size of pump pres-
sure (PP) and the pressure at the large diame-
ter piston end, and the comparative size of the
ratio of area receiving the pressure at the large
diameter piston end and small diameter piston
end.
q The movement of the servo piston is controlled
by a valve called the LS valve. Main pump
pressure (PP) and pressure (PLS) (the LS
pressure) from the control valve outlet port
enter this valve.
q The relationship between pump delivery (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.
18 D275A-5R
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
D275A-5R 19
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
20 D275A-5R
1. Operation of LS valve
1) When the control valve is at HOLD position
Operation
q The LS valve is a 3-way selector valve, and
main pump pressure (PP) and pressure (PLS)
(LS pressure) from the outlet port of the control
valve are applied to (d) port and (a) port.
q Spool (4) of this LS valve is pushed by the
force of spring (3) from the end receiving the
LS pressure, and the position of the spool (4)
is determined by the LS pressure (PLS) +
spring force (F) and the size of main pump
pressure (PP).
q Main pump pressure (PP) always effects to
ports (d) and (e). LS pressure (PLS) enters
chamber (g) from port (a).
q 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)
q 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.)
q 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 piston (1) to the left so that the swash
plate angle becomes minimum.
D275A-5R 21
2) Movement in direction to increase pump discharge (to the right)
Operation q Circuits (c) – (f), which are the pressure of (f)

q When LS differential pressure ( PLS), which port at the large diameter piston end of servo
is the difference in pressure between main piston (1), become the drain pressure, so
pump pressure (PP) and LS pressure (PLS), servo piston (1) is pushed from the small diam-
becomes smaller (for example, the area of eter piston end to the large diameter piston
opening of the control valve becomes larger end.
and pump pressure (PP) is reduced), spool (4) Rod (2) also moves to the right because of this
is pushed to the right under the combined force movement, and changes the swash plate
of the LS pressure (PLS) and the force of angle.
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 pressure (PP), so
spool (4) is pushed to the right.
q Because of the movement of spool (4), port (c)
and port (b) are connected, and circuit (c) - (f)
become drain pressure (PT).
22 D275A-5R
3) Movement in direction to reduce pump discharge (to the left)
Operation q Main pump pressure (PP) also enters the small

q The following explains the situation when diameter piston end, but servo piston (1) is
servo piston (1) moves to the left (the direction pushed from the large diameter piston end to
to make the discharge amount smaller). If LS the small diameter piston end because of the
differential pressure ( PLS) becomes larger difference in area between the large diameter
(for example, the area of opening of the control piston end and the small diameter piston end.
valve becomes smaller and pump pressure q As a result, rod (2) moves in the direction to
(PP) increases), spool (4) is pushed to the left make the swash plate angle smaller (to the
by pump pressure (PP). left).
q Because of the movement of spool (4), main
pump pressure (PP) flows into port (c), and
main pump pressure (PP) enters the large
diameter piston end from port (f).
D275A-5R 23
4) When servo piston is balanced
Operation q When this happens, the force pushing the

q In the LS valve, lf main pump pressure (PP) is small diameter piston and the force pushing
balanced with the combined force of LS pres- the large diameter piston are balanced, so
sure (PLS) at chamber (g) and force (F) of servo piston (1) stops. In other words, the fol-
spring (3), servo piston (1) stops at the inter- lowing condition is reached.
mediate position for the swash plate angle. q Pump pressure (PP) x area receiving pressure
[Force (F) of spring (3) converted to the at small diameter piston end = hydraulic pres-
hydraulic power: Approx. 1.96 MPa {20kg/ sure (PNC) at the large diameter piston end x
cm2}]. area receiving pressure at large diameter pis-
q If an LS pressure (main pump pressure – force ton end.
of spring) that fulfills the above conditions for The difference I area between the large diame-
balancing enters ports (a), main pump pres- ter piston and small diameter piston is normally
sure (PP) entering from port (d) and combined approx. 2:1, so the pressure at the large diam-
force (F) of spring (3) and the force from LS eter piston end is approx. 1/2 of pump pres-
pressure (PLS) are balanced, and pressure of sure (PP).
a certain size enters port (f) from port (c).
24 D275A-5R
2. Operation of variable throttle valve

1) Properties of variable throttle valve
q 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
between the LS valve and the port at the large
diameter end of the servo piston for the follow-
ing reasons.
i 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 exces-
sive response.
ii To prevent cavitation at the suction port
caused by the sudden increase in the suc-
tion volume when changing from MIN to
MAX.
q 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 (A) of the opening smaller
at high pressure and the area (A) of the open-
ing larger at low pressure, and by preventing
the above problems i and ii at high pressure.
D275A-5R 25
2) Pump discharge pressure at high pressure
Operation
q In the variable throttle valve (6), main pump
pressure (PP) from LS valve (5) passes
through port (b) and enters port (f).
q 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 diam-
eters at both ends of chamber (f), spool (4) is
moved to the left.
q 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 servo piston (1) from port (d) is reduced and
the speed of movement of servo piston (1)
becomes slower.
26 D275A-5R
3) Pump discharge pressure at low pressure
Operation
q 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.
q The area of the opening from port (a) to port (c)
becomes larger, so output pressure (PNC)
from the LS valve (5) is transmitted as it is.
D275A-5R 27
D275A-5R Bulldozer
© 2007 KOMATSU
All Rights Reserved
28 D275A-5R
SEN02170-00
D275A-5R

D275A-5R 35001 and up

Control valve ................................................................................................................................................... 2
Operation of control valve ............................................................................................................................. 12
Self pressure reducing valve......................................................................................................................... 29
D275A-5R 1
Control valve 1
Standard specification
Cautions for tightening bolts marked with *
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}
2 D275A-5R
A: Pump pressure pick-up port

B: LS pressure pick-up port
C: PPC main pressure
T: Drain
A1: To blade tilt right cylinder head
A2: To blade lift cylinder head
A3: To ripper lift cylinder head
A4: To ripper tilt cylinder bottom
B1: To blade tilt right cylinder bottom
B2: To blade lift cylinder bottom
B3: To ripper lift cylinder bottom
B4: To ripper tilt cylinder head
LS: To HSS pump LS valve
P1: From pump
PR: PPC output
TS: Seal drain
PA1: From blade PPC valve port P3
PA3: From ripper PPC valve port P3
PB1: From blade PPC valve port P4
PB3: From ripper PPC valve port P4
D275A-5R 3
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
209.37N 167.50N
76.3 x 30 68.5 —
{21.35kg} {17.08kg}
140.1N 111.7N
10 Spool return spring 51.7 x 31.3 50 —
{14.3kg} {11.4kg} If damaged or
Spool return spring 216.6N 173.5N deformed,
11 54.7 x 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 x 10.2 13.5 —
{1.3kg} {1.0kg}
Pressure compensation valve 562N 449N
13 108.3 x 29.5 81 —
spring {57.3kg} {45.8kg}
192.4N 154N
14 Unload spring 86.7 x 30 66 —
{19.63kg} {15.7kg}
4 D275A-5R
1. LS check valve 4. Unload valve

2. Main relief valve 5. Suction valve
3. LS relief valve 6. Check valve (built in spool)
Unit: mm
Free length
x Outside Free length
7 Suction valve spring length load load
diameter
6.37N 5.1N If damaged or
64.9 x 12.5 56 —
{0.65kg} {0.52kg} deformed,
14.7N 11.8N replace spring
8 Check valve spring in spool 27.9 x 6.5 22.5 —
{1.5kg} {1.2kg}
0.29N 0.20N
{0.03kg} {0.02kg}
D275A-5R 5
1. Suction valve
2. Preset check valve
3. LS bypass valve
Unit: mm
Free length
Installed Installed Installed If damaged or
4 Suction valve spring length load load deformed,
diameter
replace spring
5.49N 4.4N
46.8 x 7.5 40.6 —
{0.56kg} {0.45kg}
6 D275A-5R
D275A-5R 7
Dual tilt specification

Cautions for tightening bolts marked with*
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}
8 D275A-5R
A: Pump pressure pick-up port

B: LS pressure pick-up port
C: PPC main pressure
T: Drain
A1: To blade tilt right cylinder head
A2: To blade lift cylinder head
A3: To blade tilt left cylinder head
A4: To ripper lift cylinder head
A5: To ripper tilt cylinder bottom
B1: To blade tilt right cylinder bottom
B2: To blade lift cylinder bottom
B3: To blade tilt left cylinder bottom
B4: To ripper lift cylinder bottom
B5: To ripper tilt cylinder head
LS: To HSS pump LS valve
P: From pump
PA1: From dual tilt and pitch changeover valve
PA3: From dual tilt and pitch changeover valve
PB1: From dual tilt and pitch changeover valve
PB3: From dual tilt and pitch changeover valve
D275A-5R 9
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 spool
5. Blade lift spool
Unit: mm
Free length
Spool return spring x Outside Free length
10 length load load
(only for blade lift) diameter
209.37N 167.50N
76.3 x 30 68.5 —
{21.35kg} {17.08kg}
140.1N 111.7N
11 Spool return spring 51.7 x 31.3 50 —
{14.3kg} {11.4kg} If damaged or
Spool return spring 216.6N 173.5N deformed,
12 54.7 x 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 x 10.2 13.5 —
{1.3kg} {1.0kg}
Pressure compensation valve 562N 449N
14 108.3 x 29.5 81 —
spring {57.3kg} {45.8kg}
192.4N 154N
15 Unload spring 86.7 x 30 66 —
{19.63kg} {15.7kg}
10 D275A-5R
1. LS check valve 4. Unload valve

2. Main relief valve 5. Suction valve
3. LS relief valve 6. Check valve (built in spool)
Unit: mm
Free length
7 Suction valve spring length load load
diameter
6.37N 5.1N If damaged or
64.9 x 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}
D275A-5R 11
Operation of control valve 1
Function
q 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
tion, the pump pressure passes from (FS) of spring (2), the spool moves to the
chamber (A) through oriffice (4) to cham- right and connects the passage between
ber (D). Chambers (C) and (C') are con- chamber (A) and chamber (B), so the oil
nected to the drain circuit. from the pump is drained. Therefore,
(2) When oil is supplied from the pump, the spool (1) is balanced at a position that
pressure in chamber (D) rises, and spool matches the supply of oil from the pump.
(1) is pushed to the right by pressure (FO) Actually, the amount of oil supplied from
which is determined by the cross-sectional the pump is small, so the pressure in the
area of piston (3) receiving the pressure. circuit is almost the same as the set load
of spring (2).
12 D275A-5R
2. Control of oil flow

(1) Work equipment valve (Following explanation
is for blade right tilt cylinder circuit)
q 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 compensation valve, so it pushes against the
pump pressure is sent from chamber (A) load of spring (4) and moves to the right to the
through the notch in spool (3) of the pressure maximum stroke position. In this condition, the
compensation valve, and passes through area of the opening to spool (1) of the blade tilt
chamber (B) to chamber (C). Chamber (G) is valve is at its minimum.
drained through chamber (H) to chamber (F).
When this happens, the pump pressure is act-
ing on the left end of spool (3) of the pressure
D275A-5R 13
2) At blade right tilt
[1] When the tilt lever is operated to right tilt, pilot q PLS = differential pressure between ports
pressure (PB1) acts on the right end of spool (K) and (J) = 1.96 MPa {20kg/cm2}
(1) through the PPC valve, and when the pres- q PLS' = differential pressure between ports
sure becomes greater than the set load of (I) and (D)
spring (2), the spool starts to move to the left. It q PLS C PLS'
is balanced at a position corresponding to PPC
output pressure (PB1).
14 D275A-5R
[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 chamber (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 C chamber (C) pressure,
and chamber (G) pressure C chamber (D)
pressure, so spool (3) is controlled by the dif-
ferential pressure of spool (1) (chamber (C)
pressure – Chamber (D) pressure), and bal-
ances with spring (4).
In other words, if the oil flow is too large, the
differential pressure of spool (1) becomes
larger, so spool (3) moves in the direction to
throttle the oil flow; on the other hand, if the oil
flow is too small, spool (3) moves in the direc-
tion to increase 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 differ-
ential 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.
D275A-5R 15
3) Meter-out control when blade moves down under its own weight (work equipment lever at LOWER)
16 D275A-5R
q In the case where the blade falls owing to the

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

der so that it prevents the circuit from being
evacuated.
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 open-
in g ar ea be twee n por ts (A ) a nd ( B)
squeezes the return flow from a lift cylin-
der 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.
D275A-5R 17
4) Meter-out control when blade moves down under its own weight (work equipment lever at FLOAT)
18 D275A-5R
q When the lift valve is at FLOAT, the cylinder

port and drain port are connected to put the cir-
cuit in a no-load condition.
q 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)
becomes 3.4 MPa (35 kg/cm2) 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 circuit, 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 controlled.
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 compound operations with other
control valves.
D275A-5R 19
3. At relief
(1) Blade lift, blade tilt, ripper lift, ripper tilt
a The diagram shows the condition at relief for work equipment LS relief valve (5) with blade tilt stroke
end.
q P1 = P3 + P4 = Differential pressure q P4 = Differential pressure between ports (B)

between ports (M) and (P) and (P)
q P2 = Differential pressure between ports (P) q LS = ( P1) + ( P2) = Differential pressure
and (N) between ports (M) and (N) = 1.96 MPa {20 kg/
q P3 = Differential pressure between ports (M) cm2}
and (B)
20 D275A-5R
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 chambers (B) and (C) will be throt-
tled 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
differential pressure ( LS). When this hap-
pens, pump LS valve (6) detects the differ-
ential 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 (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 actuat-
ed to relieve the excess oil flow and balance
the circuit.
D275A-5R 21
(2) Compound operation of work equipment valve

a The diagram shows the condition when the blade lift and tilt valves are operated at the same time.
22 D275A-5R
q 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
opening.
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 pump 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 demanded 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

angle
When the maximum flow of oil from the
pump is smaller than the total of the oil
flow demanded by the tilt valve and lift
valve, the flow of oil to the tilt valve and lift
valve is divided according to differential
pressure (PO) – (P2) and differential pres-
sure (PO) – (P3). In other words, more oil
flows to (P2) where the load is small.
a 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 demanded by the tilt valve is
smaller, so the condition is just as if prior-
ity was given to the oil flow for the tilt
valve.
3) When pump pressure (P2) = pump pres-

sure (P3)
(P) – (P2) C (P) – (P3), so an oil flow pro-
portional to the size of the spool opening
is distributed to each spool.
D275A-5R 23
(3) Unload valve preset system

a The diagram shows the condition with preset check valve (3) open immediately after blade lift valve is
operated.
24 D275A-5R
q This improves the response of the system

including the pump swash plate and pressure
compensation valve by sending the pilot pres-
sure (basic pressure of PPC valve) to the LS
circuit, and compensating the rise of the LS cir-
cuit 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
chamber (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 compen-
sation 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 sup-

plied to LS circuit (O) by the timing of the spool,
and the pressure in the LS circuit rises. Be-
cause 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 possible to reduce the response time
for giving the necessary oil flow. Check valve
(5) is built in the spool to prevent preset pres-
sure (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 cylin-
der port is prevented from entering the PPC
pump circuit by preset check valve (3).
D275A-5R 25
(4) Dual tilt and pitch system

a A machine with the dual tilt specification has the dual tilt and pitch system circuit.
1) When single tilt operation is carried out
q 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 circuits (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.
26 D275A-5R
2) When dual tilt operation is carried out
q 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 cir-
cuit (4) of the PPC valve.
PPC circuit (3) connected to (PA1) of the con-
trol valve is connected to output circuit (5) of
the PPC valve.
Accordingly, both tilt cylinders move in the
opposite directions to carry out the dual tilt
operation.
D275A-5R 27
3) When pitch operation is carried out
q 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 cir-
cuit (5) of the PPC valve.
PPC circuit (3) connected to (PA1) of the con-
trol 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.
28 D275A-5R
Self pressure reducing valve 1
T: To hydraulic tank
P1: From cooling fan pump
P2: To cooling fan motor
PR: Supply to PPC valve and EPC valve
D275A-5R 29
1. Valve (sequence valve) 6. Spring (pressure reducing valve main)

2. Spring 7. Valve (pressure reducing valve)
3. Screw 8. Spring (safety valve)
4. Poppet 9. Ball
5. Spring (pressure reducing valve pilot) 10. Filter
30 D275A-5R
Unit: mm
Spring Free length Installed Installed Free length Installed
11 x O.D. length load load
(pressure reduction main)
19.6 17.7 N Replace
19.2 x 7.20 16.1 {2.0 kg} – {1.80 kg} spring if any
damages or
Spring 28 N 25.6 N deforma-
12 (pressure reduction valve pilot) 17.8 x 7.20 12.7 {2.90 kg} – {2.60 kg} tions are
200 N 186 N found
13 Spring 71.0 x 18.0 59.0 –
{20.4 kg} {19.0 kg}
61.7 N 58.8 N
14 Spring (safety valve) 16.1 x 7.80 13.4 {6.30 kg} – {6.0 kg}
Function
The self pressure reducing valves reduces the dis-
charge pressure of the cooling fan pump and sup-
plies it to the PPC valve, the EPC valve, etc. as the
control pressure.
D275A-5R 31
Operation
1. At engine stop (total low pressure)
q The spring (6) pushes the poppet (5) the seat,

and the circuit between the ports (PR) and (T)
is closed.
q The spring (7) pushes the valve (8) to the left
side, and the circuit between the ports (P1)
and (PR) is open.
q The spring (3) pushes the valve (2) to the left
side, and the circuit between the ports (P1)
and (P2) is closed.
32 D275A-5R
2. When the load pressure P2 is lower than the output pressure PR of the self pressure reducing
valve.
q The spring (3) and the (PR) pressure (0 MPa q Therefore, there will occur a differential pres-
{0 kg/cm2} at the time of engine stop) pushes sure around the hold a in the spool (8) and the
the valve (2) in the direction to close the circuit spool will move in the direction to close the
between the ports (P1) and (P2). When the port (P1) and the (PR) opening. Then, the (P1)
hydraulic oil enters the (P1) port, the expres- pressure is reduced and adjusted to a certain
sion ((P1) pressure Spring (7) force + (ø(d) pressure (set pressure) with the opening and is
area x (PR) pressure)) holds, and the self pres- supplied as the (PR) pressure.
sure reducing valve will adjust the openings of
the ports (P1) and (P2) so that the (P1) pres-
sure can be maintained higher than the (PR)
pressure.
q When the (PR) pressure rises above the set
pressure, the poppet (5) will open and the
hydraulic oil flows through the route from the
(PR) port, the hole a in the spool (8), the pop-
pet (5) opening to the tank port (T).
D275A-5R 33
3. At raise of load pressure P2
q When the load pressure (P2) rises due to dig- q When the (PR) pressure rises above the set
ging or other operations, the pump delivery will pressure, the poppet (5) will open and the
increase and the (P1) pressure will rise. hydraulic oil will flow through the route from the
Then, the expression ((P1) pressure > Spring (PR) port, the hole (a) in the spool (8), the pop-
(7) force + ( (d) area x (PR) pressure)) will pet (5) opening to the tank port (T).
hold, and the valve (2) will move to the right q Therefore, there will occur a differential pres-
side till the stroke end. As a result, the open- sure around the hold (a) in the spool (8) and
ing between the ports (P1) and (P2) will the spool will move in the direction to close the
increase, the passage resistance will become port (P1) and the (PR) opening. Then, the (P1)
smaller to reduce engine loss horsepower. pressure is reduced and adjusted to a certain
pressure (set pressure) with the opening and is
supplied as the (PR) pressure.
34 D275A-5R
4. At occurrence of abnormal high pressure
q When the (PR) pressure of the self pressure

reducing valve rises abnormally high, the ball
(10) will separate from the seat against the
spring (9) force to flow the hydraulic oil to the
output ports (PR) (T) so as to reduce the
(PR) pressure. Then, the equipment (PPC
valve, solenoid valve, etc.), to which the oil
pressure is supplied, is protected from the
abnormal high pressure.
D275A-5R 35
D275A-5R Bulldozer
© 2007 KOMATSU
All Rights Reserved
36 D275A-5R
SEN02171-00
D275A-5R

D275A-5R 35001 and up

PPC valve ....................................................................................................................................................... 2
PCCS lever ................................................................................................................................................... 14
PPC lock valve.............................................................................................................................................. 17
Work equipment cylinder .............................................................................................................................. 18
Piston valve................................................................................................................................................... 21
Quick drop valve ........................................................................................................................................... 22
Pin puller switch ............................................................................................................................................ 23
Pin puller solenoid valve ............................................................................................................................... 24
Blade control knob ........................................................................................................................................ 26
Pitch, dual tilt solenoid valve......................................................................................................................... 27
Accumulator .................................................................................................................................................. 28
D275A-5R 1
PPC valve 1
1. Blade PPC valve
P: From self pressure reducing valve P3: To blade tilt valve (LEFT TILT) PPC port
P1: To blade lift valve (LOWER) PPC port P4: To blade tilt valve (RIGHT TILT) PPC port
P2: To blade lift valve (RAISE) PPC port T: To hydraulic tank
2 D275A-5R
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 connecting lever)
D275A-5R 3
Unit: mm
Free length
Centering spring x Outside Free length
12 length load load
(For port P1) diameter
94 N 75.2 N
34.0 x 15.5 31.9 —
{9.6 kg} {7.68 kg}
Centering spring 78.5 N 62.8 N If spring is
13 43.2 x 15.5 34.0 —
(For port P2) {8 kg} {6.4 kg} damaged or
Centering spring 107.9 N 86.3 N deformed,
14 48.57 x 15.5 32.5 — replace it
(For ports P3 and P4) {11 kg} {8.8 kg}
Metering spring 16.7 N 13.3 N
15 29.27 x 8.15 25.4 —
(For port P1) {1.70 kg} {1.36 kg}
16 26.3 x 8.15 24.1 —
(For port P2) {1.70 kg} {1.36 kg}
17 26.53 x 8.15 24.9 —
(For ports P3 and P4) {1.70 kg} {1.36 kg}
4 D275A-5R
Operation
1) When in neutral
(1) For lifting blade (2) For tilting blade
q Ports (A) and (B) of the blade lift valve of the- q Ports (C) and (D) of the blade tilt valve of the
control valve and ports (P1) and (P2) of control valve and ports (P3) and (P4) of the
thePPC valve are connected through fine con- PPC valve are connected through fine control
trol hole (f) of spool (1) to drain chamber (D). hole (f) of spool (1) to drain chamber (D).
D275A-5R 5
2) When in fine control

(Neutral o Fine control)
q If piston (4) is pushed by disc (5), retainer (9) is
pushed and spool (1) is also pushed down
through metering spring (2).
q Accordingly, fine control hole (f) is discon-
nected from drain chamber (D) and connected
to pump pressure chamber (PP) almost simul-
taneously, and then the pilot oil flows from port
(P1) through fine control hole (f) to port (B).
q If the pressure in port (P1) rises, spool (1) is
pushed back and fine control hole (f) is discon-
nected from pump pressure chamber (PP) and
connected to drain chamber (D) almost simul-
taneously to release the pressure in port (P1).
q As a result, spool (1) moves up and down to
balance the force of metering spring (2) with
the pressure in port (P1).
q The positional relationship between spool (1)
and body (10) [where fine control hole (f) is
between drain chamber (D) and pump pres-
sure chamber (PP)] does not change until
retainer (9) comes in contact with spool (1).
q Since metering spring (2) is compressed in
proportion to the stroke of the control lever, the
pressure in port (P1) rises in proportion to the
stroke of the control lever.
q Accordingly, the control valve spool moves to a
position at which the pressure in port (B) [equal
to the pressure in port (P1)] is balanced with
the force of the control valve spool return
spring.
6 D275A-5R
3) When in fine control 4) When lever is operated to stroke end

(When control lever is returned) q If disc (5) pushes down piston (4) and retainer
q If lever (5) begins to return, the force of center- (9) pushes down spool (1), fine control hole (f)
ing spring (3) and the pressure in port (P1) is disconnected from drain chamber (D) and
push up spool (1). connected to pump pressure chamber (PP).
q As a result, fine control hole (f) is connected to q Accordingly, the pilot oil flows through fine con-
drain chamber (D) and the oil in port (P1) is trol hole (f) and port (P1) into port (B) and
released. pushes the control valve spool.
q If the pressure in port (P1) lowers too much, q The oil returning from port (A) flows through
spool (1) is pushed down by metering spring port (P2) and fine control (f’) into drain cham-
(2) and fine control hole (f) is disconnected ber (D).
from drain chamber (D) and connected to
pump pressure chamber (PP) almost simulta-
neously. Then, the pump pressure is applied
until the pressure in port (P1) is restored to the
level corresponding to the position of the lever.
q When the control valve spool returns, the oil in
drain chamber (D) flows in through fine control
hole (f’) of the valve which is not in operation
and then flows through port (P2) into port (A).
D275A-5R 7
5) When blade is “floated” 6) When “FLOAT” state of blade is reset

q If piston (4) on the “LOWER” side of port (P1) q Disc (5) is pushed down with a force larger
is pushed down by disc (5), ball (11) touches than the oil pressure in chamber (E) to return
projection (a) of the piston in the middle of the from the “FLOAT” position.
stroke (The detent starts to operate). q As a result, chamber (E) is disconnected from
q If piston (4) is pushed in further, ball (11) passage (d) and connected to the drain cham-
pushes up collar (12) supported on detent ber. Accordingly, the oil pressure in chamber
spring (13) and escapes out to go over projec- (E) is lost and the “FLOAT” state is reset.
tion (a) of the piston.
q At this time, piston (4') on the opposite side is
pushed up by spring (14).
q As a result, the oil in chamber (F) flows
through (b) and (c) to chamber (E) and piston
(4') follows disc (5). Since passage (d) is con-
nected to port (P1), almost the same pressure
is applied to passage (d) and port (P1).
q Chamber (E) is normally connected to drain
chamber (D). If ball (11) goes over projection
(a) of the piston, passage (d) and chamber (E)
are connected and the oil starts flowing.
q At this time, the control valve moves to the
“FLOAT” position and the blade is floated.
q Since piston (4') is pushed up by the pressure
in chamber (E), the “FLOAT” state is kept even
if the lever is released.
8 D275A-5R
D275A-5R 9
2. Ripper PPC valve
P: From self pressure reducing valve 1. Spool

P1: To ripper tilt valve PPC port 2. Metering spring
P2: To ripper tilt valve PPC port 3. Centering spring
P3: To ripper lift valve PPC port 4. Piston
P4: To ripper lift valve PPC port 5. Disc
T: To tank 6. Nut (For connecting lever)
7. Joint
8. Plate
9. Retainer
10. Body
11. Filter
10 D275A-5R
Unit: mm
Free length Free Installed
Installed Installed
Centering spring x Outside
12 length load length load
(For ports P3 and P4) diameter
If spring is
55.9 N 44.7 N damaged or
50.4 x 15.5 34.0 —
{5.7 kg} {4.56 kg} deformed,
replace it
Centering spring 71.4 N 56.9 N
13 50.1 x 15.5 34.0 —
(For ports P1 and P2) {7.28 kg} {5.8 kg}
16.7 N 13.3 N
14 Metering spring 26.5 x 8.20 24.9 —
{1.70 kg} {1.36 kg}
D275A-5R 11
Operation q Since metering spring (2) is compressed in

1) When in neutral proportion to the stroke of the control lever, the
q Ports (A) and (B) of the control valve and ports pressure in port (P1) rises in proportion to the
(P1) and (P2) of the PPC valve are connected stroke of the control lever.
through fine control hole (f) of spool (1) to drain q Accordingly, the control valve spool moves to a
chamber (D). position at which the pressure in chamber (A)
[equal to the pressure in port (P1)] is balanced
with the force of the control valve spool return
spring.
2) When in fine control

(Neutral o Fine control)
q If piston (4) is pushed by disc (5), retainer (9) is
pushed and spool (1) is also pushed down
through metering spring (2).
q Accordingly, fine control hole (f) is discon-
nected from drain chamber (D) and connected
to pump pressure chamber (PP) almost simul-
taneously, and then the pilot oil flows from port
(P1) through fine control hole (f) to port (A).
q If the pressure in port (P1) rises, spool (1) is
pushed back and fine control hole (f) is discon-
nected from pump pressure chamber (PP) and
connected to drain chamber (D) almost simul-
taneously to release the pressure in port (P1).
q As a result, spool (1) moves up and down to
balance the force of metering spring (2) with
the pressure in port (P1). The positional rela-
tionship between spool (1) and body (10)
[where fine control hole (f) is between drain
chamber (D) and pump pressure chamber
(PP)] does not change until retainer (9) comes
in contact with spool (1).
12 D275A-5R
3) When in fine control 4) When lever is operated to stroke end

(When control lever is returned) q If disc (5) pushes down piston (4) and retainer
q If disc (5) begins to return, the force of center- (9) pushes down spool (1), fine control hole (f)
ing spring (3) and the pressure in port (P1) is disconnected from drain chamber (D) and
push up spool (1). connected to pump pressure chamber (PP).
q As a result, fine control hole (f) is connected to q Accordingly, the pilot oil flows through fine con-
drain chamber (D) and the oil in port (P1) is trol hole (f) and port (P1) into chamber (A) and
released. pushes the control valve spool.
q If the pressure in port (P1) lowers too much, q The oil returning from chamber (B) flows
spool (1) is pushed down by metering spring through port (P2) and fine control (f’) into drain
(2) and fine control hole (f) is disconnected chamber (D).
from drain chamber (D) and connected to
pump pressure chamber (PP) almost simulta-
neously. Then, the pump pressure is applied
until the pressure in port (P1) is restored to the
level corresponding to the position of the lever.
q When the control valve spool returns, the oil in
drain chamber (D) flows in through fine control
hole (f’) of the valve which is not in operation
and then flows through port (P2) into chamber
(B).
D275A-5R 13
PCCS lever 1
Travel and steering PCCS lever
a Do not disassemble the PCCS lever. If it is disassembled, the output voltage characteristics and operat-
ing effort characteristics will need to be adjusted.
1. Bellows 5. Screw
2. Bracket 6. Lever
3. Plate 7. Connector
4. Bolt
14 D275A-5R
Function
1. Operating effort characteristics
1) Operation for forward and reverse travel 2) Operation for steering
q The control lever is held at 3 positions of For- q Free return.
ward, Neutral, and Reverse.
D275A-5R 15
2. Output voltage characteristics

q The control unit is installed to the left control
stand and the control lever is installed directly
onto it.
q The operating angle (stroke) of the control
lever is sensed with potentiometers and signal
voltages are output to the transmission and
steering controller.
q A potentiometer is installed in each of longitu-
dinal direction and lateral direction. Each
potentiometer outputs 2 signal voltages which
are opposite to each other as shown in the fig-
ure at right.
16 D275A-5R
PPC lock valve 1
1. Lever
2. End cap
3. Ball
4. Seat
5. Body
Outline
q The PPC lock valve is installed in the PPC cir-
cuit between the PPC, HSS charge valve and
PPC valve. If the work equipment lock lever is
placed at the LOCK position, the PPC lock
valve is actuated together with the work equip-
ment lock lever. This stops the oil in the PPC
circuit and makes it impossible to operate the
work equipment.
D275A-5R 17
Work equipment cylinder 1

Blade lift cylinder
Blade tilt cylinder
Ripper lift cylinder
18 D275A-5R
Ripper tilt cylinder
Unit: mm
– 0.030 + 0.258 0.078 –
Blade lift 80 0.745
– 0.076 + 0.048 0.334
Clearance between
1 piston rod and bush- Blade tilt – 0.036 + 0.257 0.084 –
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
Clearance between + 0.100
cylinder bottom sup- + 0.207
5 Ripper lift 90 — — 1.0
port shaft and bush- + 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
D275A-5R 19
Dual tilt cylinder (If equipped)
Pin puller cylinder (If equipped)
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
– 0.065 + 0.133 0.072 –
Pin puller 30 0.55
– 0.117 + 0.007 0.250
Clearance between piston rod + 0.200
2 70 — — 1.0
support shaft and bushing 0 Replace
Clearance between piston rod – 0.100
3 29 — — —
spherical surface and bushing – 0.200
Clearance between cylinder
+ 0.174
4 bottom support shaft and bush- 70 — — 2.0
+ 0.100
ing
Clearance between cylinder
+ 0.100
5 bottom support shaft and bush- 26 — — —
– 0.100
ing
20 D275A-5R
Piston valve 1
For blade lift cylinder
Outline
q The piston valve is installed on the piston in
the blade lift cylinder. When the piston reaches
its stroke end, the valve releases the oil from
the hydraulic pump to reduce the oil pressure
being exerted 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
tortional force from occurring. When one of the
pistons 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 con-
tact with the cylinder head or the bottom and
serves to redure the subsequent surge pres-
sure in the cylinder by letting the oil escape
from the cylinder 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 cylin-
der to rise and moving piston (2) in the direc-
tion of the arrow.
2. Piston valve OPEN

Just before piston rod (1) reaches the end of
its stroke, the tip of valve (6) contacts the cylin-
der bottom, so valve (6) and piston valve (3)
stop at that position and do not move further.
Only piston (2) moves further.
When this happens, the oil at the cylinder
head, which was sealed by piston valve (3),
escapes from piston valve seats (4) and (5),
and the pressure inside the cylinder stops ris-
ing.
D275A-5R 21
Quick drop valve 1

For blade lift cylinder
Unit: mm
Clearance between spool and
1
valve body – 0.011 + 0.010 0.011 –
38.0 0.03
– 0.016 + 0.010 0.026
Replace
2 Valve spring length load load
136.3 N 122.6 N
75.2 55.9 67.7
{13.9 kg} {12.5 kg}
22 D275A-5R
Pin puller switch 1
1. Connector
2. Wire
3. Switch
4. Knob
Function
q 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.
D275A-5R 23
Pin puller solenoid valve 1
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
24 D275A-5R
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 sole-
noid (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 bottom end of pin puller cylinder
(10).
When the oil enters the bottom end of the cyl-
inder and the pressure in the circuit starts to
rise, the cylinder extends and pushes shank
mounting 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 arrow 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
retracts and pulls shank mounting pin (11) out
of shank (12).
D275A-5R 25
Blade control knob 1
1. Switch (dual-single selector switch) q If switch (2) is pressed and the lever is oper-
2. Switch (pitch) ated, the blade is pitched. If the lever is tilted
3. Cover to the left, the blade is pitched back. If the
4. Connector (male) former is tilted to the right, the latter is pitched
5. Connector (femele) forward.
q If switch (1) is set to the DUAL position and the
Outline lever is operated, blade carries out dual tilt
q If the blade control knob is tilted forward, back- operation. If the lever is tilted to the left, the
ward, to the right, or to the left, the blade is blade carries out left dual tilt operation. If the
raised, lowered, tilted to the right, or tilted to lever is tilted to the right, the blade carries out
the left. If switch (1) is set to the DUAL posi- right dual tilt operation.
tion and the lever is tilted to the right or left, q If switch (1) is set in either DUAL or SINGLE
dual tilt operation is carried out. If the lever is position and the lever is tilted to the right or left
tilted to the right or left while (2) is pressed and while switch (2) is pressed and held, the blade
held, pitching operation is carried out. is pitched.
26 D275A-5R
Pitch, dual tilt solenoid valve 1
P3 PA1
P3 P4
PB2 PA1
PB1 P4
1. Connector Outline
2. Solenoid (b) q The pitch switch solenoid valve is located
3. Valve between the PPC valve and the blade valve,
4. Solenoid (a) and at the downstream of the pitch tilt switch
5. Manual push pin solenoid valve, and its function is to switch the
PPC pilot pressure.
P3: To PPC valve port, hydraulic tank q By operating the pitch back switch or the pitch
P4: To PPC valve port, control valve P3 port dump switch of the blade control lever, the pilot
PB1:To control valve port pressure can be delivered to the left pitch cylin-
PA1: To control valve port der and the right pitch cylinder, and it enables
to switch from the tilt to the pitch.
q In addition, the pitch solenoid valve is operated
by the controller.
D275A-5R 27
Accumulator 1
For PPC valve Function
q The accumulator is installed between the PPC
charge pump and the PPC valve. Even if the
engine 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
q After the engine is stopped, when the PPC
valve is at neutral, chamber (A) inside the blad-
der is compressed by the oil pressure in cham-
ber (B).
q 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
actuates the main control valve.
1. Glass plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specificetions:
Type of gas: Nitrogen
Gas volume: 300 cc
Max. actuation pressure: 3.1 MPa {32 kg/cm2}
Max. actuation pressure: 1.2 MPa {12 kg/cm2}
28 D275A-5R
D275A-5R 29
D275A-5R Bulldozer
© 2007 KOMATSU
All Rights Reserved
30 D275A-5R
SEN02172-01
D275A-5R

D275A-5R 35001 and up

Work equipment
Cylinder stay ................................................................................................................................................... 2
Blade............................................................................................................................................................... 4
Ripper ........................................................................................................................................................... 10
D275A-5R 1
Cylinder stay 1
1. Yoke 4. Bushing
2. Oil seal 5. Air breather plug
3. Bushing
Unit: mm
Clearance between cylinder size Shaft Hole clearance limit
6
yoke and bushing – 0.172 + 0.088 0.218 –
140 —
– 0.235 + 0.046 0.323
Replace
Clearance between cylinder – 0.160 + 0.075 0.199 –
7 105 —
yoke and bushing – 0.214 + 0.039 0.289
Clearance between lift cylin- – 0.120 + 0.035 0.120 –
8 95 0.5
der support shaft and bushing – 0.207 + 0.046 0.242
2 D275A-5R
D275A-5R 3
Blade 1
Semi U-dozer, U-dozer
4 D275A-5R
Unit: mm
Clearance between brace pin size Shaft Hole clearance limit
1
and brace
– 0.3 + 0.5
ø 70 0.6 – 1.0 2
– 0.5 + 0.3
Clearance between brace pin – 0.3 + 0.3
2 ø 70 0.4 – 0.8 2
and bracket – 0.5 + 0.1 Replace
3 and bracket ø 70 0.3 – 0.8 2
– 0.5 + 0.1
4 ø 70 0.3 – 0.7 2
and brace – 0.5 + 0.1
Clearance for spherical part of
5 brace end bushing ø 130 — — 0.3 – 0.4 1
Clearance between center
brace spherical surface and – 0.2 + 0.3
6 ø 130 0.2 – 0.6 1
cap – 0.3 0
Adjust shim or
Clearance between center replace
brace spherical surface and – 0.2 + 0.3
7 ø 130 0.2 – 0.6 1
– 0.3 0
cap
Clearance between joint and – 0.2 + 0.5
8 blade bracket 120 0.5 – 1.2 2
– 0.7 + 0.3
9 ø 60 0.3 – 0.8 3
blade bracket pin – 0.5 0
Clearance between blade – 0.3 + 0.3
10 bracket pin and blade bracket ø 60 0.3 – 0.8 3
– 0.5 0
11 frame bracket 120 0.5 – 1.2 2
– 0.7 + 0.3
12 ø 60 0.3 – 0.8 3
frame pin – 0.5 0
Replace
Clearance between frame pin – 0.3 + 0.3
13 and frame bracket ø 60 0.3 – 0.8 3
– 0.5 0
Clearance between center link – 0.2 + 0.5
14 and blade bracket 400 0.2 – 0.9 2
– 0.4 0
15 ø 115 0.236 – 0.59 2
pin and center link – 0.090 + 0.2
16 pin and blade bracket ø 115 0.236 – 0.59 2
– 0.090 + 0.2
Clearance between trunnion – 0.5 + 1.0
17 and cap spherical surface ø 195 0.5 – 2.0 8
– 1.0 0
D275A-5R 5
Sigma-dozer
6 D275A-5R
Unit: mm
Clearance between brace pin size Shaft Hole clearance limit
1
and brace – 0.3 + 0.5
ø 70 0.6 – 1.0 2
– 0.5 + 0.3
2 ø 70 0.4 – 0.8 2
and bracket – 0.5 + 0.1
Replace
3 ø 70 0.3 – 0.8 2
and bracket – 0.5 + 0.1
4 ø 70 0.3 – 0.7 2
and brace – 0.5 + 0.1
Clearance for spherical part of
5 ø 130 — — 0.3 – 0.4 1
brace end bushing
Clearance between center
– 0.2 + 0.3 Adjust shim or
6 brace spherical surface and ø 200 0.2 – 0.6 1
– 0.3 0 replace
cap
Clearance between center – 0.3 + 0.3
7 ø 105 0.4 – 0.8 2
brace pin and frame bracket – 0.5 + 0.1
Clearance between center – 0.3 + 0.5
8 ø 105 0.6 – 1.0 2
brace pin and center brace – 0.5 + 0.3
9 120 0.5 – 1.2 2
blade bracket – 0.7 + 0.3
10 ø 60 0.3 – 0.8 3
blade bracket pin – 0.5 0
Clearance between blade – 0.3 + 0.3
11 ø 60 0.3 – 0.8 3
bracket pin and blade bracket – 0.5 0
Clearance between joint and – 0.2 + 0.5 Replace
12 120 0.5 – 1.2 2
frame bracket – 0.7 + 0.3
13 ø 60 0.3 – 0.8 3
frame pin – 0.5 0
Clearance between frame pin – 0.3 + 0.3
14 ø 60 0.3 – 0.8 3
and frame bracket – 0.5 0
Clearance between left hand
– 0.5 + 1.0
15 trunnion and cap spherical ø 195 0.5 – 2.0 8
– 1.0 0
surface
Clearance between right hand
– 0.5 + 1.0
16 trunnion and cap spherical ø 225 0.5 – 2.0 8
– 1.0 0
surface
D275A-5R 7
Cutting edge, End bit (for Semi U-dozer and U-dozer)
Unit: mm
1 Height of outside of end bit
415
Replace
2 Width of end bit 662
Just before blade is worn
3 Height of inside of end bit 330
4 Height of cutting edge 330 Turn or replace
8 D275A-5R
Cutting edge, End bit (for Sigma-dozer)
Unit: mm
1 Height of cutting edge (Long)
406 Turn or replace
2 Height of cutting edge (Short) 406
3 Height of inside 374 Just before blade is worn
4 End bit Width 698 Replace
5 Height of outside 400
D275A-5R 9
Ripper 1
Variable multiple shank ripper
10 D275A-5R
Giant ripper
Unit: mm
Clearance between bushing size Shaft Hole clearance limit
1
and bracket and arm mount pin – 0.036 + 0.207 0.156 –
110 1.5
– 0.090 + 0.120 0.297
Clearance between bushing – 0.036 + 0.207 0.156 –
2 120 1.5
and beam and arm mount pin – 0.090 + 0.120 0.297
Clearance between cylinder – 0.036 + 0.207 0.156 –
3 90 1.5
mount pin and bushing – 0.090 + 0.120 0.297
Replace
Clearance between shank and
4
mount pin 82 ± 0.3 —

5 Wear of point
420 255
6 Wear of protector 155 115
D275A-5R 11
D275A-5R Bulldozer
© 2008 KOMATSU
All Rights Reserved
12 D275A-5R
SEN02173-00
D275A-5R

D275A-5R 35001 and up

Cab and its attachments
Cab mount ...................................................................................................................................................... 2
Cab ................................................................................................................................................................. 3
Air conditioner ................................................................................................................................................. 5
D275A-5R 1
Cab mount 1
1. Support Outline
2. Damper mount (front) q Viscous mounts are installed at two places at
3. Damper mount (rear) the front and two places at the rear to secure
the floor frame and cab.
q An oil-filled damper mount is used to absorb
the vibration.
2 D275A-5R
Cab 1
Cab assembly
1. Front wiper
2. Front glass
3. Rear wiper
4. Door
D275A-5R 3
ROPS guard
1. ROPS guard
4 D275A-5R
Air conditioner 1
Air conditioner piping
1. Air conditioner compressor 10. Receiver tank

2. Condenser 11. Hot water return piping
3. Window defroster 12. Valve (hot water inlet)
4. Side defroster 13. Refrigerant piping
5. Air conditioner control unit
6. Vent A: Fresh air
7. Blower motor B: Recirculated air
8. Hot water pick-up piping C: Hot air/cold air
9. Valve (hot water outlet)
D275A-5R 5
D275A-5R Bulldozer
© 2007 KOMATSU
All Rights Reserved
6 D275A-5R
SEN02174-01
D275A-5R

D275A-5R 35001 and up

Electrical system
Engine control system..................................................................................................................................... 2
CRI engine control system............................................................................................................................ 12
Monitor system.............................................................................................................................................. 14
Machine monitor ........................................................................................................................................... 16
Mode selection system ................................................................................................................................. 32
Electrical equipment...................................................................................................................................... 36
Palm command control system..................................................................................................................... 38
Sensors......................................................................................................................................................... 40
KOMTRAX terminal system .......................................................................................................................... 44
D275A-5R 1
Engine control system 1
1. Decelerator pedal Outline

2. Decelerator potentiometer q The throttle signals of the fuel control dial are
3. Starter switch input to the steering controller and transmis-
4. Transmission controller sion controller and processed together with the
5. Steering controller other information, then the result is sent as the
6. Fuel control dial throttle command to the engine controller. The
7. Battery engine throttle controller controls the fuel sup-
8. Breaker ply pump according to the command.
9. Battery relay
10. Starter
11. Engine throttle controller
12. Alternator
2 D275A-5R
System diagram
Note
The design of the machine monitor differs a machine.
For details, see section "Machine monitor".
Outline q The information of the engine controller is used

q The engine throttle controller receives the 1st commonly by the all controllers through the
and 2nd throttle signal which is the manual sig- network for the optimum control of the engine
nal and the 3rd throttle signals which is the and machine body.
control signals from the machine body, then q The automatic deceleration function sets the
selects the lower engine speed and controls engine speed to 1,000 rpm temporarily when
the fuel supply pump. the travel direction is changed from F3, R3, or
The 3rd throttle control signals contain the fol- R2 (to protect the transmission clutch).
lowing.
q SSC (Shoe Slip Control) control
(if equipped)
q Automatic deceleration (F3, R3, R2)
q The steering controller selects the lowest

engine speed from these information and
transmits to the engine controller.
D275A-5R 3
Engine controller
q Meanings of signal classes in the terminal CN-CE01

table shown below are as follows. Input/
Pin No. Signal name output
A: Power supply
B: Input 11 NC(*) —
C: Ground/Shield/Return 12 NC(*) —
D: Output 13 Engine oil pressure sensor D
E: Communication 14 NC(*) —
15 Coolant temperature sensor D
CN-CE01 16 5V electric power supply for sensor A
Input/ 17 NC(*) —
Pin No. Signal name 18 NC(*) —
output
1 NC(*) — 19 NC(*) —
2 NC(*) — 20 NC(*) —
3 Atmosphere sensor D 21 NC(*) —
4 Supply pump #1 (+) B 22 NC(*) —
5 Supply pump #1 (–) C 23 Boost temperature sensor D
6 CAN(–) C 24 NC(*) —
7 NC(*) — 25 Common rail pressure sensor D
8 CAN(+) B 26 Buckup sensor D
9 Supply pump #2 (+) B 27 NE sensor (+) D
10 Supply pump #2 (–) C 28 NC(*) —
*: Never connect to NC or malfunctions or failures will 29 NC(*) —
occur. *: Never connect to NC or malfunctions or failures will
occur.
4 D275A-5R
CN-CE01 CN-CE02
Pin No. Signal name Input/ Pin No. Signal name Input/
output output
30 Fuel temperature sensor D 17 NC(*) B
31 NC(*) — 18 NC(*) B
32 NC(*) — 19 NC(*) B
33 5 V electric power supply for sensor A 20 NC(*) E
34 NC(*) — 21 NC(*) A
35 NC(*) — 22 5V electric power supply for sensor A
36 NC(*) — 23 GND C
37 5 V electric power supply for sensor A 24 NC(*) B
38 GND C 25 NC(*) B
39 NC(*) — 26 NC(*) B
40 NC(*) — 27 NC(*) B
41 NC(*) — 28 NC(*) B
42 NC(*) — 29 NC(*) C
43 NC(*) — 30 NC(*) B
44 Boost pressure sensor D 31 NC(*) B
45 Injector #1 (+) B 32 NC(*) C
46 Injector #5 (+) B 33 GND C
47 Sensor GND C 34 NC(*) C
48 Ne sensor (–) C 35 NC(*) B
49 NC(*) — 36 NC(*) B
50 NC(*) — 37 CAN shield C
51 Injector #2 (–) C 38 NC(*) D
52 Injector #3 (–) C 39 Key switch (ACC) B
53 Injector #1 (–) C 40 Electrical intake air heater relay drive D
54 Injector #2 (+) B 41 NC(*) D
55 Injector #3 (+) B 42 Electrical intake air heater relay return C
56 Injector #4 (+) B 43 NC(*) D
57 Injector #6 (+) B 44 NC(*) D
58 Injector #4 (–) C 45 NC(*) —
59 Injector #6 (–) C 46 CAN(+) E
60 Injector #5 (–) C 47 CAN(–) E
*: Never connect to NC or malfunctions or failures will 48 NC(*) D
occur. PWM OUTPUT
49 D
(Power train relay output)
CN-CE02 50 NC(*) D
*: Never connect to NC or malfunctions or failures will
Pin No. Signal name Input/
output occur.
1 NC(*) B
2 NC(*) B CN-CE03
3 NC(*) B Input/
Pin No. Signal name
4 NC(*) B output
5 NC(*) B 1 GND C
6 NC(*) B 2 NC(*) C
7 NC(*) B Electric power supply
3 A
8 NC(*) B (+24V constantly)
9 Decelerator signal B 4 NC(*) A
10 NC(*) E *: Never connect to NC or malfunctions or failures will
11 NC(*) B occur.
12 NC(*) B
13 NC(*) B
14 NC(*) B
15 NC(*) B
16 NC(*) B
occur.
D275A-5R 5
Sensors Engine controller

NE speed sensor (Crank angle sensor)
Fuel temperature sensor
q If the signal hole made on the flywheel passes
q The fuel temperature sensor senses the fuel
the sensor, the magnetic line of force changes.
temperature and sends it to the engine control-
q If the magnetic line of force changes, the out-
ler. The sensor unit is a thermistor the resis-
put of the Hall element sensor changes linearly
tance of which changes according to the
and it is converted into pulse of 0 – 5 V by the
temperature.
wave form shaping circuit in the sensor, and
q The engine controller applies voltage to the
then output.
thermistor and senses the temperature by the
voltage divided by the resistance in the com-
puter and the resistance of the thermistor.
Atmospheric pressure sensor

q This sensor is used to correct altitude.
6 D275A-5R
Common rail pressure sensor Bkup speed sensor (G sensor)

Oil pressure sensor (Cylinder No. sensor)
q Similarly to the NE speed sensor, this sensor
utilizes the pulses of 0 – 5 V generated by the
change of the magnetic line of force crossing
the sensor unit.
q The disc gear installed to the central part of the
camshaft of the high-pressure pump has teeth
(cut parts) around it at intervals of 120°.
q In addition to the above teeth, one more tooth
is installed. Accordingly, 7 pulses are gener-
ated every 2 revolutions of the engine.
q The standard pulse of the No. 1 cylinder is rec-
ognized by the combination of the NE speed
sensor pulse and Bkup speed sensor pulse.
D275A-5R 7
Charge pressure sensor Charge temperature sensor

q This sensor is used to sense the charge pres- q The charge temperature sensor senses the
sure (boost pressure). intake air temperature (boost temperature) and
sends it to the engine controller.
q The sensor unit is a thermistor the resistance
of which changes according to the tempera-
ture. The engine controller applies voltage to
the thermistor and senses the temperature by
the voltage divided by the resistance in the
computer and the resistance of the thermistor.
8 D275A-5R
Coolant temperature sensor

q The coolant temperature sensor senses the
coolant temperature and sends it to the engine
controller.
q The sensor unit is a thermistor the resistance
of which changes according to the tempera-
ture. The engine controller applies voltage to
the thermistor and senses the temperature by
the voltage divided by the resistance in the
computer and the resistance of the thermistor.
D275A-5R 9
Deceleration potentiometer
1. Connector Outline
2. Lever q The deceleration potentiometer is installed to
3. Body the front lower part of the operator's cab and
4. Potentiometer connected to the decelerator pedal by linkage.
5. Coupling
6. Shaft q 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 sig-
nal is sent through pin B to the steering con-
troller according to the position of the
decelerator pedal.
10 D275A-5R
D275A-5R 11
CRI engine control system 1

a "CRI" is an abbreviation for Common Rail Injection.
System diagram
12 D275A-5R
1. NE speed sensor System configuration

2. Engine throttle controller q The CRI system consists of fuel supply pump
3. Injector assembly (15), common rail (14), injector (3), engine
3A. Orifice throttle controller (2) to control them, and sen-
3B. Control chamber sors.
3C. Hydraulic piston q The fuel supply pump generates fuel pressure
3D. Injector in the common rail. The fuel pressure is con-
3E. Nozzle trolled by the fuel discharge rate of the supply
4. Fuel cooler pump. The discharge rate is controlled by
5. Fuel tank turning on and off PCV (discharge control
6. Strainer valve) (15A) of the fuel supply pump according
7. Pre fuel filter (with water separator) to the electric signals from the engine throttle
8. Priming pump controller.
9. Fuel filter The common rail receives the pressurized fuel
10. Engine throttle controller cooler from the fuel supply pump and distributes it to
11. Pressure limiter the cylinders.
12. Flow damper The fuel pressure is sensed by the common
13. High pressure injection pipe rail fuel pressure sensor installed to the com-
14. Common rail mon rail and controlled by the feedback
15. Fuel supply pump assembly method so that the actual fuel pressure will
15A. PCV match to the command pressure set according
15B. High pressure pump to the engine speed and the load on the
15C. Priming pump engine.
15D. Feed pump The fuel pressure in the common rail is applied
15E. Bypass valve to the nozzle (3E) side of the injector and con-
15F. Bkup speed sensor (G sensor) trol chamber (3B) through the fuel injection
16. Overflow valve pipe of each cylinder.
q The injector controls the fuel injection rate and
Outline fuel injection timing by turning on and off the
q The signals detected by various sensors are TWV (2-way solenoid valve). If the TWV is
input to the engine controller. turned on, the fuel circuit is so changed that
q The input signals are processed by the control- the high-pressure fuel in the control chamber
ler and output to each actuator to control the will flow through orifice (3A). The needle valve
fuel injection rate and fuel injection timing. is raised to start fuel injection by the nozzle
cracking pressure applied as the high-pressure
fuel on the nozzle side. If the TWV is turned
off, the fuel circuit is so 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 injec-
tion. Accordingly, the fuel injection timing and
fuel injection rate are controlled respectively by
the timing to turn on the TWV and the length of
the turn-on time of the TWV.
D275A-5R 13
Monitor system 1
Note
The design of the machine monitor differs a machine.
Outline q The machine monitor has functions of display-

q The monitor system monitors the machine con- ing data and selecting the SSC mode.
dition with the sensors installed to various The CPU (Central Processing Unit) in it pro-
parts of the machine and processes and dis- cesses, displays, and outputs the information.
plays the obtained information on the machine The display unit is LCD (Liquid Crystal Display)
monitor quickly to notify the operator of the and the switches are seat switches.
machine condition.
The main display sections and functions of the
machine monitor are as follows.
1) Monitor unit which turns on the alarm
when the machine has a trouble.
2) Gauge unit which constantly displays the
machine condition (coolant temperature,
torque converter oil temperature, fuel
level, etc.)
3) Function of displaying error codes.
4) Function of monitoring the current and
voltage of the sensors and solenoids.
14 D275A-5R
Processing in monitor system (Common to all specifications)

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

The number of pulses the engine rotation is converted controller– Steering controller–
into a gauge number and notified to the machine mon- Machine monitor
itor by CAN signals.
3) Display of troubleshooting CAN
When the machine has a trouble, the corresponding Each sensor/solenoid–Control-
failure code is notified to the machine monitor by CAN ler–Machine monitor
signals.
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 follow
ingitems are displayed Note
CAN is abbreviation for
1. Time after first occurrence
Controller Area Network,
2. Time after latest occurrence
which is a communication
3. Number of past occurrences
standard name provided
The machine monitor displays the code on the multi-in-
by ISO etc.
formation section.
Display of monitoring condition

1) The communication conditions of each sensor, each CAN
solenoid, and CAN signals are displayed.
The item Nos. and device conditions are notified to the Each sensor–Controller–Ma-
machine monitor by CAN signals. chine monitor
The machine monitor displays the items and each val-
ue on its multi-information section.
2) Each items is selected by using the cursor switches, Monitor panel–Controller–Ma-

selector switches, buzzer cancel switch, and shift UP/ chine monitor
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 coolant temperature,
etc.
4) Mode to display service meter and information related
to load on machine
D275A-5R 15
Machine monitor 1
Monitor portion
Serial No.: 35001 – 35004
1. Engine speed meter 11. Hydraulic oil temperature caution lamp

2. Engine coolant temperature gauge 12. Air cleaner clogging caution lamp
3. Power train oil temperature gauge 13. Radiator coolant level caution lamp
4. Hydraulic oil temperature gauge 14. HSS charge pressure caution lamp
5. Fuel level gauge 15. Engine pre-heating indicator lamp
6. Display section A 16. Maintenance caution lamp
(Travel direction and gear speed and others) 17. Dual tilt selector indicator lamp
7. Charging condition caution lamp 18. Warning red lamp
8. Engine oil pressure caution lamp 19. Radiator fan operation indicator orange lamp
9. Engine coolant temperature caution lamp 20. Display section B (Multi-information)
10. Power train oil temperature caution lamp 21. Mode selection switches portion
Note
Mode selection switches portion (21) are displayed on only the machines having optional functions such as
the Shoe slip control (SSC).
For the display, see "Mode selection switches portion" and "Mode selection system".
16 D275A-5R
Serial No.: 35005 and up
1. Engine speed meter 13. Radiator coolant level caution lamp

2. Engine coolant temperature gauge 14. HSS charge pressure caution lamp
3. Power train oil temperature gauge 15. Engine pre-heating indicator lamp
4. Hydraulic oil temperature gauge 16. Maintenance caution lamp
5. Fuel level gauge 17. Dual tilt selector indicator lamp
6. Display section A 18. Warning red lamp
(Travel direction and gear speed and others) 19. Radiator fan operation indicator orange lamp
7. Charging condition caution lamp (The indicator who prohibits change operation)
8. Engine oil pressure caution lamp 20. Display section B (Multi-information)
9. Engine coolant temperature caution lamp 21. Radiator fan operation indicator lamp/symbol
10. Power train oil temperature caution lamp (The indicator who admits change operation)
11. Hydraulic oil temperature caution lamp 22. Mode selection switches portion
12. Air cleaner clogging caution lamp
Note
Mode selection switches portion (22) are displayed on only the machines having optional functions such as
the Shoe slip control (SSC).
For the display, see "Mode selection switches portion" and "Mode selection system".
D275A-5R 17
Outline a The items of display category "Check before

q The monitor section is an LCD screen which starting" are monitored from when the starting
consists of the gauges that constantly indicate switch is turned ON while the engine is
the machine condition, character screen that stopped.
displays the current travel condition of the a The blinking intervals of the caution lamps and
machine (travel direction and gear speed), the sounding intervals of the alarm buzzer are
caution lamps that indicate abnormalities of the set to about 0.8 seconds, which fluctuates
machine, indicator lamps that show the opera- more or less when the ambient temperature is
tion guide, and multi-information unit that dis- low (below about –10 °C), but that does not
plays the service meter and maintenance indicate a trouble.
information.
The CPU in the machine monitor processes 3. Indicators
the signals from the sensors at various places The necessary timings of the operations of the
of the machine and indicates the results on the machine are indicated by the indicator lamps in
screen. the monitor section.
Indication items (types of the indicator lamps),
Operation their operations, and their indication methods
1. Operation check (Check before starting) are shown in the "List of display of cautions
While the engine is stopped (five or more sec- and indicators" which will appear later.
onds after the engine is stopped), if the power a The blinking intervals of the indicator lamps are
is turned ON (the starting switch is turned to the same with the caution lamps.
the ON position), all items of the gauges, indi-
cator lamps and caution lamps of the monitor
section operate as follows to indicate that each
of them operates normally.
1) All items of the gauges, indicator lamps
and caution lamps light for about 3 sec-
onds and then go off.
2) The alarm buzzer sounds for about 1 sec-
ond, synchronizing with 1) above.
2. Cautions
If the machine has any trouble, the caution
lamp corresponding to the trouble part in the
monitor section blinks or lights and the alarm
buzzer sounds as required.
The caution items (types of the caution lamps),
caution lamps corresponding to the caution
items, and operation of the alarm buzzer are
shown in the "List of display of cautions and
indicators" which will appear later.
All the items, except the items of indication cat-
egory "Check before starting" in "List of display
of cautions and indicators" shown later, are
monitored while the engine is running, from the
start to the stop of the engine.
18 D275A-5R
4. Gauges 5. Display section A

The gauges display the typical drawing of the Display section A displays the following.
items that the operator monitors constantly (1) Normal display (Operation mode display)
before and during operation among the infor- The current travel operation of the machine
mation items (signals) from the sensors at vari- is indicated by alphanumerics.
ous parts of the machine. That is, travel in forward 1st gear is indi-
The gauges display constantly from when the cated by F1, travel at reverse 2nd gear is
starting switch is turned ON to when the start- indicated by R2, and setting of the gear in
ing switch is turned OFF and operates con- neutral is indicated by N. If the parking
stantly while the engine is running. brake is set in the parking position, P is
Each scale does not read values but indicates displayed.
colored ranges. The pointer is indicated by The CPU of this monitor system pro-
changing (turning ON and OFF) the color of a cesses and indicates the set information
narrow LCD segment. items (signals) of the PCCS lever and
The operator checks in which range of each parking brake lever and those from the
gauge the coloring segment is (or the position transmission controller.
of the first segment when multiple coloring Note: PCCS: Abbreviation for Palm com-
segments are displayed in the gauge). mand control system. For details, see
The types, designs and displayed color bands the Operation and Maintenance Manual.
of the gauges are shown in the "List of display (2) Special display
of gauges" which will appear later. (Service mode choice display)
The thermometer among the gauges, if the This is special display which is not
above segment indicates the red range, the described in the Operation and Mainte-
caution lamp and the alarm buzzer described nance Manual. It is used by the service-
before operate, too. men for testing, adjusting, troubleshooting,
For the relationship between the gauge (ther- etc.
mometer), caution lamp and alarm buzzer, see In this case, the display of display section
the "List of display of cautions and indicators" B described later is changed to various
which will appear later. service mode displays, and display sec-
tion A is also changed to indicate which
service mode is selected by display sec-
tion B.
The selected service mode is indicated by
the service mode type code of 2 alphanu-
meric letters such as 1C, EE, bE, etc. For
details, see "30 Testing and adjusting" of
this manual.
D275A-5R 19
6. Display section B (Multi-information) (4) Special display (Service mode display)

Display section B is called the multi-informa- This is the special display described in
tion unit, which is set in the operation mode Display section A, (2). The modes corre-
when the starting switch is turned ON and sponding to the various service modes
which has the following 4 types of indicating displayed in Display section A are dis-
function. played.
(1) Default (Operation mode display) For the types and meanings of the various
While the machine is in operation, display service modes and remedies for them,
section B displays the service meter (inte- see "30 Testing and adjusting" of this
grated operating time of the machine) and manual.
the preset forward and reverse gear As explained in Display section A, (2), this
speeds. display is not described either in the oper-
The service meter advances and the hour- ation and maintenance manual.
glass symbol at the service meter head
blinks while the engine is running.
This machine has the function of driving in
the preset forward or reverse gear speed.
The preset gear speed is indicated by F*
for forward and R* for reverse on the left
of the service meter to indicate that the
transmission is preset and the preset gear
speed.
(2) Maintenance display
The display can be changed with a speci-
fied switch to indicate the information
related to the maintenance of the
machine.
The following modes can be selected by
this function. For details of them and the
operating procedure, see the operation
and maintenance manual or "30 Testing
and adjusting" of this manual.
q Maintenance mode
q PM clinic auxiliary mode
q Error code display mode
q Adjustment mode
(3) Action code display
If a serious trouble occurs which should
be notified to the operator while the
machine is operating in the normal display
mode, the action code is displayed instead
of the normal display.
Action codes are alphanumerics such as
E01, E02, etc. The types and meanings of
them and remedies for them are described
in the Operation and Maintenance Manual
"30 Testing and adjusting" of this manual.
If an action code other than E01 is dis-
played, the warning lamp (red) blinks and
the alarm buzzer sounds, too.
20 D275A-5R
D275A-5R 21
List of display of cautions and indicators

Serial No.: 35001 – 35004
Display
Symbol Indicated item Indication range Indication method
category
Displayed when starting switch is
before starting
turned ON while engine is stopped or

when abnormality occurs.
Check
Radiator coolant level Below low level When normal: OFF

When abnormal: Blinking. Warning
lamp blinks and alarm buzzer sounds,
too.
Displayed when abnormality occurs
while engine is running.
When charging is defec- When normal: OFF
Charging condition
tive When abnormal: Blinking. Warning
too.
Below 49.0 kPa

Engine oil press. Displayed when abnormality occurs
{0.5 kg/cm2}
When normal: OFF
Radiator coolant level Below low level too.

When clogged
When normal: OFF
Air cleaner clogging Reference:
Below – 650 mmH2O
too.
Cautions
When HSS charge pres- When normal: OFF

HSS charge oil press.
sure lowers When abnormal: Blinking. Warning
too.
When coolant tempera- 102 °C – 105 °C (1st red segment):
Engine coolant temp. ture gauge is in red seg- Blinking
ment (above 102 °C) Above 105 °C (2nd red segment): Blink-
ing. Warning lamp blinks and alarm
buzzer sounds, too.
When power train oil
120 °C – 130 °C (1st red segment):
temperature gauge is in
Power train oil temp. Blinking
red segment (above 120
Above 130 °C (2nd red segment): Blink-
°C)
buzzer sounds, too.
When hydraulic oil tem- 100 °C – 110 °C (1st red segment):
Hydraulic oil temp. perature gauge is in red Blinking
segment (above 100 °C) Above 110 °C (2nd red segment): Blink-
buzzer sounds, too.
22 D275A-5R
Display
category
After replacement period while engine is running.
Maintenance
of filter or oil When normal: OFF
When abnormal: ON
Blinking: Blinks if caution having * in in-
Cautions
dicated item column blinks.

Blinks if action code other than E01 is
displayed in Display section A (Multi-in-
Warning Auxiliary caution
formation)
Red OFF: Same as cautions having * in indi-

Non-symbol cated item column.
During preheating period: ON
Other than preheating period: OFF
If engine controller judges from coolant
When engine is preheat- temperature that preheating is neces-
Engine pre-heating
ed sary, automatic preheating starts.
When starting switch is turned to pre-
heating position (turned left), preheat-
ing starts, too.
When possible: ON
When impossible: OFF
Turned ON when tilt switch of blade
Dual tilt select When possible (work equipment) control lever is turned
to dual tilt operation position (dual tilt
Indicators
operation is possible) and turned OFF

when returned.
ON: Turned ON when fan rotation se-
lector switch is turned to CLN position.
Blinking: Blinks for 3 seconds to notify

ON: When cooling fan ro-
that cooling fan rotation direction can-
tation direction is in re-
not be changed when fan rotation selec-
verse rotation mode
tor switch is operated while engine is
Radiator fan operation
running.
Blinking: When cooling
fan rotation direction
Orange OFF: Turned OFF when fan rotation se-
cannot be changed
Non-symbol lector switch is operated again while
this lamp is ON (At this time, cooling fan
rotation direction is set in forward rota-
tion mode).
D275A-5R 23

Display
category
Displayed when starting switch is
before starting
turned ON while engine is stopped or

when abnormality occurs.
Check
Radiator coolant level Below low level When normal: OFF

too.
When charging is defec- When normal: OFF
Charging condition
tive When abnormal: Blinking. Warning
too.
Below 49.0 kPa

Engine oil press. Displayed when abnormality occurs
{0.5 kg/cm2}
When normal: OFF
Radiator coolant level Below low level too.

When clogged
When normal: OFF
Air cleaner clogging Reference:
Below – 650 mmH2O
too.
Cautions
When HSS charge pres- When normal: OFF

HSS charge oil press.
sure lowers When abnormal: Blinking. Warning
too.
When coolant tempera- 102 °C – 105 °C (1st red segment):
Engine coolant temp. ture gauge is in red seg- Blinking
ment (above 102 °C) Above 105 °C (2nd red segment): Blink-
buzzer sounds, too.
When power train oil
120 °C – 130 °C (1st red segment):
temperature gauge is in
Power train oil temp. Blinking
red segment (above 120
Above 130 °C (2nd red segment): Blink-
°C)
buzzer sounds, too.
When hydraulic oil tem- 100 °C – 110 °C (1st red segment):
Hydraulic oil temp. perature gauge is in red Blinking
segment (above 100 °C) Above 110 °C (2nd red segment): Blink-
buzzer sounds, too.
24 D275A-5R
Display
category
After replacement period while engine is running.
Maintenance
of filter or oil When normal: OFF
When abnormal: ON
Blinking: Blinks if caution having * in in-
Cautions
dicated item column blinks.

Blinks if action code other than E01 is
displayed in Display section A (Multi-in-
Warning Auxiliary caution
formation)
Red OFF: Same as cautions having * in indi-

Non-symbol cated item column.
During preheating period: ON
Other than preheating period: OFF
If engine controller judges from coolant
When engine is preheat- temperature that preheating is neces-
Engine pre-heating
ed sary, automatic preheating starts.
When starting switch is turned to pre-
heating position (turned left), preheat-
ing starts, too.
When possible: ON
When impossible: OFF
Turned ON when tilt switch of blade
Dual tilt select When possible (work equipment) control lever is turned
to dual tilt operation position (dual tilt
operation is possible) and turned OFF
Indicators
when returned.
ON: Turned ON when fan rotation se-
lector switch is turned to CLN position.
When cooling fan rota-
OFF: Turned OFF when fan rotation se-
Radiator fan operation tion direction is in re-
lector switch is operated again while
verse rotation mode
this lamp is ON (At this time, cooling fan
rotation direction is set in forward rota-
tion mode).
Blinking: Blinks for 3 seconds to notify

When cooling fan rota- that cooling fan rotation direction can-
Radiator fan operation tion direction cannot be not be changed when fan rotation selec-
changed tor switch is operated while engine is
Orange running.
Non-symbol
D275A-5R 25
List of display of gauges

Serial No.: 35001 – 35004
Display
category
Engine coolant temp.
Corresponding segment
(1 place) is turned ON.
Power train oil temp.

Gauges
Hydraulic oil temp.
Corresponding segment and

all segments under it are
turned ON.
Fuel level

Engine speed all segments under it are
turned ON.
26 D275A-5R

Display
category
Engine coolant temp.
Power train oil temp.

Gauges
Hydraulic oil temp. all segments under it are

turned ON.
Fuel level
Engine speed
D275A-5R 27
Outline of display section A and display section B

Display
Form and position Indicated item Indication method
section
Serial No.: 35001 – 35004 1) Normal display q Display unit consist of 18 segments
Fig. reference of 16p. (Operation mode display) and indicates various alphanumerics
q Current travel direction and by turning on corresponding seg-
Serial No.: 35005 and up gear speed ments.
Fig. reference of 17p. Forward 1st: F1
Display section A
Reverse 2nd: R2, etc. Example of forward 1st gear

Neutral: N, Parking: P
2) Special display
(Service mode display)
Selected service mode symbol
when display section B is changed q For details of selection of normal dis-
to special display play and special display, see "30 Test-
ing and adjusting" of this manual.
1) Normal display q Display unit displays 2 16-alphanu-

(Operation mode display) meric lines.
q Preset forward gear speed and Preset gear speed is displayed by ver-
reverse gear speed tically enlarged letters, however.
q Service meter (Integrated oper- q For details of selection of this display
ating hours of machine) and normal display, see "30 Testing
and adjusting" of this manual.
2) Indication of maintenance
Display section B (Multi-information)
Following modes related to mainte- 1) Example of normal display

nance are indicated by selecting
operation
q Maintenance mode
q PM clinic auxiliary mode
q Failure indication mode
q Adjustment mode
2) Example of maintenance display
3) Indication of action code
If serious trouble occurs while ma-
chine is operating, action code is
displayed automatically instead of
normal display.
3) Example of action code
28 D275A-5R
Display
Form and position Indicated item Indication method
section
4) Special display 4) Example of special display
(Service mode display)
Machine information necessary to
service is displayed by special se-
lecting operation.
Display section B (Continued)
Information is displayed in following

modes.
q 1C: Maintenance interval
change mode
q EE: Electric system error code
display mode
q bE: Mechanical system error
code display mode
q Cb: adjustment mode Note: Service mode symbols (1C, EE,
q Ld: Load memory display mode etc.) shown in indicated item column are
q 5R: Real-time monitoring mode selected service mode symbols described
q dR: Dual display monitoring in Display section A, which are displayed
mode in Display section A.
D275A-5R 29
Mode selection switches portion

The machine monitor has the switch to operate the
"Mode selection system" described later.
However, this switch works on only the machines
added with the SSC and the optional functions
related to it.
Serial No.: 35001 – 35004
Note
The switch operations of the 2 "Serial No." group
machine monitors are the same.
30 D275A-5R
1. Switch functions
a) Economy mode setting - OFF, mode 1, mode 2
b) ON-OFF switching in reverse slow mode
c) ON-OFF switching in SSC mode
d) SSC mode level setting - Mode 1 to 5
2. Initial setting when key is turned ON

When a new machine is shipped from the fac-
tory, all the functions are turned OFF as a rule
so that the operator can select only the neces-
sary functions depending on the job site condi-
tion.
3. Operation
For the operation, see "Mode selection sys-
tem".
D275A-5R 31
Mode selection system 1

System diagram
Note Outline
q This system is applied to the machines added q The mode selection system automatically car-
with the SSC and the optional functions related ries out engine control to match the operating
to it. mode selected by the operator, and acts to
q The design of the machine monitor differs a reduce fuel consumption, extend the life of the
machine. track shoes, and reduce the frequency of oper-
For details, see section "Machine monitor". ation of the deceleration.
q The engine control modes consist of the econ-
omy 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.
32 D275A-5R
Function of model selection system Function of engine controller

q This system consists of the mode selection 1. The engine controller controls the fuel supply
switch installed to the machine monitor (con- pump according to the lowest engine speed
taining a microcomputer) to select working (highest voltage) in the 3 signals of the manual
condition, steering controller (containing a command input from the deceleration potenti-
microcomputer) to control the engine, engine ometer, manual signal of the throttle dial, and
controller to receive the commands from the the SSC command signal.
steering controller and controls the fuel supply
pump, transmission controller to turn on and off
the lock-up system of the torque converter
according to the signals from the transmission
output speed sensor, and various sensors.
The function of each controller is explained
below.
Functions of steering controller and

transmission controller
1. The steering controller calculates the travel
speed to the ground from the signals of the
acceleration sensor and inputs the transmis-
sion output speed sensor signal to it to calcu-
late the shoe speed, then obtains the shoe slip
rate.
2. If the engine speed sensor signal and trans-
mission output speed sensor signal are input,
the steering controller calculates the traction
force.
3. The steering controller calculates the optimum
engine speed from the results of 1 and 2
above, mode set signal of the mode selection
switch, and speed information from the trans-
mission controller, then sends it as the SSC
command to the engine controller.
D275A-5R 33
Operation of mode selection system

q Work can be performed under the optimum conditions by simply or simultaneously selecting four modes
in accordance with the contents of work
Mode Simulta-
Work neous Mode work condition Mode operation, characteristic
switch selection
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
control is performed.
Economy
Dozing
2. The engine output can be suppressed in two

Q 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
performing the decelerator operation of the
Reverse slow
engine.
Q 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
[2] After the ripper down, ripper tilt levers are controller performs index characteristic down
actuated and the switch is set to ON of about 40% and performs the engine outpuut
control if a ripper down signal is input.
2. The seering controller performs the engine
output control in accordance with the index
SSC (Shoe Slip Control)
force characteristic (refer to the rock-bed se-

lection shown below) selected by the operator
Ripping
among the index force characteristics set in

five stages and suppresses the generation of
a slip.
3. The steering controller regards the index force
Q 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
performs 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 io 3 i o 5 is selected in accordance with
the state and load of the rock-bed
a When the above mode is set, the throttle lever and decelerator operations are enabled. In that case, the
engine output control is performed in accordance with the command having the smallest value among
the control command, throttle command, and decelerator command.
a Circles in the simultaneous selection column indicate the modes that can be selected simultaneously.
34 D275A-5R
D275A-5R 35
Electrical equipment 1
Operation of lamp system
Lamp system circuit diagram
36 D275A-5R
Engine preheating (Electrical intake air heater) control
Preheat circuit
D275A-5R 37
Palm command control system 1

System diagram
1. Machine monitor 6. Steering control valve

2. Auto shift-down switch 7. Transmission output speed sensor
3. Engine throttle controller 8. Transmission control valve
4. Transmission controller 9. Engine speed sensor
5. Steering controller
Note
q The design of the machine monitor differs a
machine.
38 D275A-5R
Shift mode function Auto Shift-down function

1. Function 1. Function
If you shift the lever to the forward or reverse, If the load is increased while the machine is
the gear speed selected from the shift mode is traveling or working at the 2nd or 3rd gear
turned on. speed, the gear speed is shifted down auto-
PCCS lever is control lever of steering, direc- matically.
tional and gear shift in joystick lever of left hand. q The drawbar pull (load on the machine) is
PCCS is abbreviation of Palm command con- calculated from the engine speed, travel
trol system. speed, and throttle information from the
steering controller, and the gear speed is
2. Type of modes shifted down automatically according to
q F1-R1 (Manual mode) the load and travel speed.
q F1-R2 (Shift mode 1) q Once the gear speed is automatically
q F2-R2 (Shift mode 2) shifted down, it is not automatically shifted
up to the former position. (Gear speed can
3. Selecting method be shifted up with the manual switch.)
Shift the PCCS lever to “N”. q This function is applicable to both forward
Select the shift mode using UP or DOWN switch. and reverse travels.
2. How to use
Manual mode Turn auto-shift-down switch (1) ON.
Down switch ON Up switch ON
Shift mode 1
Down switch ON Up switch ON
Shift mode 2
4. Display
The selected shift mode is displayed on the
Multi-information.
The Multi-information, see section "Machine
monitor".
D275A-5R 39
Sensors 1
Type of sensor Sensor method When normal When abnormal
Torque converter
Resistance – –
oil temperature
Hydraulic oil temperature Resistance – –
Radiator water level Contact ON OFF
Fuel level Resistance – –
Transmission output shaft

Resistance – –
speed sensor
Acceleration sensor Resistance – –
Pitch angle sensor Resistance – –
Torque converter oil temperature sensor

Hydraulic oil temperature sensor
1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector
40 D275A-5R
Radiator water level sensor
1. Float 4. Wire
2. Sensor 5. Connector
3. Tube
Fuel level sensor
1. Connector Function
2. Float q The fuel sensor is installed to the side face of
3. Arm the fuel tank. The float moves up and down
4. Body according go to the fuel level. This movement
5. Spring of the float is transmitted by the arm and actu-
6. Contact ates a variable resistance. This sends a signal
7. Spacer to the monitor panel to indicate the remaining
fuel level. When the display on the monitor
panel reaches a certain level, a warning lamp
flashes.
D275A-5R 41
Transmission output shaft speed sensor
1. Magnet
2. Terminal
3. Case
4. Boots
5. Connector
Pitch angle sensor
1. Body
2. Tube
3. Wire
4. Connector
42 D275A-5R
Acceleration sensor
1. Sensor portion
2. Wire
3. Connector
Outline
q The acceleration sensor is installed under the
front of the operator's cab.
q With the acceleration sensor, the position of
the ball inside the sensor changes according to
the acceleration.
q 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
steering controller.
q The input and output characteristics of the sen-
sor are shown in the diagram on the right.
D275A-5R 43
KOMTRAX terminal system 1
Outline
q The KOMTRAX terminal system consists of the
KOMTRAX terminal, communication antenna,
GPS antenna, etc. and the KOMTRAX terminal
is connected to the machine network.
q The KOMTRAX terminal can transmit the posi-
tion information and operating condition of the
machine wirelessly for the ease of remote
machine management.
q It is required to sign up the KOMTRAX terminal
system before using its functions.
For details, including the sign-up test, see "30
Testing and adjusting, Part 4" of this manual.
q Information transmittable from the KOMTRAX
terminal system includes the following and oth-
ers.
1. Operation map
2. Service meter
3. Position information
4. Error history
44 D275A-5R
KOMTRAX terminal
1. Communication antenna connection q The KOMTRAX terminal obtains various kinds

2. GPS antenna connection of machine information from the network sig-
3. DRC connector connection (40 poles) nals and input signal in the machine and trans-
mits them via the wireless communication
antenna. It contains a CPU (Central Process-
ing Unit) and has wireless communication
function and GPS function.
q This terminal has an LED lamp unit and a 7-
segment display lamp unit used for inspection
and troubleshooting.
Input and output signals

DRC conector DRC conector
Pin No. Signal name Input/output Pin No. Signal name Input/output
1 NC(*) — 26 NC(*) —
2 NC(*) — 27 C-terminal input Input
3 NC(*) — 28 R-terminal input Input
4 NC(*) — 29 NC(*) —
5 NC(*) — 30 NC(*) —
6 CAN shield GND — 31 NC(*) —
7 CAN signal (L) Input/output 32 NC(*) —
8 CAN signal (H) Input/output 33 NC(*) —
9 NC(*) — 34 NC(*) —
10 NC(*) Input/output 35 NC(*) —
11 NC(*) — 36 ACC input Input
12 NC(*) — 37 Power GND —
13 NC(*) — 38 Power GND —
14 NC(*) — Electric power supply
39 Input
15 NC(*) — (+24V constantly)
16 NC(*) — Electric power supply
40 Input
(+24V constantly)
17 NC(*) —
18 NC(*) —
occur.
19 NC(*) —
20 Engine control output Output
21 Action mode select 1 Input
22 Action mode select 2 Input
23 NC(*) —
24 NC(*) —
25 NC(*) —
occur.
D275A-5R 45
D275A-5R Bulldozer
© 2008 KOMATSU
All Rights Reserved
46 D275A-5R
SEN02751-01
D275A-5R

D275A-5R 35001 and up
20 Standard value table

Standard service value table
Standard value table for engine ...................................................................................................................... 2
Standard value table for machine ................................................................................................................... 3
D275A-5R 1
SEN02751-01 20 Standard value table
Standard value table for engine 1

Engine SAA6D140E-5
Cate- Standard value Service limit
Item Measurement conditions Unit
gory for new machine value
High idle rpm 2,200 ± 50 2,200 ± 50
• Engine coolant tempera-
Speed ture: Within operating Low idle rpm 700 ± 50 700 ± 50
range Rated speed rpm 2,000 2,000
• Engine coolant temperature:
Within operating range
Intake air pressure kPa Min. 116 99
• Power train oil temperature:
(Boost pressure) {mmHg} {Min. 870} {740}
• Torque converter: Stalled
Exhaust tempera- • Whole speed range
°C Max. 670 720
ture (Outside temperature: 20°C)
%
At sharp accel- Max. 40 50
• Engine coolant tempera- eration (Bosch
{Max. 4.0} {5.0}
Exhaust gas color ture: Within operating index)
range (Bosch
High idle Max. 1.0 2.0
index)
Intake valve mm 0.35 —
Valve clearance • Normal temperature
Exhaust valve mm 0.57 —
Compression MPa Min. 4.1 2.8
Compression pres- • Engine oil temperature: pressure {kg/cm2} {Min 42} {29}
Engine
sure 40 – 60°C
Engine speed rpm 200 – 250 200 – 250
• Engine coolant temperature:
kPa Max. 2.94 3.92
Blow-by pressure • Power train oil temperature:
{mmH2O} {Max. 300} {400}
• Torque converter: Stalled
• SAE0W30EOS,
MPa Min. 0.34 0.21
SAE5W40EOS, High idle
{kg/cm2} {Min. 3.5} {2.1}
SAE10W30DH,
Engine oil pressure SAE15W40DH
SAE30DH Oil MPa Min. 0.10 0.08
• Engine oil temperature: Low idle {kg/cm2} {Min. 1.0} {0.8}
Min. 80 °C
Oil temperature Whole speed range (In oil pan) °C 90 – 110 120
• Between water pump pulley – alternator
Alternator belt ten- pulley
mm 13 – 16 13 – 16
sion • Deflection under finger pressure of 98 N
{10 kg}
• Between compressor pulley – fan pulley
Air compressor belt
• Deflection under finger pressure of 59 N mm Approx. 10 Approx. 10
tension
{6 kg}
2 D275A-5R
Standard value table for machine 1

Cate- Standard value for
Item Measurement conditions Unit Service limit value
gory new machine
Decelerator pedal • Engine coolant temperature:

Within operating range 900 ± 50 900 ± 50
speed
• Torque converter oil temperature:
Auto deceleration Within operating range
2,000 ± 25 2,000 ± 25
Engine speed
speed • Hydraulic oil temperature:

rpm
Torque converter • Decelerator pedal speed: Press pedal.
1,620 ± 50 1,510
stall speed • Auto deceleration speed:
Set all equipment in neutral.
Torque converter • Torque converter stall speed: F3
stall + Work equip- • Torque converter stall + Work equip- 1,580 ± 50 1,450
ment relief speed ment relief speed: F3 + Ripper RAISE
Neutral o 30 ± 10 30 ± 10
Forward and Forward
reverse Neutral o
PCCS lever
30 ± 10 30 ± 10
• Stop engine. Reverse
mm
• Operation of lever knob 40 ± 10 40 ± 10
Neutral o Left
(Play: Max. 3) (Play: Max. 3)
Steering
Neutral o 40 ± 10 40 ± 10
Right (Play: Max. 3) (Play: Max. 3)
Stroke of control lever/pedal
• Stop engine.
Decelerator pedal mm 47 ± 5 47 ± 5
• Pressing pedal
All stroke 75 ± 8 75 ± 8
• Engine: Low idle
Brake pedal Stroke to 0 of mm
• Pressing pedal 61 ± 10 61 ± 10
oil pressure
• Engine: Low idle Neutral –
60 ± 10 60 ± 10
• Hydraulic oil tempera- Raise/Lower
(84 ± 10) (84 ± 10)
Blade lever ture: Within operating (Float) mm
range Neutral –
53 ± 10 53 ± 10
• Operation of lever knob Left/Right tilt
• Engine: Low idle Neutral –

85 ± 10 85 ± 10
• Hydraulic oil tempera- Raise/Lower
Ripper lever ture: Within operating mm
Neutral –
range
Forward/ 85 ± 10 85 ± 10
• Operation of lever knob Reverse tilt
Neutral o
Operating effort of control lever/pedal
56.9 ± 6.9 56.9 ± 6.9

Forward/
{5.8 ± 0.7} {5.8 ± 0.7}
Forward and Reverse
reverse Forward/
PCCS lever
51 ± 6.9 51 ± 6.9
• Stop engine. Reverse o N {5.2 ± 0.7} {5.2 ± 0.7}
• Operation of lever knob Neutral {kg}
Neutral o 25.5 ± 4.9 25.5 ± 4.9
Left {2.6 ± 0.5} {2.6 ± 0.5}
Steering
Neutral o 28.4 ± 4.9 28.4 ± 4.9
Right {2.9 ± 0.5} {2.9 ± 0.5}
• Stop engine. N 49.0 ± 9.8 49.0 ± 9.8
Decelerator pedal
• Pressing pedal {kg} {5.0 ± 1.0} {5.0 ± 1.0}
D275A-5R 3

gory new machine
• Engine: Low idle N 490.0 ± 49.0 490.0 ± 49.0
Brake pedal
• Pressing pedal {kg} {50.0 ± 5.0} {50.0 ± 5.0}
Operating effort of control lever/pedal
Neutral o 39.2 ± 9.8 39.2 ± 9.8

• Engine: Low idle Raise/Lower {4.0 ± 1.0} {4.0 ± 1.0}
• Hydraulic oil tempera-
Neutral o N 77.6 ± 13.9 77.6 ± 13.9
Blade lever ture: Within operating
Float {kg} {7.9 ± 1.4} {7.9 ± 1.4}
range
• Operation of lever knob Neutral o 29.4 ± 9.8 29.4 ± 9.8
Left/Right tilt {3.0 ± 1.0} {3.0 ± 1.0}
• Engine: Low idle Neutral o 24.5 ± 9.8 24.5 ± 9.8

• Hydraulic oil tempera- Raise/Lower {2.5 ± 1.0} {2.5 ± 1.0}
N
Ripper lever ture: Within operating
{kg}
range Neutral o 24.5 ± 9.8 24.5 ± 9.8
• Operation of lever knob Tilt in/out {2.5 ± 1.0} {2.5 ± 1.0}
Engine: Max. 0.2 Max. 0.2

Torque converter Low idle {Max. 2} {Max. 2}
inlet pressure Engine: 0.49 – 1.0 0.49 – 1.0
High idle {5 – 10} {5 – 10}
Engine: Max. 0.2 Max. 0.2

Torque converter Low idle {Max. 2} {Max. 2}
outlet pressure Engine: 0.49 ± 0.1 0.49 ± 0.1
High idle {5 ± 1} {5 ± 1}
Engine: 2.74 – 3.14 Min. 2.65

Transmission main Low idle {28 – 32} {Min. 27}
relief pressure Engine: 3.04 – 3.43 Min. 2.94
High idle {31 – 35} {Min. 30}
Engine: 2.84 – 3.14 Min. 2.65
Power train oil pressure
Transmission F Low idle {29 – 32} {Min. 27}

clutch pressure Engine: 3.14 – 3.43 Min. 2.94
• Torque converter oil High idle MPa {32 – 35} {Min. 30}
temperature: Within
Engine: {kg/cm2} 2.84 – 3.14 Min. 2.65
operating range
Transmission R Low idle {29 – 32} {Min. 27}
High idle {32 – 35} {Min. 30}
Engine: 2.84 – 3.14 Min. 2.65

Transmission 1st Low idle {29 – 32} {Min. 27}
High idle {32 – 35} {Min. 30}
Engine: 2.84 – 3.14 Min. 2.65

Transmission 2nd Low idle {29 – 32} {Min. 27}
High idle {32 – 35} {Min. 30}
Engine: 2.84 – 3.14 Min. 2.65
Transmission 3rd Low idle {29 – 32} {Min. 27}
High idle {32 – 35} {Min. 30}
4 D275A-5R

gory new machine
Transmission lubri-
Engine: 0.05 – 0.29 0.05 – 0.29
cating oil pressure
High idle {0.5 – 3.0} {0.5 – 3.0}
(For reference)
Engine: 1.77 ± 0.20 1.77 ± 0.29
Steering left clutch Low idle {18 ± 2} {18 ± 3}
pressure Engine: 1.77 ± 0.20 1.77 ± 0.29
High idle {18 ± 2} {18 ± 3}
Engine: 2.84 – 3.14 Min. 2.26

Power train oil pressure
Steering left brake Low idle {29 – 32} {Min. 23}

pressure Engine: 3.14 – 3.43 Min. 2.45
• Torque converter oil MPa
High idle {32 – 35} {Min. 25}
temperature: Within
{kg/cm2}
operating range Engine: 1.77 ± 0.20 1.77 ± 0.29
Steering right clutch Low idle {18 ± 2} {18 ± 3}
pressure Engine: 1.77 ± 0.20 1.77 ± 0.29
High idle {18 ± 2} {18 ± 3}
Engine: 2.84 – 3.14 Min. 2.26

Steering right brake Low idle {29 – 32} {Min. 23}
pressure Engine: 3.14 – 3.43 Min. 2.45
High idle {32 – 35} {Min. 25}
Ripper pin puller Engine: 3.14 – 3.43 Min. 2.45
operating pressure High idle {32 – 35} {Min. 25}
• Flat road F1 3.6 ± 0.2 3.6 ± 0.2

• Engine coolant temper-
Performance of power train
ature: Within operating F2 6.7 ± 0.3 6.7 ± 0.3

range
• Torque converter oil F3 11.2 ± 0.6 11.2 ± 0.6
temperature: Within
Travel speed km/h
operating range
• Engine: High idle R1 4.7 ± 0.2 4.7 ± 0.2
• Run up distance:
10 – 30 m R2 8.7 ± 0.4 8.7 ± 0.4
• Measuring distance:
20 m R3 14.9 ± 0.7 14.9 ± 0.7
Engine: — —
Low idle
Unload pressure
Work equipment oil pressure
+1.37 +1.37
• Hydraulic oil tempera- Engine: 2.45 +0 2.45 +0
ture: Within operating High idle {25 +14
+0 } {25 +14
+0 }
range
Engine: 27.44 ± 1.37 27.44 ± 1.37
• Unload pressure: Set all
Blade lift relief Low idle MPa {280 ± 14} {280 ± 14}
equipment in neutral.
pressure {kg/cm2}
• Relief pressure: Set cyl- Engine: 27.44 ± 1.37 27.44 ± 1.37
inder to stroke end. High idle {280 ± 14} {280 ± 14}
• LS pressure: Set cylin-
Engine: 27.44 ± 1.37 27.44 ± 1.37
der to stroke end.
Blade tilt relief Low idle {280 ± 14} {280 ± 14}
pressure Engine: 27.44 ± 1.37 27.44 ± 1.37
High idle {280 ± 14} {280 ± 14}
D275A-5R 5

gory new machine
Engine: 27.44 ± 1.37 27.44 ± 1.37
Ripper lift relief Low idle {280 ± 14} {280 ± 14}
pressure Engine: 27.44 ± 1.37 27.44 ± 1.37
ture: Within operating High idle {280 ± 14} {280 ± 14}
range 27.44 ± 1.37 27.44 ± 1.37
Engine:
Work equipment oil pressure
• Unload pressure: Set all Low idle {280 ± 14} {280 ± 14}
Ripper tilt relief MPa
equipment in neutral.
pressure Engine: {kg/cm2} 27.44 ± 1.37 27.44 ± 1.37
• Relief pressure: Set cyl-
inder to stroke end. High idle {280 ± 14} {280 ± 14}
• LS pressure: Set cylin- Engine: 25.48 ± 1.27 25.48 ± 1.27
LS pressure der to stroke end. Low idle {260 ± 13} {260 ± 13}
(Load sensing
pressure) Engine: 25.48 ± 1.27 25.48 ± 1.27
High idle {260 ± 13} {260 ± 13}
Control circuit main
3.43 +0.49
+0
+0.49
3.43 –0.20
pressure
• Hydraulic oil temperature: {35 +5
+0 }
+5
{35 –2 }
(PPC, fan) MPa
{kg/cm2}
PPC valve output • Engine: High idle 3.14 – 3.92 3.14 – 3.92
pressure {32 – 40} {32 – 40}
Low idle 8 – 15 20
Raise
High idle 3–5 6
Blade lift sec
Low idle 1 – 1.5 2

ture: 45 – 55°C
Lower
Work equipment speed
• Apply no load to blade.

Work equipment
• Between ground level

High idle 1 – 1.5 2
and rising end of blade
Low idle 3–5 7

Left tilt
High idle 2.8 ± 0.5 3.5
Blade tilt sec
• Hydraulic oil tempera- Low idle 3–5 7

Right tilt
ture: 45 – 55°C
• Between left tilt end and
High idle 2.8 ± 0.5 3.5
right tilt end
6 D275A-5R

gory new machine
Low idle 5–8 10
Left tilt
High idle 2.8 ± 0.5 3.5
Blade dual tilt sec
• Hydraulic oil tempera- Low idle 5–8 10
Right tilt
ture: 45 – 55°C
• Between left tilt end and
High idle 2.8 ± 0.5 3.5
right tilt end
Low idle 6–9 12

Forward
High idle 2.8 ± 0.5 3.5
Blade pitch sec

ture: 45 – 55°C Low idle 5–8 10

Backward
Work equipment

• Between forward end
and backward end High idle 2.8 ± 0.5 3.5
Low idle 7 – 10 13
Raise
High idle 2.8 ± 0.5 3.5
Ripper lift sec

ture: 45 – 55°C Low idle 3.3 – 4.3 6
Lower
• Apply no load to ripper.

• Between ground level
and rising end of blade High idle 3.5 ± 0.5 4.5
Low idle 12 – 18 21
Tilt in
High idle 4.5 ± 0.5 5.5
Ripper tilt sec

ture: 45 – 55°C Low idle 8 – 14 17
Tilt out
• Apply no load to ripper.

• Between tilt-in end and
tilt-out end High idle 3.5 ± 0.5 4.5
D275A-5R 7

gory new machine
• Hydraulic oil temperature:
45 – 55°C Low idle Max. 8 11
• Move lever to stroke end.
Blade • Lower blade from max. ris-
ing position and measure
time after blade comes in
contact with ground until
Time lag
idler is lifted.
sec
• Hydraulic oil temperature:
45 – 55°C Low idle Max. 6 8
• Move lever to stroke end.
Ripper • Lower ripper from max. ris-
ing position and measure
time after ripper comes in
contact with ground until
sprocket is lifted.
Hydraulic drift Max. 150/15

300/15 minutes
of lifted blade minutes
• Hydraulic oil temperature: 45 – 55°C

Work equipment
• Engine: Stopped
• Measure reduction of blade bottom
height h (for 15 minutes).
Hydraulic drift
Hydraulic drift
of machine mm Max. 50/5 minutes 100/15 minutes
lifted by blade

• Engine: Stopped
• Measure reduction of idler center height
h (for 5 minutes).
Hydraulic drift
of machine Max. 50/5 minutes 100/15 minutes
tilted by blade

• Engine: Stopped
• Measure reduction of idler center height
h (for 5 minutes).
8 D275A-5R

gory new machine
Hydraulic drift Max. 80/15

160/15 minutes
of lifted ripper minutes

• Engine: Stopped
Hydraulic drift
• Measure reduction of shank bottom

mm
Work equipment
Hydraulic drift
of machine Max. 30/5 minutes 60/5 minutes
lifted by ripper

• Engine: Stopped
• Measure reduction of sprocket center
Leakage from cylinder
Blade tilt
4 16
cylinder
• Engine: High idle
Ripper lift • Hydraulic oil temperature: 45 – 55°C
cc/min 4 16
cylinder • Relieve cylinder and measure leakage
for 1 minute.
Ripper tilt
4 16
cylinder
• Fan: 100% speed mode Min.

450 ± 30 —
• Engine: Low idle speed
Cooling fan
Fan speed rpm

• Fan: 100% speed mode Max.
1,300 ± 50 1,200
• Engine: High idle speed
Fan pump oil • Fan: 100% speed mode MPa 17.17 – 20.60 17.17 – 20.60
pressure • Engine: High idle {kg/cm2} {175 – 210} {175 – 210}
D275A-5R 9
D275A-5R Bulldozer
© 2008 KOMATSU
All Rights Reserved
10 D275A-5R
SEN02752-01
D275A-5R

D275A-5R 35001 and up
30 Testing and adjusting 1

Testing and adjusting, Part 1
Tools for testing, adjusting, and troubleshooting............................................................................................. 3
Testing engine speed ...................................................................................................................................... 7
Testing intake air pressure (Boost pressure) ................................................................................................ 10
Testing exhaust temperature......................................................................................................................... 12
Testing exhaust gas color ............................................................................................................................. 14
Adjusting valve clearance ............................................................................................................................. 16
Testing compression pressure ...................................................................................................................... 18
Testing blow-by pressure .............................................................................................................................. 20
Testing engine oil pressure ........................................................................................................................... 21
Handling of fuel system devices ................................................................................................................... 22
Releasing residual pressure from fuel system .............................................................................................. 22
Testing fuel pressure..................................................................................................................................... 23
Testing fuel return rate and fuel leakage....................................................................................................... 24
Bleeding air from fuel circuit.......................................................................................................................... 28
Testing fuel circuit for leakage....................................................................................................................... 30
Testing and adjusting alternator belt tension................................................................................................. 31
D275A-5R 1
SEN02752-01 30 Testing and adjusting
Testing and adjusting air conditioner compressor belt .................................................................................. 32

Testing fan speed .......................................................................................................................................... 33
Testing fan circuit oil pressure....................................................................................................................... 34
Bleeding air from fan pump ........................................................................................................................... 35
Adjusting fuel control dial and decelerator pedal .......................................................................................... 36
2 D275A-5R
Tools for testing, adjusting, and troubleshooting 1

Sym-
Q'ty
Testing and adjusting item Part No. Part name Remarks
bol
–101 – 200 kPa
Testing intake air 799-201-2202 Boost gauge kit 1
A {–760 – 1,500 mmHg}
pressure (boost pressure)
799-401-2220 Hose 1 Straight type quick coupler
Testing exhaust B 799-101-1502 Digital thermometer 1 –99.9 – 1,299°C
temperature — 799-201-1150 Adapter connector 1 For Pm clinic specification
1 799-201-9001 Handy smoke checker 1
Testing exhaust gas color C Commercially Bosch index: 0 – 9
2 Smoke meter 1
available
Commercially Air intake: 0.35 mm,
Adjusting valve clearance D Thickness gauge 1
available Exhaust: 0.57 mm
2
1 795-502-1590 Compression gauge 1 0 – 7 MPa {0 – 70 kg/cm }
Testing compression KIT No.: 795-502-1205
E
pressure 795-471-1330 Adapter 1
2
6261-71-6150 Gasket 1
Testing blow-by pressure F 799-201-1504 Blow-by checker 1
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa
Testing engine oil 1 {25, 60, 400, 600 kg/cm2}
G Pressure gauge: 60 MPa
pressure
790-261-1204 Digital hydraulic tester 1
{600 kg/cm2}
2 799-401-2320 Hydraulic tester 1 Pressure gauge: 1 MPa {10 kg/cm2}
Pressure gauge:
1 {25, 60, 400, 600 kg/cm2}
Pressure gauge: 60 MPa
Testing fuel pressure H 790-261-1204 Digital hydraulic tester 1
{600 kg/cm2}
795T-471-2010 Adapter 1
3 8 × 1.25 mm o R1/8
07005-00812 Gasket 1
1 6151-51-8490 Spacer 1 Inside diameter: 14 mm
2 6206-71-1770 Joint 1 Inside diameter of joint: 10 mm
Commercially
3 Hose 1 ø5 mm × 2 – 3 m
available
Testing fuel return rate Commercially
J 4 Hose 1 ø15 mm × 2 – 3 m
and fuel leakage available
Commercially
5 Measuring cylinder 1
available
Commercially
6 Stopwatch 1
available
Testing fan speed K 799-205-1100 Tachometer kit 1 6.0 – 99999.9 rpm
Pressure gauge:
1 {25, 60, 400, 600 kg/cm2}
Testing fan circuit Pressure gauge: 60 MPa
L 790-261-1204 Digital hydraulic tester 1
pressure {600 kg/cm2}
2 799-401-3400 Adapter 1 Size: 05
799-101-5220 Nipple
3 1 Size: 10 × 1.25 mm
07002-11023 O-ring
D275A-5R 3
Sym-
Q'ty
bol
Pressure gauge:
1 {25, 60, 400, 600 kg/cm2}
Testing power train oil Pressure gauge: 60 MPa
N 790-261-1204 Digital hydraulic tester 1
pressure {600 kg/cm2}
799-101-5220 Nipple 1 Size: 10 × 1.25 mm
3
07002-11023 O-ring 1
19M-06-32820 Switch assembly 1
Emergency escape when 1 7824-66-6430 Resistor 1
Q
power train has trouble 17M-06-41530 Wiring harness 1
2 790-190-1601 Pump assembly 1
Pressure gauge:
1 {25, 60, 400, 600 kg/cm2}
Testing and adjusting work Pressure gauge: 60 MPa
R 790-261-1204 Digital hydraulic tester 1
equipment oil pressure {600 kg/cm2}
799-101-5220 Nipple 1 Size: 10 × 1.25 mm
2
07002-11023 O-ring 1
Pressure gauge:
1 {25, 60, 400, 600 kg/cm2}
Testing control circuit Pressure gauge: 60 MPa
S 790-261-1204 Digital hydraulic tester 1
basic pressure {600 kg/cm2}
Oil pressure pickup
799-401-3100 1 Size: 02
2 adapter
02896-11008 • O-ring 1
Pressure gauge:
1 {25, 60, 400, 600 kg/cm2}
Pressure gauge: 60 MPa
790-261-1204 Digital hydraulic tester 1
{600 kg/cm2}
Testing PPC valve output Oil pressure pickup
T 799-401-3100 1 Size: 02
pressure adapter
2
02896-11008 • O-ring 1
Oil pressure pickup
799-401-3200 1 Size: 03
3 adapter
02896-11009 • O-ring 1
Pressure gauge:
1 {25, 60, 400, 600 kg/cm2}
Testing ripper pin puller Pressure gauge: 60 MPa
solenoid valve outlet U 790-261-1204 Digital hydraulic tester 1
{600 kg/cm2}
pressure
Oil pressure pickup
799-401-3200 1 Size: 03
2 adapter
02896-11009 • O-ring 1
Testing leakage in work Commercially
V Measuring cylinder 1
equipment cylinder available
Testing coolant
temperature and oil — 799-101-1502 Digital thermometer 1 – 99.9 – 1,299°C
temperature
Testing operating effort 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
—
and pressing force 79A-264-0091 Push-pull scale 1 0 – 490 N {0 – 50 kg}
Testing stroke and Commercially
— Ruler 1
hydraulic drift available
4 D275A-5R
Sym-
Q'ty
bol
Testing work equipment Commercially
— Stopwatch 1
speed available
Testing voltage and Commercially
— Circuit tester 1
resistance available
799-601-7400 T-adapter assembly 1 For AMP040
799-601-7500 T-adapter assembly 1 For AMP070
799-601-9100 T-adapter assembly 1 For HD30
799-601-9200 T-adapter assembly 1 For DT connector
799-601-9300 T-adapter assembly 1 For DRC26-24 (40 pins)
799-601-9310 Plate 1 For 24-pole
799-601-9320 T-adapter box 1 For 24-pole
799-601-7360 Adapter 1 For relay (5 pins)
799-601-4101 T-adapter assembly 1 Connector for engine
799-601-4130 • T-adapter 1 Ne sensor
799-601-4150 • T-adapter 1 Oil pressure sensor
799-601-4180 • T-adapter 1 EGR gas pressure sensor
Diagnosis of sensor and 799-601-4211 • T-adapter 1 Connector (50-pole)
—
harness 799-601-4220 • T-adapter 1 Connector (60-pole)
799-601-4240 • Socket 1 Ambient pressure sensor
799-601-4250 • Socket 1 Boost pressure sensor
799-601-4260 • T-adapter 1 Connector (4-pole)
799-601-4330 • Socket 1 G (Bkup) sensor
799-601-4350 • T-adapter box 1 60-pole
799-601-9020 • T-adapter 1 Injector
799-601-9040 • T-adapter 1 By-pass/EGR valve
799-601-9420 • T-adapter 1 Common rail pressure
799-601-9430 • Socket 1 Supply pump PCV
Coolant, fuel and oil temperature
795-799-5530 • Socket 1
sensor
795-799-5540 • Socket 1 Boost and intake temperature sensor
D275A-5R 5
Sketches of special tools

Note) Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
H3 Adapter
6 D275A-5R
Testing engine speed 1 3. Testing high idle speed

k
1) Start the engine and set the fuel control
Stop the machine on level ground, lower
dial in the high idle position.
the work equipment to the ground, stop the
engine, and set the parking brake lever and 2) Set the PCCS lever and work equipment
work equipment lock lever in the lock posi- control lever in neutral and test the engine
tion. speed.
a Test the engine speed under the following con- a The high idle speed tested in the "Monitor-
dition. ing mode" or in the "Pm Clinic auxiliary
q Engine coolant temperature: mode" is the auto-deceleration speed.
Within operating range a When testing the high idle speed of the
q Hydraulic oil temperature: engine, use the "Adjustment mode".
Within operating range Adjustment code:
q Power train oil temperature: 0007 (Engine decelerator cut mode)
Within operating range Serial No.: 35001 – 35004
1. Preparation work
Turn the starting switch ON and set the
machine monitor in the "Monitoring mode" to
prepare for test of the engine speed.
a For the operating method, see "Special
functions of machine monitor (EMMS)".
q Monitoring code: 01000 (Engine speed)
Serial No.: 35001 – 35004
4. Testing decelerator pedal speed

dial in the high idle position.
2) Set the PCCS lever and work equipment
control lever in neutral and press the
decelerator pedal and test the engine
speed.
2. Testing low idle speed

dial in the low idle position.
2) Set the PCCS lever and work equipment
control lever in neutral and test the engine
speed.
D275A-5R 7
5. Testing torque converter stall speed Serial No.: 35005 and up

q Adjustment mode:
0530 (Stall speed check mode)
k This machine is equipped with the
cooling fan speed control function to
protect the radiator when the engine is
not fully warmed up. Since that func-
tion does not work while this mode is
used, warm up the engine fully before
using this mode.
q Hydraulic oil temperature: Min. 40°C
2) With the brake pedal depressed securely
and the parking brake lever in the “free”
6) Repeat above steps 2) – 5) 3 times.
position, set the PCCS lever in the “for-
7) Perform steps 2) – 4) again and measure
ward” and 3rd gear speed position.
the engine speed when the power train oil
a Before going to the next step, check
temperature gauge upper section (a) of
that the upper display unit of the mon-
the green range.
itor panel is set in the normal display
a After finishing measurement, return
state and it displays [F3].
the direction of the PCCS lever into
a Keep the steering unit in neutral.
neutral and lower the power train oil
3) Press the decelerator pedal and set the
temperature with the engine at high
fuel control dial in the high idle position.
idle.
4) Return the decelerator pedal slowly to stall
a After finishing measurement, finish
the torque converter with the engine at
the Adjustment mode.
high idle.
k Keep pressing the brake pedal
6. Measuring torque converter stall + work
securely and keep your right foot
equipment relief speed (full stall speed)
on the decelerator pedal for safety
q Adjustment mode:
until the work is finished.
0530 (Stall speed check mode)
k This machine is equipped with the
5) Just after the power train oil temperature
gauge upper section (a) of the green
cooling fan speed control function to
range, return the direction of the PCCS
protect the radiator when the engine is
lever into neutral.
not fully warmed up. Since that func-
Serial No.: 35001 – 35004
tion does not work while this mode is
used, warm up the engine fully before
using this mode.
q Hydraulic oil temperature: Min. 40°C
2) With the brake pedal depressed securely
and the parking brake lever in the “free”
position, set the PCCS lever in the “for-
ward” and 3rd gear speed position.
a Before going to the next step, check
that the upper display unit of the mon-
itor panel is set in the normal display
state and it displays [F3].
a Keep the steering unit in neutral.
3) Press the decelerator pedal and set the
fuel control dial in the high idle position.
8 D275A-5R
4) Return the decelerator pedal slowly to stall a The engine speed can be tested in the "Pm
the torque converter with the engine at Clinic auxiliary mode: 01" of the machine mon-
high idle. itor (Test the high idle speed of the engine in
k Keep pressing the brake pedal the "Adjustment mode", however).
securely and keep your right foot Serial No.: 35001 – 35004
5) Operate the ripper lever to raise the ripper
lift cylinder to the stroke end or pitch back
stroke end.
6) Just after the power train oil temperature
gauge upper section (a) of the green
range, return the direction of the PCCS
lever into neutral.
Serial No.: 35001 – 35004
7) Repeat above steps 2) – 6) 3 times.

8) Perform steps 2) – 4) and also operate rip-
per RAISE relief and pitch back relief and
measure the engine speed when the
power train oil temperature gauge upper
section (a) of the green range.
a After finishing measurement, return
the direction of the PCCS lever into
neutral and lower the power train oil
temperature with the engine at high
idle.
a After finishing measurement, finish
the Adjustment mode.
D275A-5R 9
Testing intake air pressure (Boost 3. Install nipple [1] of boost gauge kit A and con-
pressure) 1 nect gauge [2].
a Testing instruments for intake air pressure

(boost pressure)
Symbol Part No. Part name
799-201-2202 Boost gauge kit
A
799-401-2220 Hose
a A nipple (quick coupler) is installed to the

intake air pressure (boost pressure) testing
port of the Pm clinic specification machine.
k Stop the machine on level ground, lower
engine, and set the parking brake lever and
work equipment lock lever in the lock posi- 4. Run the engine at medium or higher speed and
tion. drain the oil from the hose.
k When installing and removing the testing a Insert the joint of the gauge and hose half-
instrument, take care not to touch a hot way and open the self-seal on the hose
part. side repeatedly, and the oil is drained.
a Test the intake air pressure (boost pressure) a If Pm kit (A) is available, the air bleeding
under the following condition. coupling (790-261-1130) in it may be
q Engine coolant temperature: used.
Within operating range a If any oil is left in the hose, the gauge does
q Torque converter oil temperature: not move. Accordingly, be sure to drain
Within operating range the oil.
q Hydraulic oil temperature:
Within operating range 5. Run the engine at high idle and stall the torque
converter and test the intake air pressure
1. Open the left side cover of the engine. (boost pressure) at this time.
a For the procedure for stalling the torque
2. Remove boost pressure testing plug (1). converter, see "Testing engine speed".
a Normally, the intake air pressure (boost
pressure) should be measured while the
engine is operated at the rated output. In
the field, however, an approximate value
can be obtained by stalling the torque con-
verter.
10 D275A-5R
6. After finishing test, remove the testing instru-

ment and return the removed parts.
q Remove the gasket sealant remaining on
the threads of the removed plug with a
wire brush and apply new adhesive or
gasket sealant to the plug before install-
ing.
2 Plug: LT2 or LG-5
3 Plug:
9.8 – 19.6 Nm {1.0 – 2.0 kgm}
a The boost pressure can be tested in the
"Pm Clinic auxiliary mode" of the machine
monitor.
Serial No.: 35001 – 35004
a The boost pressure displayed in the Pm clinic

auxiliary mode is absolute pressure.
D275A-5R 11
Testing exhaust temperature 1 3. Install sensor [1] of digital thermometer B and

connect them to meter [2].
a Testing instrument for exhaust temperature
a Clamp the wiring harness of the digital
Symbol Part No. Part name thermometer so that it will not touch a hot
B 799-101-1502 Digital thermometer
part during measurement.
a Testing instruments for exhaust temperature

(Pm clinic specification)
An exhaust temperature sensor is installed to
the Pm clinic specification machine. Accord-
ingly, prepare an adapter connector to connect
the exhaust temperature sensor to a digital
thermometer.
B 799-101-1502 Digital thermometer
— 799-201-1150 Adapter connector

the work equipment to the ground, stop the 4. Procedure for testing maximum exhaust tem-
engine, and set the parking brake lever and perature for troubleshooting
work equipment lock lever in the lock posi- Operate the machine actually and measure the
tion. maximum exhaust temperature.
k Install and remove the testing instrument a Use the PEAK mode of the digital ther-
after the exhaust manifold is cooled. mometer.
a Test the exhaust temperature under the follow- a The exhaust temperature largely depends
ing condition. on the outside air temperature (intake air
q Engine coolant temperature: temperature of the engine). Accordingly, if
Within operating range any abnormal value is obtained, correct it
q Torque converter oil temperature: by the following calculation.
Within operating range q Corrected value [°C] = Measured value
q Hydraulic oil temperature: + 2 x (20 – Outside air temperature)
1. Open the engine right side cover.
2. Remove 1 exhaust temperature pickup plug (1)

under the turbocharger.
a You may remove either of the right and left
plugs.
12 D275A-5R
5. Procedure for measuring exhaust temperature k Just after the torque converter oil tem-
periodically for preventive maintenance (Pm perature gauge reads the red range,
clinic) return the direction of the PCCS lever
a If the torque converter is stalled simply, into neutral and lower the torque con-
the torque converter oil temperature is verter oil temperature.
overheated before the exhaust tempera-
ture is stabilized. Accordingly, test accord-
ing to the following procedure.
1) Stall the torque converter fully to raise the
exhaust temperature to about 650°C
according to the following procedure
(Condition a in the figure).
i) Start the engine and set the fuel con-
trol dial to the low idle 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 idle
position.
iv) Return the decelerator pedal slowly to
stall the torque converter and relieve
the ripper in raising direction with the
engine at high idle.
k Press the brake pedal securely and
keep your right foot on the deceler-
ator 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 6. After finishing test, remove the testing instru-
figure). ment and return the removed parts.
a If the temperature does not lower but q Clean the thread of the removed plug and
rises, set the temperature in step 1). apply seizure prevention compound to the plug
before installing.
2 Plug: Seizure prevention compound
3) After the temperature lowers and is stabi-
lized, measure it (Condition c in the fig-
(LC-G)
ure).
(NEVER-SEEZ (NEVER-SEEZ COM-
POUND CO, LTD) or equivalent)
3 Plug: 2.9 – 5.9 Nm {0.3 – 0.6 kgm}
D275A-5R 13
Testing exhaust gas color 1 2. Testing with smoke meter C2

1) Insert probe [1] of smoke meter C2 in the
a Testing instrument for exhaust gas color
outlet of the exhaust pipe and fix it to the
Symbol Part No. Part name exhaust pipe with a clip.
1 799-201-9001 Handy smoke checker
C Commercially
2 Smoke meter
available

work equipment lock lever in the lock posi-
tion.
k When installing and removing the testing
instrument, 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
2) Connect the probe hose, receptacle of the
checker C1. When recording official data, use
accelerator switch, and air hose to smoke
smoke meter C2.
meter C2.
a Test the exhaust gas color under the following
a Limit the supplied air pressure to 1.5
condition.
MPa {15kg/cm2}.
q Engine coolant temperature:
Within operating range 3) Connect the power cable to a receptacle
of AC power supply.
1. Measuring with handy smoke checker C1 a Before connecting the cable, check
1) Stock a sheet of filter paper to C1. that the power switch of the smoke
2) Insert the exhaust gas intake pipe in the meter is turned off.
exhaust pipe. 4) Before connecting the cable, check that
3) Start the engine. the power switch of the smoke meter is
4) Accelerate the engine suddenly or run it at turned off.
high idle and operate the handle of smoke a Fit the filter paper securely so that the
checker C1 so that the filter paper will exhaust gas will not leak.
absorb the exhaust gas. 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 test, remove the testing
instrument and return the removed parts.
14 D275A-5R
6) Start the engine.

7) Accelerate the engine suddenly or run it at
high idle and press the accelerator switch
of smoke meter C2 and collect the
exhaust gas into the filter paper.
8) Place the contaminated filter paper on the
clean filter paper (at least 10 sheets) in the
filter paper holder and read the indicated
value.
D275A-5R 15
Adjusting valve clearance 1 a When the No. 1 cylinder piston is at the

compression top dead center, the No. 1
a Adjusting instrument for valve clearance cylinder rocker arm can be moved with the
Symbol Part No. Part name hand by the valve clearance. If the rocker
arm does not move, the piston is not at the
Commercially
D Thickness gauge compression top dead center. In this case,
available
revolve the crankshaft 1 more turn.
tion.
1. Open the inspection cover under the universal

joint (1) and disconnect universal joint (1) from
the engine.
4. While fixing adjustment screw (6), loosen lock-

nut (7).
a After setting the No. 1 cylinder to the com-
pression top dead center, adjust its valve
clearance.
5. Insert thickness gauge D in clearance (b)

between rocker arm (4) and cross head (5) and
adjust the valve clearance with adjustment
2. Open the right side cover of the engine and screw (6).
remove six cylinder head covers (2). a Adjust the adjustment screw with the
thickness gauge inserted so that the filler
gauge can be moved lightly.
6. Fix adjustment screw (6) and tighten locknut

(7).
3 Locknut:
45.1 – 51.0 Nm {4.6 – 5.2 kgm}
a After tightening the locknut, check the
valve clearance again.
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 (c) of the water
pump drive shaft end to crank the engine.
16 D275A-5R
7. Rotate the crankshaft forward by 120° and

repeat steps 3 – 6 for each cylinder in the firing
order.
q Firing order: 1 – 5 – 3 – 6 – 2 – 4
8. After finishing adjustment, return the removed

parts.
3 Cylinder head cover mounting bolt:
29.4 – 34.3 Nm {3.0 – 3.5 kgm}
3 Universal joint mounting bolt:
98.0 – 122.5 Nm {10.0 – 12.5 kgm}
D275A-5R 17
Testing compression pressure 1

a Testing tools for compression pressure
1 795-502-1590 Compression gauge
E 795-471-1310 Adapter
2
6261-71-6150 Gasket

tion.
k When testing the compression pressure, 5. Install adapter E2 to the mounting hole on the
take care n ot to burn you rself on t he injector and connect compression gauge E1.
exhaust manifold, muffler, etc. or get a Be sure to fit the gasket to the injector
caught in a rotating part. end.
a Test the compression pressure under the fol- a Fix the adapter with the injector holder.
lowing conditions. 3 Holder mounting bolt:
q Engine oil temperature: 40 – 60 °C 58.8 – 73.5 Nm {6.0 – 7.5 kgm}
a Apply a little amount of engine oil to the
1. Remove the engine hood assembly and air connecting parts of the adapter and gauge
cleaner together. so that air will not leak easily.
4 Engine hood assembly: 170 kg 6. Install rocker arm assembly (2) and adjust the
valve clearance.
3 Rocker arm mounting bolt:
2. Remove cylinder head cover (1) of the cylinder
to test the compression pressure. 93 – 103 Nm {9.5 – 10.5 kgm}
a See "Adjusting valve clearance".
3. Bring the cylinder to be tested to the compres-

sion top dead center and remove rocker arm
assembly (2).
a For the procedure for bringing each cylin-
der to the compression top dead center,
see "Adjusting valve clearance".
4. Remove fuel injector assembly. For details,

see item "Removal and installation of fuel
injector assembly (3)" on Disassembly and
assembly section.
18 D275A-5R
7. Disconnect power supply connector EGC3 (6) Serial No.: 35005 and up
of the engine controller.
k If this connector is not disconnected,

the engine will start during test and will
be dangerous. Accordingly, be sure to
disconnect this connector.
k Cover the controller side and wiring
harness side with vinyl sheets, etc. to
prevent electric leakage and ground
fault.
a If the starting switch is turned ON while
the connector is disconnected, errors are
made in the engine controller CAN com-
munication etc.
9. Rotate the engine with the starting motor and
test the compression pressure.
a Read the pressure gauge pointer when it
is stabilized.
a When testing the compression pressure,
check that the engine speed is in the
range of the test condition.

ments and return the removed parts.
a Install fuel injector assembly. For details,
see item "Removal and installation of fuel
injector assembly" on Disassembly and
assembly section.
8. Turn the starting switch ON and set the a Adjust the valve clearance. For details,
machine monitor to real-time monitoring mode see "Adjusting valve clearance".
of the service mode. 3 Cylinder head cover mounting bolt:
q Monitoring code: 01000 Engine Speed 29.4 – 34.3 kgm {3.0 – 3.5 kgm}
a For the operating method, see "Special
Serial No.: 35001 – 35004
D275A-5R 19
Testing blow-by pressure 1 a The blow-by pressure may vary largely

with the engine condition. If the measured
a Testing instrument for blow-by pressure value is judged abnormal, check for
Symbol Part No. Part name increase of oil consumption, bad exhaust
gas color, deterioration of oil, high deterio-
F 799-201-1504 Blow-by checker
ration speed of oil, etc. which are related
k Stop the machine on level ground, lower to the abnormal blow-by pressure.
tion.
a Test the blow-by pressure under the following
condition.
q Engine coolant temperature:
q Torque converter oil temperature:
1. Open the left side cover of the engine and pull

out blow-by hose (1).
2. Install nozzle [1] of blow-by checker F to the
end of blow-by hose (1).
3. Connect hose [2] and then connect it to gauge

[3].
4. Run the engine at high idle, stall the torque

converter, and test the blow-by pressure.
a For the procedure for stalling the torque
converter, see "Testing engine speed".
a Normally, the blow-by pressure should be
tested while the engine is operated at the
rated output. In the field, however, an
approximate value can be obtained by
stalling the torque converter.
a If it is impossible to run the engine at the
rated output or stall the torque converter,
test while the engine is running at high
idle. The value obtained in this case is
about 80% of the blow-by pressure at the
rated output.
20 D275A-5R
Testing engine oil pressure 1 3. Run the engine at low idle and high idle and
measure the engine oil pressure in each
a Testing instruments for engine oil pressure
speed.
799-101-5002 Hydraulic tester
1
G 790-261-1204 Digital hydraulic tester
2 799-401-2320 Hydraulic tester

tion.
a A nipple (quick coupler: 799-101-5160) is
installed to the engine oil pressure switch
mounting part of the Pm clinic specification
machine. 4. After finishing test, remove the testing instru-
a Measure the engine oil pressure under the fol- ments and return the removed parts.
lowing condition. q Remove the gasket sealant remaining on the
q Engine coolant temperature: threads of the removed plug with a wire brush
Within operating range and apply new adhesive or gasket sealant to
the plug before installing.
1. Open the engine left side cover and remove 2 Plug: LT2 or LG-5
engine oil pressure pickup plug (1) from the 3 Plug: 16.7 – 37.2 Nm {1.7 – 3.8 kgm}
cylinder block.
2. Install nipples [1] and [2] of hydraulic tester G1

and connect them to hydraulic tester G2.
a Since the size of plug holes is R 1/4, you
may use quick nipples (799-101-5210)
instead of nipples [1] and [2].
D275A-5R 21
Handling of fuel system devices 1 Releasing residual pressure from

a Precautions for testing and adjusting fuel sys- fuel system 1
tem a Pressure is generated in the low-pressure cir-
The common rail fuel injection system (CRI) cuit and high-pressure circuit of the fuel sys-
consists of more precise parts than the con- tem while the engine is running.
ventional fuel injection pump and nozzle. If for- Low-pressure circuit:
eign matter enters this system, it can cause a Feed pump – Fuel filter – Fuel supply pump
trouble. High-pressure circuit:
When testing and adjusting the fuel system, Fuel supply pump – Common rail – Fuel
take care more than the past. If dust, etc. sticks injector
to any part, wash that part thoroughly with a The pressure in both low-pressure circuit and
clean fuel. high-pressure circuit lowers to a safety level
a Precautions for replacing fuel filter capacitor automatically 30 seconds after the engine is
Be sure to use Komatsu genuine fuel filter car- stopped.
tridge. a Before the fuel circuit is tested and its parts are
Since the common rail fuel injection system removed, the residual pressure in the fuel cir-
(CRI) consists of more precise parts than the cuit must be released completely. Accordingly,
conventional fuel injection pump and nozzle, it observe the following.
employs a high-efficiency special filter to pre- k Before testing the fuel system or removing
vent foreign matter from entering it. its parts, wait at least 30 seconds after stop-
If a filter other than the genuine one is used, ping the engine until the residual pressure
the fuel system may have a trouble. Accord- in the fuel circuit is released. (Do not start
ingly, never use such a filter. the work just after stopping the engine
since there is residual pressure.)
22 D275A-5R
Testing fuel pressure 1 3. Run the engine at high idle and test the fuel
pressure.
a Testing instruments for fuel pressure a If the fuel pressure is in the following
Symbol Part No. Part name range, it is normal.
799-101-5002 Hydraulic tester Engine speed Fuel pressure
1
790-261-1204 Digital hydraulic tester 0.15 – 0.3 MPa
High idle
H 2 799-401-2320 Hydraulic tester {1.5 – 3 kg/cm²}
795T-471-2010 Adapter
3
07005-00812 Gasket

tion.
a Test only the fuel pressure in the low-pressure
circuit from the feed pump through the fuel fil-
ter to the supply pump.
k Since the pressure in the high-pressure cir-
cuit from the supply pump through the
common rail to the injector is very high, it
cannot be tested. 4. After finishing test, remove the testing instru-
1. Open the engine left side cover and remove 3 Plug (1): 7.8 – 9.8 Nm {0.8 – 1.0 kgm}
fuel pressure pickup plug (1) from the top of

the fuel filter.
2. Install adapter H3 and nipple [1] of hydraulic

tester H1 and connect them to hydraulic tester
H2.
D275A-5R 23
Testing fuel return rate and fuel leakage 1
a Testing instruments for return rate and fuel

leakage
1 6151-51-8490 Spacer
2 6206-71-1770 Joint
3 Commercially available Hose
J
4 Commercially available Hose
5 Commercially available Measuring cylinder
6 Commercially available Stopwatch
a Prepare an oil pan of about 20 l to receive the

fuel flowing out during the test.
tion.
24 D275A-5R
1. Preparation work 5) Connect test hose J3 to the end of joint

1) Open the engine left side cover and left J2.
mudguard. a Bind the connecting part of the test
2) Remove tube (3) between supply pump hose with a wire, etc. to prevent it
(1) and common rail (2). from coming off.
a In the figure, 1 oil filter is removed a The above is the preparation work for
temporarily from the common rail testing the leakage from the pressure
side. limiter.
a Disconnect both ends of the tube,
loosen the clamp, and move the tube
to the opposite side of the cylinder
block.
2. Testing leakage from pressure limiter

1) Lay test hose J3 so that it will not slacken
and put its end in the oil pan.
2) Warm up the machine sufficiently.
3) Insert spacer J1 on supply pump (1) side k If it is not, the radiator may be broken.
and tighten the removed joint bolt again. 3) Turn the starting switch ON and set the
a Connect the return pipe to the fuel machine monitor to Monitoring function of
tank again, too. the service mode.
a Be sure to fit the gaskets to both ends q Adjustment code:
of the spacer J1. 0530 (Stall speed check mode)
a For the operating method, see "Spe-
cial functions of machine monitor
(EMMS)".
4) Insert joint J2 on common rail (2) side and

tighten the removed joint bolt again.
a In the figure, 1 oil filter is removed
4) Run the engine at high idle and stall the
temporarily from the common rail
torque converter. After the engine speed
side. is stabilized, measure the leakage in 1
a Be sure to fit the gaskets to both ends minute with measuring cylinder J5.
of the joint. a For the procedure for stalling the
torque converter, see "Testing torque
converter stall speed" of "Testing
engine speed".
a You may test the leakage for 20 sec-
onds and judge by multiplying the
result by 3.
D275A-5R 25
a If the leakage from the pressure lim- 4) Turn the starting switch ON set the
iter is in the following range, it is nor- machine monitor to Adjusting function of
mal. the service mode.
q Adjustment code:
Leakage
Engine speed 0530 (Stall speed check mode)
(cc/min)
a For the operating method, see "Spe-
Install torque cial functions of machine monitor
Max. 10
converter (EMMS)".
5) Run the engine at high idle and stall the

5) After finishing test, stop the engine.
torque converter. After the engine speed
is stabilized, measure the return rate in 1
3. Testing return rate from injector
minute with measuring cylinder J5.
a Keep the hose on the pressure limiter side
a For the procedure for stalling the
connected and keep its end in the con-
torque converter, see "Testing engine
tainer while testing the return rate from the
speed".
injector.
a You may measure the return rate for
1) Disconnect return hose (5) of return block
20 seconds and judge by multiplying
(4) and connect test hose J4.
the result by 3.
a Stop the return hose with a plug, etc.
a If the supply pump is not supplying
and fix it to the fuel tank.
fuel, the engine speed may not rise.
Plug: 07376-70315
In this case, record the engine speed,
a Bind the connecting part of the test
too, during the test.
hose with a wire or clamp, etc. to pre-
a If the return rate (spill) from the injec-
vent it from coming off.
tor is in the following range, it is nor-
2) Lay test hose J4 so that it will not slacken
mal.
and put its end in the container.
Torque converter Limit of return rate
stall speed (rpm) (spill) (cc/min)
1,600 960
1,700 1,020
1,800 1,080
1,900 1,140
2,000 1,200
3) Warm up the machine sufficiently.

k If it is not, the radiator may be broken.
26 D275A-5R
6) After finishing testing, stop the engine.
4. Work after finishing testing

After finishing all testing, remove the testing
instruments and return the removed parts.
3 Common rail pressure limiter joint bolt:
17.7 – 22.6 Nm {1.8 – 2.3 kgm}
3 Supply pump over flow joint bolt:
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
D275A-5R 27
Bleeding air from fuel circuit 1 a This switch has a timer in it to start and
stop the electric priming pump automati-
a Bleed air from the fuel circuit in the following cally (See the figure).
cases according to this procedure. a The electric priming pump stops while the
q When the fuel filter is replaced lamp is blinking. This phenomenon is not
q When fuel is used up abnormal, however.
q When the engine is started for the first a If the switch is turned to the "OFF" position
time after the fuel piping or supply pump is while the lamp is blinking, the lamp goes
replaced off and the electric priming pump stops.
a If the fuel filter was replaced, do not fill the
main fuel filter and pre-fuel filter with the fuel.
k While the electric priming pump is in opera-
tion, pressure is applied to the fuel circuit.
Do not loosen the air bleeding plug at this
time, since the fuel may spout out.
1. Turn the starting switch to the "OFF" position.
2. Open the engine hood and open air bleeding

valve.
a Set the valve lever (1) in the open posi-
tion.
4. After the specified time (approx. 6 minutes 30

seconds), lamp (3) goes off and the electric
priming pump stops automatically.
a If only the fuel filter was replaced, the air
bleeding work is completed now.
5. If the fuel was used up or the fuel piping or

supply pump was replaced and there is not fuel
in the fuel circuit, turn switch (2) to the "ON"
position after the electric priming pump stops
automatically.
6. When lamp (3) goes off, the air bleeding work

3. Turn electric priming pump switch (2) to the is completed.
"ON" position.
a The switch returns to the "N" position 7. Close air bleeding valve.
automatically. a Set the valve lever (1) in the close posi-
a Lamp (3) blinks and the electric priming tion.
pump operates.
28 D275A-5R
8. Start the engine with the starting motor.

a The air in the high-pressure circuit is bled
automatically if the engine is cranked.
a If the engine does not start, there may be
still air in the low-pressure circuit. In this
case, start the engine according to the fol-
lowing procedure.
1) Turn the electric priming pump switch
to the "ON" position.
a The switch returns to the "N" position
automatically.
2) While the electric priming pump is
operating, start the engine.
a If the engine still does not start,
repeat the above operation.
3) After the engine starts, keep it run-
ning for at least 5 minutes to bleed all
air from the fuel circuit.
D275A-5R 29
Testing fuel circuit for leakage 1 9. Check the fuel piping and devices for fuel leak-
age.
k Very high pressure is generated in the high- a Check mainly around the high-pressure
pressure circuit of the fuel system. If fuel circuit parts coated with the color checker
leaks while the engine is running, it is dan- for fuel leakage.
gerous since it can catch fire. a If any fuel leakage is detected, repair it
a After testing the fuel system or removing and and inspect again from step 1.
installing its parts, test it for fuel leakage a If no fuel leakage is detected, inspection is
according to the following procedure. completed.
a Clean and degrease the engine and the parts
around it in advance so that you can test it eas-
ily for fuel leakage.
1. Spray color checker (developer) over the joints

of the fuel supply pump, common rail, fuel
injector, and high-pressure piping.
2. Run the engine at speed below 1,000 rpm and

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

age.
a Check mainly around the high-pressure
circuit parts coated with the color checker
for fuel leakage.
a If any fuel leakage is detected, repair it
and inspect again from step 1.
4. Run the engine at low idle.

age.
for fuel leakage.
6. Run the engine at high idle.

age.
for fuel leakage.
8. Run the engine at high idle and load it.

a Relieve the ripper circuit by raising the rip-
per.
30 D275A-5R
Testing and adjusting alternator 6. Install belt cover (1) with the 2 mounting bolts.
belt tension 1 a Check for breakage of the pulleys, wear of
the V-grooves, contact of the belts and V-
k Stop the machine on level ground, lower grooves, and contact of the belt covers
the work equipment to the ground, stop the and rotating parts.
engine, and set the parking brake lever and a If the belt is lengthened to the adjustment
work equipment lock lever in the lock posi- limit, cut, or cracked, replace it with new
tion. one.
a If the V-belt is replaced, adjust its tension
Testing again after 1 operating hour.
1. Open the engine right side cover and remove a After tightening the bolts, check that the
the inspection plate on the right of the radiator belt tension is normal according to the
guard. above procedure.
2. Press the intermediate point of the belt

between alternator pulley and water pump pul-
ley with a finger and measure deflection (a) of
the belt.
a Pressing force:
Approx. 98 N {Approx. 10 kg}
a Deflection (a): 13 – 16 mm
7. After testing and adjusting, return the removed

parts.
Adjusting
a If the deflection is out of the standard range,
adjust it according to the following procedure.
1. Remove the 2 mounting bolts and belt cover

(1).
a Remove the belt cover only when replac-
ing the belt.
2. Loosen 2 mounting bolts (3) of alternator (2),

and then loosen lock bolt (4) of the adjustment
rod.
3. Loosen locknut (5) of the adjustment rod and

move alternator (2) with adjustment nut (6) to
adjust the tension of the belt.
4. While fixing adjustment nut (6), tighten locknut

(5).
5. Tighten locknut (4) of the adjustment rod and 2

mounting bolts (3) of alternator (2).
D275A-5R 31
Testing and adjusting air a After tightening the bolts, check that the
conditioner compressor belt 1 belt tension is normal according to the
above procedure.
tion.
Testing
1. Open the left engine side cover and remove
the left mudguard.
2. Press the intermediate point of the belt between

the drive pulley and compressor pulley with a
finger and measure deflection (a) of the belt.
a Pressing force:
Approx. 59 N {Approx. 6 kg} 5. After testing and adjusting, return the removed
a Deflection (a): 10 mm parts.
Adjusting
a If the deflection is abnormal, adjust it according
to the following procedure.
1. Loosen the locknut of bolt (1).
2. Loosen locknuts (2) and (3) and move com-

pressor (5) and bracket as a unit with adjust-
ment nut (4) to adjust the belt tension.
3. While fixing adjustment nut (4), tighten lock-

nuts (3) and (2).
4. Tighten the locknut of bolt (1).

a Check for breakage of the pulleys, wear of
the V-grooves and contact of the belts and
V-groove.
a If the belt is lengthened to the adjustment
limit, cut or cracked, replace it with new
one.
a If the V-belt is replaced, adjust its tension
again after 1 operating hour.
32 D275A-5R
Testing fan speed 1 5. Start the engine and set the machine monitor
to Adjusting function of the service mode.
a Testing instrument for fan speed a Adjustment code: 1005 (Fan 100% mode)
Symbol Part No. Part name a For the operating method, see "Special
K 799-205-1100 Tachometer kit
a If this adjustment code is displayed, the
fan speed is kept at 100% speed in accor-
k Stop the machine on level ground, lower dance with the engine speed, regardless
the work equipment to the ground, stop the of the state of the machine.
tion.
a Test the fan motor speed under the following
condition.
q Hydraulic oil temperature: Within operat-
ing range
q Engine coolant temperature: Within oper-
ating range
q Power train oil temperature: Within operat-
ing range
k Warm up the machine sufficiently to
prevent breakage of the radiator.
1. Open the radiator mask and remove the fan 6. While running the engine at low idle and high
net. idle, test the fan speed
2. Stick 1 reflection tape [1] of tachometer kit K to

fan (1)
3. Set probe [2] to the reflection tape with stand

[3] and connect it to tachometer [4].
k Take care that the probe will not inter-
fere with the fan.
a Rotate the fan with the hand and check
that the probe can sense the rotation of
the reflection tape.
a Set probe [1] 100 – 200 mm apart from the
fan to stabilize the measured value.
4. Close the radiator mask.

k Before starting the engine, be sure to
close the radiator mask. Do not start
the engine while the radiator mask is
open.
D275A-5R 33
Testing fan circuit oil pressure 1

a Testing instruments for fan circuit oil pressure
1
790-261-1204 Digital hydraulic tester
L 2 799-401-3400 Adapter (05)
799-101-5220 Nipple (10 x 1.25 mm)
3
07002-11023 O-ring

engine, and set the parking brake lever and 5. Close the radiator mask.
work equipment lock lever in the lock posi- k Before starting the engine, be sure to
tion. close the radiator mask. Do not start
a Test the fan circuit oil pressure under the fol- the engine while the radiator mask is
lowing condition. open.
q Hydraulic oil temperature: Within operat-
ing range 6. Start the engine and set the machine monitor
q Engine coolant temperature: Within oper- to Adjusting function of the service mode.
ating range a Adjustment code: 1005 (Fan 100% mode)
q Power train oil temperature: Within operat- a For the operating method, see "Special
ing range functions of machine monitor (EMMS)".
k Warm up the machine sufficiently to a If this adjustment code is displayed, the
prevent breakage of the radiator. fan speed is kept at 100% speed in accor-
dance with the engine speed, regardless
1. Open the radiator mask and remove the fan of the state of the machine.
net.
2. Disconnect supply hose (1) of the fan motor.
3. Install adapter L2 and connect the discon-

nected hose again.
4. Install nipple L3 and connect it to oil pressure

gauge [2].
a When using an analog oil pressure gauge,
use one of 39.2 MPa {400 kg/cm²}.
34 D275A-5R
7. While running the engine at high idle, test the Bleeding air from fan pump 1
fan circuit oil pressure.
a If the fan pump is removed and installed or its
piping is disconnected and connected, bleed
air from the fan pump case according to the
a Before starting the following work, check that
the hydraulic oil level is normal.
1. Remove the floor inspection cover (1).

2. Loosen air bleeder (2) and leave it for 15 min-

utes.
3. After 15 minutes, start the engine and run it at

low idle.
4. After oil flows out of air bleeder (2), tighten air

bleeder (2) and stop the engine.
D275A-5R 35
Adjusting fuel control dial and decelerator pedal 1
k Stop the machine on level ground, lower [1] Fuel control dial (2nd throttle signal)
the work equipment to the ground, stop the [2] Engine controller
engine, and set the parking brake lever and [3] Steering controller
work equipment lock lever in the lock posi- [4] Decelerator pedal (1st throttle signal)
tion. [5] Decelerator potentiometer
1. Outline of fuel control system [6] Engine (CRI system)
q The following signals are inputted as rota- [7] Machine control signal
tion command signals to the engine con- (3rd throttle signal)
troller. [8] Rod
q Decelerator pedal potentiometer signal
q 3rd throttle signal
The engine controller controls the fuel
control system of the engine (CRI system)
according to the lowest engine speed sig-
nal among those input signals.
q Adjust the deceleration slow speed by
adjusting the decelerator pedal linkage.
36 D275A-5R
2. Preparatory work a If engine speed is too low:

1) Start the engine, set the monitor panel in Adjust the high idle speed with stopper
the “Adjustment mode”, and prepare to bolt (9).
measure the engine speed.
a For the operation method, see “Spe- 5. Check of decelerator position (decelerator
cial functions of monitor panel potentiometer signal)
(EMMS)”. a Measure the decelerator position in the
q Adjustment code: 0007 real-time monitoring mode.
(Engine deceleration cut mode) q Monitoring code: 31701
a The engine speed is displayed by 1 rpm. (Decelerator position)
Serial No.: 35001 – 35004 Check that displayed position is 100% while
the decelerator pedal is released.
If the displayed position is less than 100%,
adjust it to 100% with the pedal linkage.
If this adjustment is not made perfectly, the
engine control function etc. may not operate
normally. Accordingly, be sure to check the dis-
played position.
a The decelerator position can be checked
while the engine is stopped.
6. Check of final accelerator position

a Finish the check in 5 above in advance.
a Measure the final accelerator position in
the real-time monitoring mode.
q Monitoring code: 31706
(Final accelerator position)
While the decelerator pedal is released, set the
fuel control dial to the MAX position, set the
parking brake lever in the FREE position, set
the PCCS lever in the F or R position, and
check that the displayed position is 100%.
If the displayed position is less than 100%,
check the voltage signal of the fuel circuit for
error.
If this adjustment is not made perfectly, the
engine control function etc. may not operate
normally. Accordingly, be sure to check the dis-
played position.
3. Adjusting decelerator pedal speed a The accelerator position can be checked
Set the fuel control dial at the high idle position, while the engine is stopped.
depress decelerator pedal (4) until it contacts
the stopper, and check that the decelerator
pedal speed is normal.
q Decelerator pedal speed: 900 ± 50 rpm
a If the engine speed is not correct, adjust
installation dimension (a) of rod (8).
q Installation dimension (a): 123 mm
4. Adjusting high idle speed

Set the fuel control dial to the high idle position
and check that the high idle speed is correct.
q High idle speed: 2,150 ± 25 rpm
a If engine speed is too high:
To remove the play in the decelerator
pedal, set the engine speed to less than
1,900 rpm with stopper bolt (9), then
adjust it to the high idle speed.
D275A-5R 37
D275A-5R Bulldozer
© 2008 KOMATSU
All Rights Reserved
38 D275A-5R
SEN02753-01
D275A-5R

D275A-5R 35001 and up

Testing power train oil pressure ...................................................................................................................... 3
Adjusting transmission speed sensor ........................................................................................................... 12
Simple method of testing brake performance ............................................................................................... 13
Adjusting brake pedal and parking brake lever ............................................................................................. 14
Adjusting PCCS lever console position......................................................................................................... 17
Emergency escape method when power train has trouble ........................................................................... 18
Adjusting clearance of idler........................................................................................................................... 21
Inspecting wear of sprocket .......................................................................................................................... 21
Testing and adjusting track shoe tension ...................................................................................................... 22
Testing and adjusting work equipment oil pressure ...................................................................................... 23
Testing control circuit main pressure............................................................................................................. 27
Testing PPC valve output pressure............................................................................................................... 28
Adjusting play of PPC valve.......................................................................................................................... 30
Testing outlet pressure of ripper pin puller solenoid valve ............................................................................ 31
Testing parts which cause hydraulic drift of blade and ripper........................................................................ 32
Testing internal leakage of work equipment cylinder .................................................................................... 33
D275A-5R 1
Releasing residual pressure from work equipment cylinder.......................................................................... 34

Bleeding air from work equipment cylinder ................................................................................................... 34
Adjusting ripper lever position ....................................................................................................................... 35
Adjusting work equipment lock lever............................................................................................................. 36
Adjusting blade.............................................................................................................................................. 37
Testing and adjusting operator's cab............................................................................................................. 41
2 D275A-5R
Testing power train oil pressure 1 12 RB

Steering right brake oil
6 {60}
pressure
a Testing instruments for power train oil pressure
Transmission lubricating oil
Symbol Part No. Part name 13 — 1 {10}
pressure
799-101-5002 Hydraulic tester Out put pressure of sudden
1 LB stop prevention valve (For 6 {60}
steering left brake oil pressure)
Hydraulic tester
N 2 799-401-2320 14 Out put pressure of sudden
(1 MPa {10 kg/cm2})
stop prevention valve
799-101-5220 Nipple (10 x 1.25 mm) RB 6 {60}
(For steering right brake oil
3
07002-11023 O-ring pressure)
a A nipple (quick coupler) is installed to the

transmission 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 parking brake lever and safety
lock lever in the lock position.
a Test the power train oil pressure under the fol-
lowing condition.
a Centralized pressure pickup ports (1) – (12)
and (14) are installed inside the inspection
cover on the right outside of the operator's cab
and transmission lubricating oil pressure
pickup port (13) is installed to the top of the
power train filter.
a Table of locations of centralized pressure

pickup points for testing oil pressure and
gauges to use
Gauge
No. Stamp Oil pressure to be tested
(MPa {kg/cm2})
Torque converter inlet oil
1 IN 2.5 {25}
pressure
Torque converter outlet oil
2 OUT 1 {10}
pressure
Transmission main relief
3 TM 6 {60}
pressure
Transmission forward clutch oil
4 FWD 6 {60}
pressure
Transmission reverse clutch oil
5 R 6 {60}
pressure
Transmission 1st clutch oil
6 1ST 6 {60}
pressure
Transmission 2nd clutch oil
7 2ND 6 {60}
pressure
Transmission 3rd clutch oil
8 3RD 6 {60}
pressure
9 LC Steering left clutch oil pressure 6 {60}
10 LB Steering left brake oil pressure 6 {60}
Steering right clutch oil
11 RC 6 {60}
pressure
D275A-5R 3
1. Testing torque converter inlet pressure (IN) 2. Testing torque converter outlet pressure
1) Connect oil pressure gauge [1] of hydrau- (OUT)
lic tester N1 to oil pressure pick-up nipple 1) Connect hydraulic tester N1 to oil pres-
(1). sure pick-up nipple (2).
a Use an oil pressure gauge of 2.5 MPa a Use an oil pressure gauge of 1 MPa
{25 kg/cm2}. {10 kg/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) Test the oil pressure while the engine is 3) Test the oil pressure while the engine is
running at low idle and high idle. running at low idle and high idle.
4) After finishing test, remove the testing 4) After finishing test, remove the testing
instrument and return the removed parts. instrument and return the removed parts.
4 D275A-5R
3. Testing transmission main relief pressure 4. Testing transmission forward clutch pres-
(TM) sure (FWD)
1) Connect oil pressure gauge [1] of hydrau- 1) Connect oil pressure gauge [1] of hydrau-
lic tester N1 to oil pressure pick-up nipple lic tester N1 to oil pressure pick-up nipple
(3). (4).
a Use an oil pressure gauge of 6 MPa a Use an oil pressure gauge of 6 MPa
{60 kg/cm2}. {60 kg/cm2}.
2) Run the engine and set the PCCS lever in 2) Run the engine and set the parking brake
the full neutral position. lever in the FREE position.
3) Test the oil pressure while the engine is 3) Press the brake pedal and set the PCCS
running at low idle and high idle. lever in the FORWARD and 3rd gear
speed position.
4) Test the oil pressure while the engine is
running at low idle.
k Since the torque converter will be
stalled, press the brake pedal
securely and keep your right foot


D275A-5R 5
5. Testing transmission reverse clutch pres- 6. Testing transmission 1st clutch pressure
sure (R) (1ST)
(5). (6).
{60 kg/cm2}. {60 kg/cm2}.
2) Run the engine and set the parking brake 2) Run the engine and set the parking brake
lever in the FREE position. lever in the FREE position.
3) Press the brake pedal and set the PCCS 3) Press the brake pedal and set the PCCS
lever in the REVERSE 3rd gear speed lever in the FORWARD and 1rd gear
position. speed position.
running at low idle. running at low idle.
k Since the torque converter will be k Since the torque converter will be
stalled, press th e b rake pedal stalled, press pressing the brake
securely and keep your right foot pedal securely.
on the decelerator pedal for safety k Do not raise the engine speed to
until the work is finished. hight idle during test.
6 D275A-5R
7. Testing transmission 2nd clutch pressure 8. Testing transmission 3rd clutch pressure
(2ND) (3RD)
(7). (8).
{60 kg/cm2}. {60 kg/cm2}.
3) Press the brake pedal and set the PCCS 3) Press the brake pedal and set the PCCS
lever in the FORWARD and 2nd gear lever in the FORWARD and 3rd gear
speed position. speed position.
running at low idle. running at low idle.
k Since the torque converter will be k Since the torque converter will be
stalled, keep pressing the brake stalled, keep pressing the brake
pedal securely. pedal securely.
k Do not raise the engine speed to k Do not raise the engine speed to
high idle during test. hight idle during test.
D275A-5R 7
9. Testing steering left clutch pressure (LC) 10. Testing steering left brake pressure (LB)
(9). (10).
{60 kg/cm2}. {60 kg/cm2}.
3) Set the PCCS lever in the steering neutral 3) Set the PCCS lever in the steering neutral
position. position.
a Check that the oil pressure lowers to a Check that the oil pressure lowers to
0 when the PCCS lever is moved to 0 when the PCCS lever is moved to
the left steering stroke end. the left 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.


8 D275A-5R
11. Testing steering right clutch pressure (RC) 12. Testing steering right brake pressure (RB)
(11). (12).
{60 kg/cm2}. {60 kg/cm2}.
3) Set the PCCS lever in the steering neutral 3) Set the PCCS lever in the steering neutral
position. position.
a Check that the oil pressure lowers to a Check that the oil pressure lowers to
0 when the PCCS lever is moved to 0 when the PCCS lever is moved to
the right steering stroke end. 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.


D275A-5R 9
13. Testing transmission lubricating oil pressure 14. Testing output pressure of sudden stop
1) Remove oil pressure pickup plug (13). prevention valve
1) Connect oil pressure gauge (1) of hydrau-
lic tester N1 to oil pressure pickup nipples
(10) and (12).
a Use an oil pressure gauge of 6 MPa
{60 kg/cm2}.
q (10):
For steering left brake oil pressure
2) Install nipple N3 and connect hydraulic

tester N2.
{10 kg/cm2}.
q (12):
For steering right brake oil pressure
3) Run the engine at high idle and test the oil

pressure.
2) Run the engine and set the monitor panel

in the adjustment mode.
a For the method of operating the
adjustment mode, see "Special func-
tions of monitor panel (EMMS)".
a Adjustment code: 9995
(Electric brake constant ON mode)
3) Set the parking brake lever in the FREE
position and set the all PCCS levers in the
NEUTRAL position.
10 D275A-5R
4) Test the oil pressure while the engine is

running at low idle.
a If the output pressure of the sudden
stop prevention valve is in the follow-
ing range, it is normal.
q 1.13 – 1.57 MPa {11.5 – 16.0 kg/cm2}

D275A-5R 11
Adjusting transmission speed 6. Remove sensor (1) and flange (2) together and
sensor 1 secure them with nut (3).
a Take care not to change the adjustment
1. Remove the undercover of the fuel tank and angle of the sensor.
then remove transmission speed sensor (1) 3 Nut: 49.0 – 68.6 Nm {5 – 7 kgm}
and flange together.
a Before adjusting transmission speed sen- 7. Install flange (2) and sensor to the HSS case
sor (1), remove it and check that its tip is with the mark of "HSS UP" directed to the
free from steel chips and flaws, then install upper side of the HSS case.
it again.
a Before installing, separate sensor (1),
flange (2), and nut (3).
8. After finishing adjustment, set the machine

monitor in the "Monitoring display mode" and
check that it displays the transmission speed
2. Install flange (2) to the HSS case temporarily normally.
with the mark of "HSS UP" directed to the a For the operating method, see "Special
upper side of the HSS case. functions of machine monitor (EMMS)".
a Monitoring code:
3. Look at bevel gear (4) through the hole of 31400 (Transmission output speed)
flange (2) and check that a tooth tip is at the
center of the hole.
a If the tooth tip is not at the center of the
h o l e , r u n th e e n g i n e a n d m o v e t h e
machine forward 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.

a Returning angle of sensor: 1/2 – 1 turn
a Adjust clearance (b) between the sensor
tip and gear tooth tip to 0.75 – 1.50 mm.
12 D275A-5R
Simple method of testing brake

performance 1
a Carry out the simple test of brake performance
under the following condition.
1. Set the blade and ripper in the travel position

on a level place.
2. Run the engine and set the parking brake lever

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

pedal and set the PCCS lever in the FOR-
WARD and 2nd gear speed position.
k If this test is carried out in the 1st gear
position, the brake will be overloaded.
Accordingly, be sure to carry out in the
2nd gear speed.
a Set the steering unit in neutral.
4. Press the decelerator pedal and set the fuel

control dial in the high idle position.
5. Return the decelerator pedal slowly and check

that the machine does not start when the
engine speed reaches the high idle level.
k Since the torque converter will be
stalled, press the brake pedal securely
and keep your right foot on the deceler-
ator pedal for safety until the work is
finished.
D275A-5R 13
Adjusting brake pedal and parking brake lever 1

Brake pedal
Parking lever
14 D275A-5R
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 adjust- Turn the starting switch ON and set the
ing installed dimension (b) of stopper bolt (2). machine monitor in the adjustment mode and
a Adjust the brake pedal stroke with the set the brake potentiometer to the initial posi-
brake rod disconnected from the pedal. tion.
q Pedal stroke (a): 74 mm a For the method of operating the adjust-
q Installed dimension (b) of stopper bolt: ment mode, see "Special functions of
42 mm machine monitor (EMMS)".
a Adjustment code:
2. Adjusting installed length of brake rod 0005 (Brake pedal standard value)
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 6. Assembly and installation of lever assem-
brake rod (3) with turnbuckle (5) so that bly
the spool of brake valve (4) will be at the 1) Assemble lever assembly (7) and adjust
OFF position. the operation of limit switch (8).
a The locknut screw of the turnbuckle a Assemble the lever assembly with the
o n t h e b r a k e p e d a l s i d e i s l e ft- parking brake cable (9) disconnected from
handed. the lever.
q Installed dimension (c): 32 mm q When lever is at upper position: OFF, at
q Installed dimension (d): 14 mm lower position: ON
3 Locknut: q Operating stroke of limit switch: 3 mm
34.3 – 58.8 Nm {3.5 – 6.0 kgm} 2) Install lever assembly (7).
3. Checking brake pedal stroke 7. Adjusting installed length of parking brake

1) Press brake pedal (1) and check that its cable
stroke is as adjusted in step 1 above. 1) Connect parking brake cable (9) to the
2) Press brake pedal (1) and check that it is lever side and valve side, and then adjust
stopped at stopper (6). installed dimensions (f) and (g).
3) Press brake pedal (1) and check that q Installed dimension (f) of cable:
spool stroke (e) of brake valve (4) is in the 112.8 mm
normal range at this time. q Installed dimension (g) of cable:
q Spool stroke (e): 19 – 23 mm 114 mm
2) Operate parking brake lever (10) between
4. Checking brake oil pressure the FREE position and LOCK position and
1) Run the engine and set the machine mon- adjust the position of rod end (11) so that
itor in the adjustment mode. spool stroke (h) of brake valve (4) will be
a For the method of operating the normal.
adjustment mode, see "Special func- q Spool stroke (h): 23.0 mm
tions of machine monitor (EMMS)".
a Adjustment code: 9996 8. Checking brake oil pressure
(Mechanical brake operation check) Run the engine and set the parking brake lever
2) Press the brake pedal fully with the park- in the FREE position and LOCK position and
ing brake lever in the FREE position and check that the brake oil pressure will be as fol-
check that the brake oil pressure on both lows.
right and left sides is 0. a For the measuring point of the brake oil
a For the point to measure the brake oil pressure, see "Testing power train oil
pressure, see "Testing power train oil pressure".
pressure". q LOCK position: 0, FREE position: Speci-
fied pressure
D275A-5R 15
9. Checking limit switch

1) Turn the starting switch ON and set the
machine monitor in the display mode.
a For the method of operating the dis-
play mode, see "Special functions of
machine monitor (EMMS)".
(Steering controller input signal 1)
2) Set the parking brake lever in the FREE
position and LOCK position and check
that the limit switch signals are input nor-
mally.
16 D275A-5R
Adjusting PCCS lever console position 1
1. Set operator’s seat (1) in the forward (dozing)

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

in parallel with operator’s seat (1).
a If the console is not parallel with the oper-
ator’s seat, adjust dimension (a) of rod (3).
q Standard dimensions (a): 179mm
a The locknut on the rear side of the turn-
buckle is a left-handed (reversing) screw.
D275A-5R 17
Emergency escape method when a Since the female side of connector

power train has trouble 1 PL2 is kept disconnected, mask it
with a vinyl sheet, etc.
a Devices used for emergency escape a Put switch assembly [1] in the cab
through the cab window.
19M-06-32820 Switch assembly
1 7824-66-6430 Register
Q
17M-06-41530 Wiring harness
2 790-190-1601 Pump assembly
1. Escape with switch box (Use Q1)

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
a The engine must be startable for the fol-
lowing procedure. If the engine cannot be 3) Disconnect neutral safety relay (NSF) in
started, see "Emergency escape with the fuse room and connect pins [3] and [5]
brake releasing device". of the connector on the wiring harness
1) Connect switch assembly [1] and register side.
[2] to wiring harness [3] of emergency k If the engine is started by this
escape device Q1. method, the neutral safety function
k Since register [2] controls the drive does not work. Accordingly, before
voltage of the solenoid, connect it starting the engine, set the parking
to the wiring harness before con- brake lever in the LOCK position
necting to the machine. and set the PCCS lever in the full
k Set the all gear speed switches of neutral position.
switch assembly [1] in the OFF k Start the engine by this method
position and the direction switch in only in an emergency. If the engine
the P position to prevent the does not start in another case, be
machine from starting suddenly. 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).
q Connector PL1 (1):
Connect to male side and female side.
q Connector PL2 (2):
Connect to male side.
18 D275A-5R
4) Start the engine and set the parking brake 2. Escape with brake releasing device (Use
lever in the FREE position. Q2)
5) Operate switch assembly [1] and move a If the engine cannot be started and the
the machine to a safe place. parking brake cannot be released, escape
a The gear speed switch is so made according to the following procedure.
that the switch on the lower gear 1) Assemble pump assembly Q2.
speed will be operated first.
2) Install volume pump [4] of pump assembly

Q2 to the outside of the operator’s cab.
3) Remove the fuel tank undercover and dis-

connect supply hose (3) of the pin puller
solenoid valve.
D275A-5R 19
4) Connect end hose [5] of pump assembly

Q2 to the supply hose.
a Block the solenoid valve side with
plug [6].
5) Turn the starting switch ON and set the

parking brake lever in the FREE position.
6) Operate the vacuum pump to raise the
brake releasing oil pressure to the initial
pressure.
q Initial pressure:
Approx. 2.74 MPa {28 kg/cm2}
a Since an accumulator is installed in
the circuit, the handle must be oper-
ated 30 – 50 times to raise the oil
pressure.
a If the oil pressure does not rise above
a certain level, the relief valve may be
set to low pressure. In this case,
adjust the set pressure of the relief
valve.
7) Tow the machine to a safe place.
a The brake releasing oil pressure low-
ers gradually because of internal
leakage and the brake is applied
again about 1 minutes after. Accord-
ingly, work quickly.
a If the brake releasing pressure lowers
to about 1.5 MPa {16 kg/cm 2 }, the
brake is applied. In this case, operate
the volume pump again to raise the
brake releasing pressure to the initial
pressure.
20 D275A-5R
Adjusting clearance of idler 1 Inspecting wear of sprocket 1

a If the idler runs out or tilts because of wear of a As the wear measurement gauge for the
the side guide, upper and lower guides, and sprocket, use the "Full-scale drawing of
guide plate, adjust according to the following sprocket tooth profile" in "Structure, function
procedure. and maintenance standard", "Sprocket".
a Make a copy of the "Full-scale drawing of
1. Drive the machine for 1 – 2m on a level place, sprocket tooth profile" on a transparent sheet
then measure clearance (a) (on the inside and and apply it to the sprocket directly to see if the
outside). sprocket is serviceable.
2. If clearance (a) is more than 3mm, remove bolt

(1) and reduce shims (2).
q Standard clearance (a) on each side:
0 – 0.5 mm
q Thicknesses of shim: 0.5 mm, 1.0 mm
a When the machine is new, the total thick-
ness of the shims on each side is 7 mm.
a Reduce the shims on the inside and out-
side equally.
3 Mounting bolt:
490 – 608 Nm {50 – 62 kgm}
D275A-5R 21
Testing and adjusting track shoe

tension 1
Testing
1. Drive the machine slowly on a level place, then
stop it.
a Do not apply the brake when stopping.
2. Place straight steel bar (1) between the idler

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

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

Add grease through grease fitting (4).
a If the track shoe is not tensed well, drive
the machine forward and in reverse
slowly.
22 D275A-5R
Testing and adjusting work

equipment oil pressure 1
a Testing and adjusting instruments for work
equipment oil pressure
1
R
799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring
Testing
k Stop the machine on level ground, lower 4) Run the engine at high idle and set the
the work equipment to the ground, stop the blade lever and ripper lever in neutral and
engine, and set the parking brake lever and test the oil pressure.
tion.
a Test the work equipment oil pressure under the
following condition.
1. Testing unload pressure

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

3) Install nipple R2 and connect oil pressure

gauge [1] of hydraulic tester R1.
{60 kg/cm2}.
D275A-5R 23
2. Testing main relief pressure a The unload pressure and main relief pressure
a Test the main relief pressure at the same can be tested in the "Pm Clinic auxiliary mode"
point with the unload pressure. of the machine monitor.
a Use an oil pressure gauge of 40 MPa {400 Serial No.: 35001 – 35004
kg/cm2}.

1) Start the engine and set the work iquip-
ment lock lever in the FREE position.
2) Run the engine at high idle and operate
the blade lever and ripper lever to relieve
each cylinder at a stroke end and test the
oil pressure.

24 D275A-5R
3. Testing LS pressure (Load Sensing pres-

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

3) Install nipple R2 and connect oil pressure

gauge [1] of hydraulic tester R1.
{400 kg/cm2}.
4) Start the engine and set the work equip-

ment lock lever in the FREE position.
5) Run the engine at high idle and operate
the blade lever and ripper lever to relieve
each cylinder at a stroke end and test the
oil pressure.
D275A-5R 25
Adjusting 4) After finishing adjustment, check both

a The unload pressure cannot be adjusted. main relief pressure and LS pressure
(load sensing pressure) again according
1. Adjusting main relief pressure to the procedure for measurement
a If the main relief pressure is abnormal, described above.
adjust LS relief valve (3) of the control
valve according to the following proce- 2. Adjusting LS pressure (load sensing pres-
dure. sure)
a If the LS relief valve is adjusted, the LS a If the LS pressure (load sensing pressure)
pressure (load sensing pressure) is is abnormal, adjust LS relief valve (3) of
changed, too. the control valve.
a If the LS relief valve is adjusted, the main
relief 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 procedure for measurement described
above.
1) Fixing adjustment nut (4), loosen locknut

(5).
2) Turn the adjustment nut (4) to adjust the
pressure.
k Do not remove the adjustment nut.
If it is removed, the internal parts
may come off.
a If the adjustment nut is
q turned to the right, the pressure
rises.
q turned to the left, the pressure
lowers.
a Quantity of adjustment per turn of
adjustment nut: Approx. 19.6 MPa
{Approx. 200 kg/cm2}
3) Fixing adjustment nut (4), tighten locknut
(5).
3 Locknut: 39 – 49 Nm {4 – 5 kgm}
26 D275A-5R
Testing control circuit main 4. Install nipple [1] of hydraulic tester S1 and con-
pressure 1 nect oil pressure gauge [2].
a Use an oil pressure gauge of 6 MPa {60
a Testing instrument for control circuit main pres- kg/cm2}.
sure
1
S Oil pressure pickup adapter
799-401-3100
2 (Size 02)
02896-11008 • O-ring
a A nipple (quick coupler) is installed to the con-

trol valve outlet hose of the Pm clinic specifica-
tion machine.
a The control circuit main pressure is the pres-
sure lowered by the self-pressure reducing 5. Run the engine at high idle and set the blade
valve of the fan pump. It is used commonly for lever and ripper lever in neutral and test the oil
work equipment PPC, and fan pump control. pressure.
tion.
a Test the control circuit main pressure under the
following condition.
1. Open the right fender inspection cover.
2. Disconnect hose (1).

a The control circuit basic pressure cannot
be adjusted.
3. Install oil pressure pickup adapter S2 and con-

nect the disconnected hose again.
D275A-5R 27
Testing PPC valve output 3. Install nipple [1] of hydraulic tester T1 and con-
pressure 1 nect oil pressure gauge [2].
a Testing instruments for PPC valve output pres- kg/cm2}.
sure
1
Oil pressure pickup adapter
799-401-3100
2 (Size 02)
T
02896-11008 • O-ring
Oil pressure pickup adapter
799-401-3200
3 (Size 03)
02896-11009 • O-ring

the work equipment to the ground, stop the 4. Start the engine and set the work equipment
engine, and set the parking brake lever and lock lever in the FREE position.
tion. 5. Run the engine at high idle and operate the
a Before testing the PPC valve output pressure, control lever of the circuit to be tested and test
check that the control circuit main pressure is the oil pressure.
normal. a Test the oil pressure with the lever at a
a Test the PPC valve output pressure under the stroke end.
following condition. a When testing the blade circuit, operate the
q Hydraulic oil temperature: lever until the blade floats.
1. Open the right side cover.
2. Remove the pressure switch or pressure test-

ing plug (1) of the circuit to be tested.
a For the circuit to be tested, see the draw-
ing on the next page.
a If a circuit does not have a pressure switch
or a pressure testing plug, install pick-up
adapter T2 or T3.

28 D275A-5R
D275A-5R 29
Adjusting play of PPC valve 1

a If the end play of the blade lever and ripper
lever is excessive, adjust it with their PPC
valves according to the following procedure.
a This figure shows the PPC valve for the ripper.
q Standard play (a):
0.5 – 3.0 mm at 200 mm from revolution center
of lever (in both longitudinal and lateral direc-
tions)
1. Remove boot (1).
2. Loosen locknut (2) and turn disc (3) to adjust

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

3 Locknut: 98 – 127 Nm {10 – 13 kgm}
4. Install boot (1).
30 D275A-5R
Testing outlet pressure of ripper

pin puller solenoid valve 1
a Testing instruments for outlet pressure of rip-
per pin puller solenoid valve
1
U Oil pressure pickup adapter
799-401-3200
2 (Size 03)
02896-11009 • O-ring
k Stop the machine on level ground, lower 4. Run the engine at high idle and operate the rip-
the work equipment to the ground, stop the per pin puller switch and test the oil pressure.
tion.
a Test the outlet pressure of the ripper pin puller
solenoid valve under the following condition.
1. Disconnect pin puller cylinder hose (1) or (2).

2. Install oil pressure pickup adapter U2 and con-

nect the disconnected hose again.
3. Install nipple [1] of hydraulic tester U1 and con-

nect oil pressure gauge [2].
kg/cm2}.
D275A-5R 31
Testing parts which cause

hydraulic drift of blade and
ripper 1
a 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 fol-
lowing procedure.
1. Set the cylinders to be tested in the following

positions and stop the engine.
1) Blade lift cylinder
Brace the blade to raise the front side of
the machine body.
a Since the blade lift cylinder is equipped 2. Turn the starting switch ON and set the work
with a piston valve, do not extend it to equipment lock lever in the FREE position.
the stroke end.
3. Extend the cylinder to be tested with the corre-
sponding lever and check its movement.
q If the lowering speed is increased, the cyl-
inder packing is defective.
q If the lowering speed does not change, the
control valve is defective.
a 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
hydraulic drift:
2) Blade tilt cylinder 1. If the machine is set in the above position
Extract the tilt cylinder to the stroke end (where the holding pressure is applied to the
and brace the blade to push up the right bottom side), the oil leaks from the bottom side
side of the machine body. 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 increased,
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 lever
(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 pressure is
3) Ripper lift cylinder unbalanced and the lowering speed is
Brace the ripper to push up the rear side increased.
of the machine body.
32 D275A-5R
Testing internal leakage of work 3. Run the engine at high idle and apply the relief
equipment cylinder 1 pressure to the cylinder bottom side.
q Blade tilt cylinder:
a Testing instruments for internal leakage of Operate to extend the cylinder to
work equipment cylinder be tested.
Symbol Part No. Part name q Ripper lift cylinder:
Operate to lower ripper.
Commercially
V Measuring cylinder q Ripper Tilt cylinder:
available
Operate to tilt ripper forward.
4. After 30 second, test leakage in 1 minute by
the measuring cylinder V.
5. After finishing test, return the removed parts.
tion.
a Referring to "Bleeding air from work equip-
a Test the internal leakage of work equipment
ment cylinder", bleed air from the cylinder
cylinder under the following condition.
circuit.
q Hydraulic oil temperature: 45 – 55°C
a Since the blade lift cylinder is equipped with a
piston valve, its internal leakage cannot be
tested.
1. Extend the cylinder to be tested to the stroke

end and set the machine in the testing position.
1) Blade tilt cylinder
Extend the cylinder to be tested to the
stroke end.
2) Ripper lift cylinder
Pull out the shank pin and lower the ripper
to the end.
3) Ripper tilt cylinder
Tilt the ripper forward to the end.
2. Disconnect hose on the cylinder head side and

block the hose side with a plug.
a Remove the hose cover of the blade tilt
cylinder.
k Take care not to disconnect the hose
on the bottom side.
D275A-5R 33
Releasing residual pressure from Bleeding air from work equipment

work equipment cylinder 1 cylinder 1
a When disconnecting the piping between the a If the work equipment cylinder is removed and
control valve and work equipment cylinder, installed or its piping is disconnected and con-
release the residual pressure from the circuit nected, bleed air from its circuit according to
according to the following procedure. the following procedure.
k Stop the machine on level ground, lower a Before performing the following operation,
the work equipment to the ground, stop the check that the hydraulic oil level is normal.
work equipment lock lever in the LOCK 1. Run the engine at low idle for about 5 minutes.
position.
2. While running the engine at low idle, extend
1. Loosen oil filler cap (1) of the hydraulic tank and retract the cylinder to be bled 4 – 5 times.
gradually to release the residual pressure from a Move the piston rod to about 100 mm
the tank. before the stroke end and never relieve
the oil.
3. While running the engine at high idle, carry out

the operation in step 2.
4. While running the engine at low idle, move the

cylinder to the stroke end to relieve the oil.
2. Turn the starting switch ON and set the work

equipment lock lever in the FREE position.
3. Operate the blade control lever and ripper

control lever to each direction.
a If the control lever is operated 2 – 3 times,
the residual pressure in the accumulator is
released.
4. Run the engine at low idle for about 10 sec-

onds to increase the pressure in the accumula-
tor, then stop it.
5. Repeat steps 2 – 4 above 2 – 3 times.
34 D275A-5R
Adjusting ripper lever position 1
a Adjust the ripper lever to the best position 5) Loosen nut (3).
according to the following procedure. 6) Reverse 180° knob (4).
a The ripper lever can be adjusted forward and 7) Tighten nut (3) to secure knob (4).
in reverse within the range of ± 40 mm from the
center of the lever shaft.
1. Adjusting within range of backward 40 mm

from neutral position
1) Loosen lock bolt (1).
2) Set lever (2) to the best position.
3) Tighten lock bolt (1) to secure lever (2).
2. Adjusting within range of forward 40 mm

from neutral position
1) Remove lock bolt (1).
2) Remove lever (2) and reverse 180° it.
3) Install lever (2) to lever (5) and set it to the
best position.
4) Tighten lock bolt (1) to secure lever (2).
D275A-5R 35
Adjusting work equipment lock lever 1
1. Adjust dimension (a) between pins of rod (1).

q Dimension (a) between pins: 444mm
2. Connect rod (1) to work equipment lock lever

(2) and PPC lock valve (3).
a Install connecting pin (4) on the work
equipment lock lever side with the cotter
pin on the outside of the machine.
36 D275A-5R
Adjusting blade 1
Semi U-dozer, U-dozer
a 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. Standard
Adjusted Adjusted Standard
shim
point clearance clearance
thickness
1. Adjusting shims for assembly
1) Adjust the shim of center (1). 2 b Max. 1mm 4.0mm
Adjusted Adjusted Standard Standard

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

the ball in the axial direction will be
less than 1mm and the ball can ro-
tate smoothly.
D275A-5R 37
3) Adjust the shim of trunnion (3).

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

1) Adjust dimension (d) of brace (4) with the
handle.
q Dimension (d) of brace: 1,460 mm
38 D275A-5R
Sigma-dozer
a 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. Standard
shim
thickness
1. Adjusting shims for assembly
1) Adjust the shim of center (1). 2 b Max. 1mm 4.0mm
Adjusted Adjusted Standard Standard

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

the ball in the axial direction will be
less than 1mm and the ball can ro-
tate smoothly.
D275A-5R 39
3) Adjust the shim of trunnion (3).

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

Adjust dimension (d) of brace (4) with the han-
dle.
q Dimension (d) of brace: 1,403 mm
40 D275A-5R
Testing and adjusting operator's a [a] side: Inside of cab (Pressurized)

cab 1 [b] side: Out of cab
(Atmospheric pressure)
a If the operator's cab is removed and installed
or disassembled and transported and assem-
bled in the field, test and adjust it according to
the following procedure.
1. Testing pressure in cab

q Criterion:
Measured value X 78.5 Pa {8 mmH2O}
q Engine speed: High idle
q Fan speed: 100% mode
(Refer to service mode on machine moni-
tor)
q Air conditioner fan switch: High
q Air conditioner Fresh/Recirculation switch:
Fresh air position 2. Check of searing performance
a If the measured value is lower than the 1) Close the all openings of the cab.
standard value, check the seals of the 2) Splash water around the hatched part of
holes for wiring harnesses and optional the cab at the rate of about 19 l/min for 10
parts in the cab. minutes.
q At this time, it is not necessary to
1) A simple method of testing the internal splash pressurized water.
pressure is as follows. 3) Splash water horizontally from a hose over
i) Prepare a transparent vinyl hose. sealing surface (4).
q Inside diameter: 6 mm, 4) Check around the dashboard carefully.
Length: 3,000 mm a If water leaks, caulk the leaking part and
ii) Secure the inside end of the hose to check again.
the top of the back seat with a tape.
iii) Remove bolt (1) under the left con-
sole box. Pass the other end of the
hose through the bolt hole and take it
out of inspection 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 idle and mea-
sure water level difference (c).
(Value (c): Pa {mmH2O})
D275A-5R 41
D275A-5R Bulldozer
© 2008 KOMATSU
All Rights Reserved
42 D275A-5R
SEN02754-01
D275A-5R

D275A-5R 35001 and up

Special functions of machine monitor (EMMS) ............................................................................................... 2
D275A-5R 1
Special functions of machine monitor (EMMS) 1
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
2 D275A-5R
Normal function and special functions of machine monitor (EMMS)

The machine monitor (EMMS) has the normal function and special functions and displays information of var-
ious 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
testing, 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: 9 items
Travel direction/Gear speed [>] [<]
[U]
+
(W) 3 Error code display mode
Shift mode/Service meter
[>] [<]
[T] 4 Adjustment mode Adjustment menu: 5 items
[>] [<]
(Automatic) 1 Maintenance mode
Action code display function
[ON] & [U](W) [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: 25 items
[>] [<]
9 Load memory display mode Display menu: 9 items
[>] [<]
10 Real-time monitoring mode
[>] [<]
11 Dual display monitoring mode [ON] Service switch
[>] [<] [U]: Buzzer cancel switch (Left)
[T]: Buzzer cancel switch (Right)
Maintenance interval change [ > ]: Information switch (Right)
5
mode [ < ]: Information switch (Left)
(W): Min. 2.5 sec
D275A-5R 3
Operation and display in operator mode 1. Maintenance mode

(Outline) (1-OIL, FILTER MAINTENANCE MODE)
a In this section, only the outline of the operation In this mode, the time up to the next replace-
mode is described. For the details of the con- ment of oils and filters is displayed on the
tents and operation method of each function multi-information section (2) and to update the
and mode, see "Operation Manual". maintenance history.
a Gear speed display section (1) keeps dis-
Normal display mode (Default) playing normally.
The monitor panel displays the following informa- Order Display Item
tion normally. 1 01:ENG OIL Engine oil
Gear speed display section (1):
2 02:ENG FILT Engine oil filter
q Left side: Travel direction (P · N · F · R)
q Right side: Gear speed (1 · 2 · 3) 3 03:FUEL FILT Fuel main filter
q Graphics: Engine speed 4 04:HYD FILT Hydraulic oil filter
Multi-information section (2): 5 06:CORR RES Corrosion resistor
a Information is displayed in 2 lines of 16 charac-
6 07:DAMP OIL Damper oil
ters each.
q Left side: 7 08:FNL OIL Final drive oil
Gear shift mode (F1-R1 · F1-R2 · F2-R2) 8 10:HYD OIL Hydraulic oil
q Right side: 9 12:HSS FILT Charge filter
Service meter (Unit: 0.1h)
10 19:POWL OIL Power train oil
a To change the normal display mode to the
operator mode, hold buzzer cancel switch (4) 11 20:POWL FILT Power train oil filter
in the [U] position for 3 seconds. 12 41:F. PRE-FLT Fuel pre-filter
Serial No.: 35001 – 35004
a The displayed numbers are specific to the
corresponding items. (Some of them may
not be used in some models.)
Serial No.: 35001 – 35004
4 D275A-5R
2. Pm clinic auxiliary mode 3. Error code display mode

(2-PM CLINIC MODE) (3-FAULT CODE DISPLAY MODE)
In this mode, the condition of the machine is In this mode, the contents of each fault in the
displayed on multi-information section (2) as machine are displayed by a 6-character error
an auxiliary function of the periodic diagnoses code on the multi-information section (2).
such as the Pm clinic, even if any measuring
When the user or the operator needs to be
instrument is not connected.
a Gear speed display section (1) keeps dis- notified of the error code of each fault, this
playing normally. mode is applied.
a Gear speed display section (1) keeps dis-
Or- playing normally.
Display Item Unit
der
1 01-ENG SPEED Engine speed rpm
a When a serviceman needs to check the
error codes for troubleshooting, the Elec-
Engine coolant tempera-
2 02-COOLANT TEMP. °C tric system error code display mode and
ture
3 03-ENG OIL PRESS Engine oil pressure kPa the Mechanical system error code display
4 05-BOOST PRESS. Boost pressure kPa mode should be used for more detailed
5 06-BOOST TEMP. Boost temperature °C information.
Torque converter oil tem- a Method of checking error code:
6 07-T/C TEMP. °C Turn buzzer cancel switch (4) to the [U]
perature
7 08-HYD TEMP. Hydraulic oil temperature °C position on the screen shown at right, and
8 09-HYD PRESS. Hydraulic oil pressure MPa the all error codes detected currently are
9 13-BATTERY VOLT. Battery voltage mV mV displayed at the interval of about 2 sec-
onds. (To finish displaying, turn the buzzer
a The displayed numbers are specific to the
cancel switch to the [T] position.)
corresponding items. (Some of them may
a For details of the displayed failure code,
not be used in some models.)
a The boost pressure is indicated by the see Troubleshooting Volume, "Failure
absolute pressure. code table".
Serial No.: 35001 – 35004 Serial No.: 35001 – 35004
Serial No.: 35005 and up Serial No.: 35005 and up
D275A-5R 5
4. Adjustment mode (4-USER ADJUST MODE) 1) Brightness of LCD

In this mode, the display condition of the This function is used to adjust the bright-
machine monitor can be adjusted and the fan ness of the back light of the LCD gauge
speed (for cleaning the radiator) can be unit (See the operation manual).
changed on the multi-information section (2).
a Gear speed display section (1) keeps dis- 2) Brightness of display
playing normally. This function is used to adjust the bright-
Order Display Item
ness of the back light of the multi-informa-
tion unit (See the operation manual).
Adjustment of LCD
1 01:LCD BRIGHTNES
brightness
3) Contrast of display
Adjustment of display This function is used to adjust the contrast
2 02:DSP BRIGHTNES
brightness of the LCD of the multi-information unit
Adjustment of display (See the operation manual).
3 03:DSP CONTRAST
contrast
Fan 100% speed 4) Fan 100% mode
4 04:FAN 100%SPEED mode (For cleaning This function is to control rotation speed of
radiator) the cooling fan forcedly at approximately
Non-injection crank- 100% of the maximum speed.
5 05:NO INJECTION
ing mode 1] This mode is selected by operating
the information switch.
Serial No.: 35001 – 35004 2] The mode is selected by turning the
buzzer cancel switch to the [U] posi-
tion.
3] The function is effective under this
condition and the rotation speed of
the cooling fan is controlled to
approximately 100% of the maximum
speed.
a Exiting this mode disables the
function.
6 D275A-5R
5) No-injection cranking mode iv) Under this condition, set the starting
This function is used to stop fuel injection switch in the START position to per-
into all the cylinders of the engine to lubri- form non-injection cranking.
cate the engine parts simply before start- v) Return the starting switch to the ON
ing the engine after a long-time stop. position and set the buzzer cancel
i) Operate the information switch to switch in the [t] position to reset the
select this mode. mode.
ii) Set the buzzer cancel switch in the a If the system gets out of the mode,
[U] position to settle the mode. this function is set ineffective.
k Limit the continuous no-injection
cranking to 20 seconds to protect
the starting motor.
k This function is set ineffective for
safety while the engine is running.
At this time, "NOT AVAILABLE" is
displayed on the lower line to indi-
cate that the mode is ineffective.
iii) After about 3 seconds, "WAIT" dis-

played on the lower line changes to
"ACTIVE" and the mode becomes
effective.
D275A-5R 7
Action code display function Serial No.: 35001 – 35004

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).
a Gear speed display section (1) keeps display-
ing normally.
a The phone No. is displayed only when an action
code of high importance is displayed. The fig-
ure shown at right is an example (The display
style of the phone No. depends on its input
style).
a If an important action code is displayed, the
caution lamp flashes and the caution buzzer
sounds.
<Reference> Serial No.: 35005 and up
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 Example of contents of fault Remedy
code
• Automatic function stops or nor-
• Torque converter is not locked
mal function stops partially but
up.
E01 • Only action code is displayed. machine can work.
• Blade dual tilt mechanism does
• Call your Komatsu distributor for
not work.
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 coolant temperature is
defective.
• 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.
8 D275A-5R
Operation and display in service mode 2) Selecting and executing mode to be used
Method of changing to service mode Select the mode to be used with information
a When using the service mode, change the switch (5) and execute it with buzzer cancel
screen by the following special operation. switch (4).
q [ > ]: Next mode No.
1) Special operation of switches q [ < ]: Previous mode No.
Set the monitor panel in the service mode by q [U]: Execute mode.
operating service switch (3) and buzzer cancel a For the details of operation in each mode,
switch (4). see the following pages.
a While keeping the service switch in the Gear
ON position (hold it up), keep the buzzer Order speed Display and item
display
cancel switch in the [U] position for a min-
5-EXCHG, INTVAL INTERVAL MODE
imum of 3 seconds. 1 1C
a If the multi-information section changes to Maintenance interval change mode
the mode display shown below, the sys- 6-ELEC. FAULT CODE MODE
2 EE
tem is in the service mode. Electric system fault code display mode
a The mode displayed first depends on each 7-MACHINE CHECK CODE MODE
case. 3 bE
Mechanical system fault code display mode
8-SERVICE ADJUST MODE
4 Cb
Adjustment mode
9-LOAD MAP 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
3) Finishing mode and function

The current mode and function can be finished
by either of the following method, regardless of
the current mode and hierarchy.
[1] When continuing the operation in another
mode or function or in the operator mode:
Return to the mode screen or function
screen to be used next by operating
buzzer cancel switch (4).
q [T]: Screen returns.
[2] When finishing the all operation:
Turn off the starting switch.
D275A-5R 9
5. Maintenance interval change mode 2) Selecting and displaying maintenance

(5-EXCHG. INTVAL. INTERVAL MODE) item
In this mode, you can check and set the main- i) Operate information switch (5) on the
tenance interval times of various filters and oils maintenance item selection screen to
which are the bases of the maintenance dis- select a maintenance item.
play function in the operator mode. q [ > ]: Next code
q [ < ]: Previous code
1) Selecting and executing mode ii) Display the maintenance item selec-
i) Select "Maintenance interval change tion screen by operating buzzer can-
mode" on the mode selection screen. cel switch (4).
a If the mode is selected, code q [U]: Execute item.
(1C) is displayed on gear speed
display section (1) and the title is
displayed on multi-information
section (2).
ii) Display the maintenance item selec-
tion screen by operating buzzer can-
cel switch (4).
q [U]: Execute mode.
Serial No.: 35001 – 35004
3) Contents of information section

The following items are displayed on the
information section.
[1]: Code
[2]: Maintenance item
[3]: Replacement interval time (Set time)
a The items shown at right are exam-
ples.
a If the replacement interval does not
Serial No.: 35005 and up need to be changed, finish the opera-
tion on this screen.
a If the replacement interval needs to
be changed, go to step 4).
10 D275A-5R
4) Changing replacement interval time ii) If the input time is correct, enter the
i) Change the set time by operating change of setting by operating buzzer
information switch (5), shift-up switch cancel switch (4).
(6), and shift-down switch (7). q [U]: Enter change.
q [ > ]: Move cursor to right. a If the change is finished normally,
q [ < ]: Move cursor to left. the information display screen
q [UP]: Increase number. appears after the screen shown
q [DOWN]: Decrease number. at right.
a If you do not use the mainte- a If the change is not finished nor-
nance function, set the all times mally, the information display
to 0. screen before the change
appears after the screen shown
at right. In this case, execute the
above operation again.
D275A-5R 11
Maintenance items table

1st time 2nd time and after
Order Display Item
(Cannot be changed) (Can be changed)
1 01:ENG OIL Engine oil 0500h 0500h
2 02:ENG FILT Engine oil filter 0500h 0500h
3 03:FUEL FILT Fuel main filter 1000h 1000h
4 04:HYD FILT Hydraulic oil filter 0250h 2000h
5 06:CORR RES Corrosion resistor 1000h 1000h
6 07:DAMP OIL Damper oil 2000h 2000h
7 08:FNL OIL Final drive oil 0250h 2000h
8 10:HYD OIL Hydraulic oil 0250h 2000h
9 12:HSS FILT Charge filter 1000h 1000h
10 19:POWL OIL Power train oil 0250h 1000h
11 20:POWL FILT Power train oil filter 0250h 0500h
12 41:F. PRE-FLT Fuel prefilter 0500h 0500h
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.
a The displayed numbers are the ID numbers specific to the corresponding items and are not the display
order numbers. Some of them may not be used in some models. In addition there is a thing becoming
a missing number by a model.
a Set the replacement interval time of the charge filter to "0".
12 D275A-5R
6. Electric system error code display mode 2) Display in the case where no codes are
(6-ELEC. ERROR CODE MODE) recorded
In this mode, you can check the past electric If no error codes have been output up to
system error codes. now, the information section displays as
shown below.
1) Selecting and executing mode
i) Select "Electric system error code
display mode" on the mode selection
screen.
a If the mode is selected, code
(EE) is displayed on gear speed
section (2).
ii) Display the error code display screen
by operating buzzer cancel switch (4).
Serial No.: 35001 – 35004
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 below.
[1]: Record No. (Up to 20)
[2]: Error code (Code being output cur-
rently is flashing)
[3]: Number of past occurrences
[4]: Elapsed time on service meter after
first occurrence
[5]: Elapsed time on service meter after
last occurrence
Serial No.: 35005 and up a The items shown below are exam-
ples.
a For the details of displayed error
codes, see the errors code table in
"Troubleshooting when error code is
indicated (Error code)".
D275A-5R 13
a Flashing and lighting of error code

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

recorded.
When multiple codes are recorded, they
can be displayed one by one by operating
information switch (5).
q [ > ]: Next code
a 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 an error code to be deleted, operate
shift-up switch (6) or shift-down switch (7).
q [UP] or [DOWN]: Delete error code.
a An error code which is being output
currently (which is flashing) cannot be
deleted.
14 D275A-5R
7. Mechanical system error code display mode 2) Display in the case where no codes are
(7-MACHINE CHECK CODE MODE) recorded
In this mode, you can check the past mechani- If no error codes have been output up to
cal system error codes. now, the information section displays as
shown below.
i) Select "Mechanical system error code
display mode" on the mode selection
screen.
a If the mode is selected, code
(bE) is displayed on gear speed
section (2).
ii) Display the error code display screen
by operating buzzer cancel switch (4).
Serial No.: 35001 – 35004
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 below.
[1]: Record No. (Up to 15)
[2]: Error code (Code being output cur-
rently is flashing)
[3]: Number of past occurrences
[4]: Time measured by service meter after
first occurrence
[5]: Time measured by service meter after
last occurrence
Serial No.: 35005 and up a The items shown below are exam-
ples.
a For the details of displayed error
codes, see the errors code table in
"Troubleshooting when error code is
indicated (Error code)".
D275A-5R 15
a Flashing and lighting of error code

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

recorded.
When multiple codes are recorded, they
can be displayed one by one by operating
information switch (5).
q [ > ]: Next code
5) Method of deleting error code

The mechanical system error codes can-
not be deleted.
16 D275A-5R
8. Adjustment mode 2) Selecting adjustment items

(8-SERVICE ADJUST MODE) On the adjustment code input screen,
In this mode, you can adjust the control system input the 4-digit code of the item to be
and various devices of the machine. adjusted by operating information switch
(5), shift-up switch (6), and shift-down
1) Selecting and executing mode switch (7).
i) Select "Adjustment mode" on the q [ > ]: Move cursor to right.
mode selection screen. q [ < ]: Move cursor to left.
a If the mode is selected, code q [UP]: Increase number.
(Cb) is displayed on gear speed q [DOWN]: Decrease number.
display section (1) and the title is a Input a 4-digit code and set buzzer
displayed on multi-information cancel switch (4) to the [U] position,
section (2). and the information on that item is
ii) Display the adjustment code input displayed.
screen by operating buzzer cancel
switch (4).
Serial No.: 35001 – 35004
3) Contents of display on adjustment screen

[1]: Code
[2]: Adjustment item
[3]: Related information
Serial No.: 35005 and up a For the detailed information and
adjustment procedure, see "Adjust-
ment mode table and adjustment pro-
cedure".
D275A-5R 17
a If an incorrect code is input, the 5) Automatic selection of adjustment item

adjustment code input screen (Limited function)
appears again after the screen shown After one of some adjustment items is
below. In this case, execute the selected, if the information switch is oper-
above operation again.
ated, the next adjustment item is selected
automatically, even if the code of the next
adjustment item is not input.
q [ > ]: Code is increased
q [ < ]: Code is decreased
a This function is applied to only the
items having numbers in the Auto-
matic selection column of the Adjust-
ment mode table. Those items are
selected in the order of their numbers.
a Note that this operation is not effec-
tive while the parking brake lever is in
the RESET position.
a You may return to the screen for
4) When operating machine in adjustment inputting codes and enter a code
mode without using this function.
If the parking brake lever is set in the
FREE position, gear speed display section
(1) displays normally and the machine can
be operated normally.
a To select another screen, return the
parking brake lever to the LOCK posi-
tion and perform the necessary pro-
cedure.
k Since the operation may be differ-
ent from the usual, take extreme
care when operating.
Serial No.: 35001 – 35004
18 D275A-5R
Adjustment mode table and adjustment procedure

Adjust-
Disassembly/ Automatic
No. ment Adjustment item Displayed data Unit
Assembly selection
code
[1] 0001 INP TEL NO. Phone No. input mode Phone No. (None) —
[2] 0002 S/T S. CODE Steering controller model code setting Code Character q 1
[3] 0003 T/M S. CODE Transmission controller model code setting Code Character q 2
[4] 0004 BODY TYPE Machine specification code setting Code Character q 3
Voltage offset
[5] 0005 BRAKE BASE Brake pedal standard value set mV q 4
quantity
[6] 0007 ENG. FULL CH Engine decelerator cut mode Engine speed rpm 5
Engine speed/In-
[7] 0008 INJ->123456 Reduced cylinder mode rpm/mg —
jection quantity
Voltage offset
[8] 0009 PITCH SENS. Pitch angle sensor standard value set mV q 6
quantity
Adjustment
[9] 0010 FAN 70%MODE Fan 70% mode (None) 8
quantity
Setting
[10] 0021 KMTRX INST KOMTRAX specification setting Character q 7
condition
[11] 0530 STALL CHECK Stall speed check mode Engine speed rpm —
Adjustment
[12] 1005 FAN 100%MODE Fan 100% mode (None) 9
quantity
Steering lever
[13] 1012 S/T N-SET Steering lever neutral value set mV —
voltage
Steering lever
[14] 1013 S/T M. L-SET Steering lever left max. value set mV —
voltage
Steering lever
[15] 1014 S/T M. R-SET Steering lever right max. value set mV —
voltage
[16] 1015 BRK LH. OFST Left brake oil pressure offset (set) Oil pressure MPa —
[17] 1016 BRK RH. OFST Right brake oil pressure offset (set) Oil pressure MPa —
Setting
[18] 2223 R SLOW CUT Reverse slow cut function setting Character —
condition
Transmission
[19] 5535 CLUTCH OPEN Clutch disengagement mode rpm —
speed
[20] 5537 CLT LH. OFST Left clutch oil pressure offset (set) Oil pressure MPa —
[21] 5538 CLT RH. OFST Right clutch oil pressure offset (set) Oil pressure MPa —
Sudden stop prevention valve operation Brake potentiom-

[22] 9995 LOCK BRAKE mV —
mode eter voltage
Brake potentiom-
[23] 9996 MECHA BRAKE Mechanical brake operation check mode mV —
eter voltage
Adjustment
[24] 9997 HI IDLE SET High idle limit setting rpm —
quantity
Setting
[25] 9998 SFT INHIBIT 3rd gear speed cut setting Character —
condition
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 after replacement of controller".)
D275A-5R 19
[1] 0001: Phone number input mode [2] 0002: Steering controller model code setting
q This code inputs or changes a phone number q This code is used to initialize the model codes
to be displayed simultaneously with when the recognized by the steering controller and the
user code is displayed. set values of the memory in the controller.
q The lower part displays a phone number and q The model code is displayed on the lower line.
symbols. q Adjustment method:
q Available characters: 0 1 2 3 4 5 6 7 8 9 : ; < > ? 1) Set buzzer cancel switch (4) in the [U]
q Instructions for use: position and check that the caution buzzer
By operating the information switch (5), shift up sounds.
switch (6), and shift down switch (7), input a 2) Check that the displayed model code has
phone number and symbols. changed from [A*A] to [AAA].
q [ > ]: Moves the cursor rightward. a If model code [AAA] is not displayed, the
q [ < ]: Moves the cursor leftward. controller wiring harness or the controller
q [UP]: Advance the numeric character or unit may be defective.
character (in the order of available a Even if this code is turned off, the setting
characters). is effective.
q [DOWN]:Reverse the numeric character
or character (in the reverse order
of available characters).
a Sixteen digits of numeric characters are
provided. To avoid confusion, input sym-
bols other than numeric characters at dig-
its you will not use.
a 0 (zero) is input at all places of the lower
part before shipment from our factory.
a The setting is enabled even after ending
this code.
20 D275A-5R
[3] 0003:Transmission controller model code setting [4] 0004: Machine specification code setting
q This code is used to initialize the model codes q This code is used to have the machine specifi-
recognized by the transmission controller and cation recognized by the controllers which
the set values of the memory in the controller. compose the system.
q The model code is displayed on the lower line. q The specifications of the work equipment, SSC
q Adjustment method: and travel lever are set with this code.
1) Set buzzer cancel switch (4) in the [U] a Since setting of this code is reset when "Trans-
position and check that the caution buzzer mission controller specification setting" is exe-
sounds. cuted, adjust it after that.
2) Check that the displayed model code has q Adjustment procedure
changed from [9*9] to [999]. 1) Select code 0004 in the adjustment mode.
a If model code [999] is not displayed, the (a): Indicates specification of travel lever
controller wiring harness or the controller (1st place)
unit may be defective. (b): Indicates specification of work equip-
a Even if this code is turned off, the setting ment (2nd place)
is effective. (c): Indicates specification of SSC (3rd
place)
2) Each time shift-up switch (6) is pressed,

display of the 2nd place and 3rd place
changes. Select proper specifications of
the work equipment and SSC.
a If the SSC is installed to the machine,
be sure to select Power setting 1 (do
not select Power setting 2).
q Example of operation
Upper line: Indicates specifications of
single tilt and without-SSC.
Lower line: Indicates specifications of
dual tilt and with-SSC.
D275A-5R 21
List of specifications of work equipment [5] 0005: Brake pedal standard value setting
and SSC q This code is used to adjust the zero point of the
Specification of brake pedal potentiometer.
No. work equipment Specification of SSC q The deviation from the standard value is indi-
X00 Single tilt Without SSC cated by voltage on the lower line (Indication
X01 Single tilt SSC power setting 1 range: –2,500 – 2,500).
X02 Single tilt SSC power setting 2 q Adjustment method:
X10 Dual tilt Without SSC 1) Check that the brake pedal is in neutral (it
X11 Dual tilt SSC power setting 1 is not pressed).
X12 Dual tilt SSC power setting 2 2) Set buzzer cancel switch (4) in the [U]
position and check that the alarm buzzer
Note) "X" indicates the travel lever code. sounds.
a This adjustment is performed to have the
3) Each time shift-down switch (7) is pressed, zero point of the potentiometer recognized
display of the 1st place changes. Select a by the controller. It is not performed to
proper specification (standard specification adjust the effect of the brake.
or optional specification) of the travel lever. a Even if this adjustment is performed, the
q Example of operation indication on the lower line does not
Upper line: Indicates standard specifi- change.
cation of travel lever. a Even if this code is turned off, the setting
Lower line: Indicates optional specifi- is effective.
cation of travel lever.
a Be sure to select the standard travel
lever specification. (Do not select the
optional travel lever specification.)
Travel lever specification table

Code Travel lever specification
8XX Standard travel lever specification
9XX Optional travel lever specification
Note) XX indicates the work equipment and

SSC code.
4) Set buzzer cancel switch (4) in the [U]

position to save the machine specification.
a When the buzzer cancel switch is
operated, the alarm buzzer sounds.
k If the actual machine specification
is different from the setting in the
controller, the machine may move
unexpectedly or an error is made.
Accordingly, be sure to set the
machine specification correctly.
a Even if this code is turned OFF, the setting
is effective.
22 D275A-5R
[6] 0007: Engine deceleration-cut mode [7] 0008: Reduced cylinder mode
q This code is used to stop the auto-deceleration a When the engine common rail system seems
function of the engine and check the high idle to be faulty, this code is used to stop injecting
speed of the engine singly. fuel into 1 or more cylinders (reduce the num-
q The engine speed is displayed on the lower ber of effective cylinders) while the engine is
line (Display range: 0 – 3000). running and find out a faulty cylinder from the
q Using method: change of the engine speed and fuel injection
While this code is displayed, its function is quantity.
turned on and the auto-deceleration function is a Since a fault is detected by the difference of
turned off. the engine speed and fuel injection quantity in
a If this code is turned off, its function is the reduced cylinder mode operation from that
turned off. in the normal mode operation, use this function
while the engine is running.
q Engine speed (A) and fuel injection quantity
(B) are displayed on the lower line.
D275A-5R 23
q Using method: [8] 0009: Pitch angle sensor standard value set
Select the cylinders to be turned off for the q This code is used to adjust the zero point and
reduced cylinder mode operation by operating correct the installation error of the pitch angle
information switch (5) and buzzer cancel sensor.
switch (4). q The deviation from the standard neutral posi-
Use this method to turn on the selected cylin- tion is displayed by voltage on the lower line
ders again, too. (Display range: –2500 – 2500).
q [ > ]: Move cursor to right. q Adjustment method:
q [ < ]: Move cursor to left. i) Stop the machine on level ground.
q [U]: Execute or stop reduced cylinder mode ii) Buzzer cancel switch (4) in the [U] posi-
operation. tion and check that the caution buzzer
a The figure at below is an example that No. sounds.
2 cylinder is turned off for reduced cylinder a Even after adjustment, the display of the
mode operation and turned on again (The lower line does not change.
cylinder No. lamp is turned off in the a Even if this code is turned off, the setting
reduced cylinder mode operation and on is effective.
in the normal mode operation).
a Only one or more cylinders can be turned
off for the reduced cylinder mode opera-
tion.
a If this code is turned off, its function is
turned off.
k Since this mode is for troubleshooting,
do not carry out work in this mode.
[9] 0010: Fan 70% mode

q This code forcedly sets the rpm of cooling fan
at approximately 70% of the maximum speed.
q The lower part displays data for adjustment.
q Instructions for use:
The function is enabled with this code dis-
played to control the rpm of cooling fan to
approximately 70% of the maximum speed.
a Ending this code disables the function.
24 D275A-5R
[10] 0021: KOMTRAX specification setting [11] 0530: Stall speed check mode
q This code is used to select installation condi- q This code is used to obtain the torque con-
tion of the KOMTRAX terminal. verter stall speed while keeping the cooling fan
a Set this specification before starting the speed to the maximum.
operation of the KOMTRAX. k This machine is equipped with the cooling
q The installation condition of the KOMTRAX ter- fan speed control function to protect the
minal is displayed on the lower line. radiat or when the engine is not fully
q ACTIVE: KOMTRAX is installed. warmed up. Since the protective function
q DEACTIVE: KOMTRAX is not installed. does not work while this mode is used,
q Setting method warm up the engine fully before using this
1) Select installation condition of the mode.
KOMTRAX terminal with shift-up switch k If the machine is not warmed up suffi-
(6) and shift-down switch (7). ciently, durability of the radiator may be
2) After selecting the installation condition of reduced.
the terminal correctly, set buzzer cancel Rough standard of warming up: All of the
switch (4) in the [U] position and check hydraulic oil temperature, engine coolant
that the alarm buzzer sounds. temperature and power train oil tempera-
a Even if this code is turned OFF, the setting ture are within the operating range.
is effective. q The engine speed is displayed on the lower
a After replacing the controller, be sure to line. (Display range: 0 – 3,000)
perform (check) the setting. q Using method
While this code is displayed, its function is
effective and the cooling fan speed is set to the
maximum.
a Adjust the cooling fan maximum speed in
advance in the fan maximum speed adjust-
ment mode (ID: 1005).
a After this code is turned OFF, its function
becomes ineffective.
D275A-5R 25
[12] 1005: Fan 100% mode [13] 1012: Steering lever neutral value setting
q This code forcedly sets the rpm of cooling fan q This code is used to adjust the steering poten-
at approximately 100% of the maximum speed. tiometer neutral position of the PCCS lever.
It is also used to set the adjustment value of q The output signal of steering potentiometer
the maximum speed. from displayed by voltage on the lower line
q The lower part displays data for adjustment. (Display range: 0 – 5000).
q Instructions for use: q Adjustment method:
a The function is enabled with this code dis- i) Shift the PCCS lever in the steering neu-
played to control the rpm of cooling fan to tral position.
approximately 100% of the maximum ii) Set buzzer cancel switch (4) in the [U]
speed. position and check that the caution buzzer
i) Change the adjustment value of the maxi- sounds.
mum speed by operating shift-up switch a Even after adjustment, the display of the
(6) and shift-down switch (7). lower line does not change.
q [UP]: Increase the adjustment value. a Even if this code is turned off, the setting
q [DOWN]: Decrease the adjustment is effective.
value. a This code is not for adjustment of the
ii) To settle the adjustment value, set buzzer steering performance, etc.
cancel switch (4) in the [U] position and
check that the alarm buzzer sounds.
k When using this mode, warm up the
machine sufficiently. If the machine is
not warmed up sufficiently, durability
of the radiator may be reduced.
Rough standard of warming up: All of
the hydraulic oil temperature, engine
coolant temperature and power train oil
temperature are within the operating
range.
a If this code is finished, the function
becomes ineffective but the set adjust-
ment value is effective.
26 D275A-5R
[14] 1013: Steering lever left maximum value set [15] 1014: Steering lever right maximum value set
q This code is used to adjust the maximum left q This code is used to adjust the maximum right
steering potentiometer position of the PCCS steering potentiometer position of the PCCS
lever. lever.
q The output signal of the steering potentiometer q The output signal of steering potentiometer from
from displayed by voltage on the lower line displayed by voltage on the lower line (Display
(Display range: 0 – 5000). range: 0 – 5000).
q Adjustment method: q Adjustment method:
i) Set the PCCS lever to the left steering i) Set the PCCS lever to the right steering
stroke end. stroke end.
ii) Set buzzer cancel switch (4) in the [U] ii) Set buzzer cancel switch (4) in the [U]
position and check that the caution buzzer position and check that the caution buzzer
sounds. sounds.
a Even after adjustment, the display of the a Even after adjustment, the display of the
lower line does not change. lower line does not change.
a Even if this code is turned off, the setting a Even if this code is turned off, the setting
is effective. is effective.
a This code is not for adjustment of the a This code is not for adjustment of the
steering performance, etc. steering performance, etc.
D275A-5R 27
[16] 1015: Left brake oil pressure offset [17] 1016: Right brake oil pressure offset
q This code is used to adjust the left brake oil q This code is used to adjust the right brake oil
pressure manually. pressure manually.
q The offset oil pressure (Unit: MPa) is displayed q The offset oil pressure (Unit: MPa) is displayed
on the lower line (If it has been adjusted, its on the lower line (If it has been adjusted, its
value is displayed. It can be adjusted further value is displayed. It can be adjusted further
within the allowable range). within the allowable range).
a The allowable adjustment range is ± 0.3 a The allowable adjustment range is ± 0.3
MPa {3 kg/cm2} (Displayed value: 0.3) MPa {3 kg/cm2} (Displayed value: 0.3)
1) Operate the shift switch to set the offset oil 1) Operate the shift switch to set the offset oil
pressure. pressure.
q Shiftup switch (6): Increase oil pres- q Shiftup switch (6): Increase oil pres-
sure sure
q Shiftdown switch (7): Decrease oil q Shiftdown switch (7): Decrease oil
pressure pressure
a The offset pressure is increased or a The offset pressure is increased or
decreased by 0.05 MPa {0.5 kg/cm2} decreased by 0.05 MPa {0.5 kg/cm2}
(Displayed value: 0.05). (Displayed value: 0.05).
2) Set buzzer cancel switch (4) in the [U] 2) Operate the buzzer cancel switch to [U]
position and check that the caution buzzer side and check that the caution buzzer
sounds. sounds.
28 D275A-5R
[18] 2223: Reverse slow cut function setting [19] 5535: Both steering clutches disengagement
q This code is used to forcibly stop the reverse q This code is used to engage the transmission
slow function in the R1 gear speed, regardless clutch without driving the machine for testing,
of the switch operations of the machine moni- adjusting, troubleshooting, Pm Clinic, etc.
tor. q The transmission speed (Unit: rpm) is dis-
q This code does not affect the reverse slow played on the lower line.
function in the R2 and R3 gear speeds. q Using method:
q Whether the reverse slow cut function is turned While this code is displayed, the function is
on is displayed by letters on the lower line. effective and steering clutches on both sides
q Adjustment method: are disengaged. Accordingly, the machine
Change the setting by operating information does not travel even if the PCCS lever is oper-
switch (5). ated.
q [ < ], [ > ]: Change setting. a If this code is turned off, the function
q [DEACTIVE]: Turn off reverse slow cut func- becomes ineffective.
tion.
q [ACTIVE]: Turn on reverse slow cut func-
tion.
a If the reverse slow function is stopped, the
reverse speed is not slowed down in the
R1 gear speed even if the reverse slow
mode switch on the machine monitor is
turned ON.
a Even if this code is turned off, the setting
is effective.
D275A-5R 29
[20] 5537: Left steering clutch oil pressure offset [21] 5538: Right steering clutch oil pressure offset
q This code is used to adjust the left clutch oil q This code is used to adjust the right clutch oil
pressure manually. pressure manually.
q The offset oil pressure (Unit: MPa) is displayed q The offset oil pressure (Unit: MPa) is displayed
on the lower line (If it has been adjusted, its on the lower line (If it has been adjusted, its
value is displayed. It can be adjusted further value is displayed. It can be adjusted further
within the allowable range). within the allowable range).
a The allowable adjustment range is ± 0.3 a The allowable adjustment range is ± 0.3
MPa {3 kg/cm2} (Displayed value: 0.3) MPa {3 kg/cm2} (Displayed value: 0.3)
1) Operate the shift switch to set the offset oil 1) Operate the shift switch to set the offset oil
pressure. pressure.
q Shiftup switch (6): Increase oil pres- q Shiftup switch (6): Increase oil pres-
sure sure
q Shiftdown switch (7): Decrease oil q Shiftdown switch (7): Decrease oil
pressure pressure
a The offset pressure is increased or a The offset pressure is increased or
decreased by 0.05 MPa {0.5 kg/cm2} decreased by 0.05 MPa {0.5 kg/cm2}
(Displayed value: 0.05). (Displayed value: 0.05).
2) Set buzzer cancel switch (4) in the [U] 2) Set buzzer cancel switch (4) in the [U]
position and check that the caution buzzer position and check that the caution buzzer
sounds. sounds.
30 D275A-5R
[22] 9995: Operation mode of emergency stop pre- [24] 9997: High idle limit setting
vention valve q This code is used to limit the use high idle
q This code is used to check that the sudden speed.
stop prevention valve works normally. q The engine speed limit adjustment value is dis-
q The voltage of the brake potentiometer is displayed on the lower line.
played on the lower line. q Limit range: High idle speed – –400rpm
q Using method: q Using method:
While this code is displayed, its function is 1) Select a limit speed by setting information
effective and the emergency stop prevention switch (5) in the [ > ] position or [ < ] posi-
valve keeps operating. tion.
Under this condition, operate the brake pedal 2) Set buzzer cancel switch (4) in the [U]
or parking brake lever and check the brake oil position and check that the caution buzzer
pressure. sounds.
a If this code is turned off, its function is a If the high idle speed is limited, the engine
turned off. speed is not set to the normal high idle
even if the fuel control dial is set to the
maximum position.
is effective.
[23] 9996: Mechanical brake operation check mode

q This code is used to check the operation of the
mechanical brake.
q The voltage of the brake potentiometer is dis-
played on the lower line.
q Using method:
While this code is displayed, its function is
turned on and the electric brake is normally
released.
Under this condition, operate the brake pedal
or parking brake lever and check the brake oil
pressure.
a If this code is turned off, its function is
turned off.
D275A-5R 31
[25] 9998: 3rd gear speed cut setting

q This code is used to limit the use of the 3 gear
speeds.
q The usable gear speeds are displayed by bits
on the lower line (in the order of the 3rd, 2nd,
and 1st from the left).
q Using method:
Limit or allow the use of the maximum gear
speed by operating information switch (5) and
q [ < ], [ > ]: Display changes.
q [U]: Enter setting.
q Display on lower line [ o ]:
Gear speed is effective.
q 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.
is effective.
32 D275A-5R
9. Load memory display mode 2) Changing information screen

(9-LOAD MAP DISPLAY MODE) Change the information screen by operat-
In this mode, you can check the load on the ing information switch (5).
machine, forward odometer, and reverse q [ > ]: Next screen.
odometer. q [ < ]: Previous screen.
No. Display Item
i) Select "Load memory display mode" 1000 rpm service
1 01-1000 rpm SMR
on the mode selection screen. meter
a If the mode is selected, code (Ld) 2 02-FOWARD ODO M
Forward travel
is displayed on gear speed dis- distance
play section (1) and the title is Reverse travel
3 03-REVERSE ODO M
displayed on multi-information distance
section (2). 4 04-F1 ODO Meter F1 travel distance
ii) Display the information screen by
5 05-F2 ODO Meter F2 travel distance
operating buzzer cancel switch (4).
q [U]: Execute mode. 6 06-F3 ODO Meter F3 travel distance
Serial No.: 35001 – 35004 7 07-R1 ODO Meter R1 travel distance
8 08-R2 ODO Meter R2 travel distance
9 09-R3 ODO Meter R3 travel distance
3) Displayed information of 1000 rpm service

meter (01)
This code is used to display the service
meter which integrates the operation hours
only while the engine speed is higher than
1,000 rpm.
a The data cannot be reset.
D275A-5R 33
4) Displayed information of forward odome- 7) Display of F2 odometer (05)

ter (02) On this screen, the integrated F2 (forward
On this screen, the integrated forward 2nd gear speed) travel distance is dis-
travel distance is displayed. played.
a The data cannot be reset. a The data cannot be reset.
5) Display of reverse odometer (03) 8) Display of F3 odometer (06)

On this screen, the integrated reverse On this screen, the integrated F3 (forward
travel distance is displayed. 3rd gear speed) travel distance is dis-
a The data cannot be reset. played.
6) Display of F1 odometer (04)

On this screen, the integrated F1 (forward 9) Display of R1 odometer (07)
1st gear speed) travel distance is dis- On this screen, the integrated R1 (reverse
played. 1st gear speed) travel distance is dis-
a The data cannot be reset. played.
34 D275A-5R
10) Display of R2 odometer (08) 12) When operating machine in load memory
On this screen, the integrated R2 (reverse display mode
2nd gear speed) travel distance is dis- If the parking brake lever is set in the FREE
played. position, gear speed display section (1) dis-
a The data cannot be reset. plays normally and the machine can be
operated normally.
cedure.
Serial No.: 35001 – 35004
11) Display of R3 odometer (09)

On this screen, the integrated R3 (reverse
3rd gear speed) travel distance is dis-
played.
D275A-5R 35
10. Real-time monitoring mode 2) Selecting and entering monitored items

(10-REAL TIME MONITORING MODE) i) On the code input screen, input the 5-
In this mode, the speeds, oil pressures, oil digit code of the item to be monitored
temperatures, currents, voltages, etc. can be by operating information switch (5),
monitored by using the signals from sensors, shift-up switch (6), and shift-down
switches, and solenoids installed various parts switch (7).
of the machine. q [ > ]: Move cursor to right.
a This mode is used to monitor 1 item. q [ < ]: Move cursor to left.
When monitoring 2 items simultaneously, q [UP]: Increase number.
use the "Dual display monitoring mode". q [DOWN]:Decrease number.

i) Select "Real-time monitoring mode"
on the mode selection screen.
a If the mode is selected, the title is
section (2).
ii) Display the monitoring code input
switch (4).
Serial No.: 35001 – 35004
ii) After inputting the code, display the

m on i to r in g s c r e en b y op er a ti n g
q [U]: Enter input code.
a If the input code is correct, the
monitoring screen shown at right
appears.
36 D275A-5R
a If the input code is abnormal, the 4) Function of holding monitoring information

code input screen appears again If an information item such as the engine
after the screen shown. speed is not stabilized and cannot be read
easily in the monitoring mode, it can be
held and released by operating buzzer
cancel switch (4).
q [U]: Hold and release.
a While the monitored item is held, the
letter "H" is displayed at the left end of
the lower line.
3) Contents of display on monitoring screen

(Figure shows examples)
[1] Code
[2] Monitoring item
[3] Information
[4] Unit (Not displayed for some items)
a For the details, see the "Monitor-
ing mode table". 5) When operating machine in monitoring
mode
If the parking brake lever is set in the
FREE position, gear speed display section
cedure.
Serial No.: 35001 – 35004
D275A-5R 37
6) Automatic selection of monitoring item

(Limited function)
After one of some monitoring items is
selected, if the information switch is oper-
ated, the next monitoring item is selected
automatically, even if the code of the next
monitoring item is not input.
q [ > ]: Code is increased
q [ < ]: Code is decreased
a This function is applied to only the
items having numbers in the Auto-
matic selection column of the Moni-
toring mode table. Those items are
selected in the order of their numbers.
a Note that this operation is not effec-
tive 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.
38 D275A-5R
Monitoring mode table

Automatic
No. Code Monitoring item Unit Remarks
selection
1 00201 ENG M ID Engine controller model name Character —
2 01000 ENG REV Engine speed rpm 1
3 01603 Remote Th 2nd throttle position % —
4 03000 FUEL DIAL Fuel control dial voltage mV 22
5 03200 BATTERY Battery voltage mV 36
6 03201 S/T ACC Steering controller ACC input voltage mV —
Steering controller load power supply
7 03202 S/T PWR2 mV —
voltage
8 03203 E-ECM PW Engine controller power supply voltage mV —
Steering controller unswitched power
9 03207 S/T PWR1 mV —
supply voltage
Transmission controller unswitched
10 03208 T/M PWR1 mV —
power supply voltage
Transmission controller ACC input
11 03212 T/M ACC mV —
voltage
Transmission controller load power
12 03216 T/M PWR2 mV —
supply voltage
13 04104 COOLANT TP Engine coolant temperature °C 5
Engine coolant temperature sensor
14 04105 COOLANT TP mV —
voltage
15 04200 FUEL SENS Fuel level sensor voltage mV 34
16 04401 HYD. TEMP. Hydraulic oil temperature °C 6
17 08100 HSI BREAK HSI line Brake point rpm —
18 08200 TQ Sel Torque curve selection Character —
19 08300 Droop Type Droop type selection Character —
20 08400 Droop SW Droop switch selection Character —
21 08500 Droop Trim Droop trim selection Character —
Steering controller sensor 5V power
22 10500 S/T 5V PW1 mV —
supply voltage (for potentiometer)
Transmission controller sensor 5V power
23 10501 T/M 5V PW1 mV —
supply voltage (for potentiometer)
24 10505 S/T 5V PW2 mV —
supply voltage 2
Transmission controller sensor 5V power
25 10506 T/M 5V PW2 mV —
supply voltage 2
26 10700 S/T 24V PW mV —
supply voltage
Transmission controller sensor 24V
27 10701 T/M 24V PW mV —
power supply voltage
28 14200 FUEL TMP Fuel temperature °C —
29 14201 FUEL TMP Fuel temperature sensor voltage mV —
30 17201 PCV TMG PCV opening timing CA —
31 17500 ENG MODE Engine controller mode selection Character —
32 18300 ENG IVSW 1 Engine controller idle validation switch 1 bit See detailed information —
33 18301 ENG IVSW 2 Engine controller idle validation switch 2 bit See detailed information —
34 18500 BOOST TMP Boost temperature °C —
35 18501 BOOST TMP Boost temperature sensor voltage mV —
D275A-5R 39
Automatic
selection
36 18600 INJECT CMD Final injection quantity command mg/st —
37 18700 ENG TRUQUE Engine output torque Nm —
Engine controller engine internal
38 18900 E-ECM TP °C —
temperature
39 20201 T/M. PROGRM Transmission controller program version Character —
40 20202 S/T. PROGRM Steering controller program version Character —
41 20216 ENG BLD Engine controller build version Character —
42 20217 ENG CAL Engine controller calibration data version Character —
43 20300 KOMTRAX KOMTRAX LED monitor LED 37
44 20400 E-ECM SN Engine controller ECM serial No. Character —
45 30100 T/C TEMP. Power train oil temperature °C 7
46 31400 T/M OUT Transmission controller output speed rpm 2
Transmission controller fill switch input
47 31520 T/M-FILL bit See detailed information —
condition
Steering controller fill switch input
48 31521 S/T FILL bit See detailed information —
condition
49 31602 1st CLUTCH 1st clutch ECMV current command value mA —
2nd clutch ECMV current command
50 31603 2nd CLUTCH mA —
value
51 31604 3rd CLUTCH 3rd clutch ECMV current command value mA —
Reverse clutch ECMV current command
52 31606 Rev CLUTCH mA —
value
Forward clutch ECMV current command
53 31608 Frd CLUTCH mA —
value
1st clutch ECMV output current
54 31612 1 CLUTCH F mA 30
(Feedback value)
2nd clutch ECMV output current
55 31613 2 CLUTCH F mA 31
(Feedback value)
3rd clutch ECMV output current
56 31614 3 CLUTCH F mA 32
(Feedback value)
Reverse clutch ECMV output current
57 31616 R CLUTCH F mA 29
(Feedback value)
Right brake ECMV output current
58 31618 BRAKE R. H. mA 24
(Feedback value)
Left brake ECMV output current
59 31619 BRAKE L. H. mA 23
(Feedback value)
Right brake ECMV current command
60 31620 BRAKE R. H. mA —
value
Left brake ECMV current command
61 31621 BRAKE L. H. mA —
value
Forward clutch ECMV output current
62 31622 F CLUTCH F mA 28
(Feedback value)
63 31623 FAN PUMP. O Fan pump EPC current command value mA —
Fan pump EPC output current
64 31624 FAN PUMP. F mA —
(Feedback value)
65 31625 PITCH SOL. Pitch solenoid current mA —
66 31626 HSS M. FREE Motor free solenoid voltage mV —
67 31627 L/U SOL Lockup solenoid current mA 33
Emergency stop prevention solenoid
68 31628 E. BRAKE SL mA 25
current
40 D275A-5R
Automatic
selection
69 31701 DECEL Decelerator position % 8
70 31703 DECEL Decelerator pedal potentiometer voltage mV 21
71 31706 F THROTTLE Final accelerator position % 9
72 32900 BODY ANGLE Machine pitch angle deg 15
73 36001 Accel Adj Throttle correction value % —
74 36200 PRESS CMD Final common rail command MPa —
75 36300 INJECT CMD Final injection timing command CA —
76 36400 RAIL PR Common rail pressure MPa 11
77 36401 RAIL PR Common rail pressure sensor voltage mV —
78 36500 BOOST PRS Boost pressure kPa (Absolute pressure) 12
79 36501 BOOST PRS Boost pressure sensor voltage mV —
80 36700 ENG TORQUE Engine conversion torque % 13
81 37200 EG OIL PRS Engine oil pressure kPa 10
82 37201 EG OIL PRS Engine oil pressure sensor voltage mV —
83 37301 FUEL RATE Momentary fuel consumption L/h —
84 37400 AMB PRESS Ambient pressure kPa (Absolute pressure) —
85 37401 AMB PRESS Ambient pressure sensor voltage mV —
86 40001 VEHICLE SP Theoretical travel speed km/h 3
Transmission controller switch input
87 40905 T/M-SW1 bit See detailed information —
signal 1
Transmission controller switch input
88 40906 T/M-SW2 bit See detailed information —
signal 2
Transmission controller operation input
89 40907 T/M OP SIG bit See detailed information —
signal
Transmission controller blade lever oil
90 40908 T/M HYD SW bit See detailed information —
pressure switch input signal
Transmission controller ON/OFF output
91 40909 T/M SOL. 2 bit See detailed information —
signal 2
92 40910 S/T-SW1 Steering controller switch input signal 1 bit See detailed information —
Steering controller ON/OFF output
95 40914 S/T SOL. 1 bit See detailed information —
signal 1
Steering controller ON/OFF output
96 40915 S/T SOL. 2 bit See detailed information —
signal 2
97 43502 IdleCancel Warm-up operation cancel flag bit See detailed information —
98 44202 Accel Up Throttle upper limit value data % —
99 44203 Accel Low Throttle lower limit value data % —
100 50200 T/M LEVR 1 FR lever potentiometer 1 voltage mV 16
101 50201 T/M LEVR 2 FR lever potentiometer 2 voltage mV 17
102 50300 S/T LEVR 1 Steering lever potentiometer 1 voltage mV 18
103 50301 S/T LEVR 2 Steering lever potentiometer 2 voltage mV 19
104 50400 BRAKE PEDL Brake pedal potentiometer voltage mV 20
105 50900 N-SAFTY Neutral safety relay drive voltage mV 35
106 51000 ENG REG Regulation circuit command value rpm —
107 51100 FUEL DIAL Fuel control dial command speed rpm —
108 60000 TRACTION Theoretical traction force W 4
D275A-5R 41
Automatic
selection
109 60100 BODY ANGLE Pitch angle sensor voltage mV —
110 60200 ACCELERATN Acceleration sensor voltage mV —
111 60300 SSC ORDER SSC command value rpm —
112 60400 S/T-SW6 Steering controller SW input signal 6 bit See detailed information —
Engine controller ACC cut relay drive
113 60500 ENG. CON. PW mV —
voltage
Steering controller battery relay drive
114 60600 BR HOLD mV —
voltage
115 60700 S/T MODE Steering condition variable Character —
116 60800 FILL MODE Fill condition setting variable Character —
117 60909 MOD. MODE Modulation condition setting variable Character —
118 70000 CHG. P. MODE Gearshift point condition setting variable Character —
Transmission output speed sensor
119 70200 T/M OUT mV —
voltage
Transmission controller blade lever knob
120 70300 B. KNOB SW bit See detailed information —
switch input signal
Transmission controller ON/OFF output
121 70304 T/M SOL. 1 bit —
signal 1
122 70305 T/M RIPER2 Ripper lever oil pressure switch input bit See detailed information —
123 70400 BACK ALARM Backup alarm relay drive voltage mV —
124 70600 DUAL SOL. Dual tilt solenoid current mA —
125 70700 HYD. PUMP Work equipment oil pressure MPa 14
Work equipment oil pressure 1 sensor
126 70701 HYD. PUMP 1 mV —
voltage
Left clutch ECMV output feedback
127 90600 S/T CLT LH mA 26
current
Right clutch ECMV output feedback
128 90601 S/T CLT RH mA 27
current
129 90602 S/T CLT LH Left clutch ECMV current command mA —
130 90603 S/T CLT RH Right clutch ECMV current command mA —
131 92100 F1 SMR F1 travel integrated time h —
134 92200 R1 SMR R1 travel integrated time h —
137 99901 TRIG T F Trigger time F msec —
138 99902 TRIG T R Trigger time R msec —
139 99903 TRIG T 1 Trigger time 1 msec —
142 99906 TM SFT Transmission shift condition Character —
143 99907 LU Lockup condition bit See detailed information —
144 99908 TM IN TRQ Transmission input torque Nm —
145 99909 DOZING h Dozing time h —
146 99910 RIPPING h Ripping time h —
147 99911 PATH NUM Number of path path —
42 D275A-5R
Automatic
selection
148 99913 TC IN TRQ Torque converter input torque Nm —
149 99914 H. P 1 TRQ Work equipment pump 1 input torque Nm —
150 99917 BR L PRESS Left brake command pressure MPa —
151 99918 BR R PRESS Right brake command pressure MPa —
152 99919 CL L PRESS Left clutch command pressure MPa —
153 99920 CL R PRESS Right clutch command pressure MPa —
a The numbers in the Automatic selection column can be displayed in numeric order by setting the infor-
mation switch in the ">" or "<" position.
D275A-5R 43
Detailed information on bit display codes
Examples of display of bit information 18301: Engine controller idle validation switch 2
a The display position of the bit information in the 1: Idle validation switch: When detected
"Real-time monitoring mode (Display of only 1 2: (Unused)
item)" is different from that in the "Dual display 3: (Unused)
monitoring mode (Simultaneous display of 2 4: (Unused)
items)". 5: (Unused)
a The bit information is displayed by [ _ ] for OFF 6: (Unused)
and [ o ] for ON in the places 1 – 8. 7: (Unused)
a The state of each item shown below is the con- 8: (Unused)
dition for turning on the bit.
31520: Input state of transmission controller related

18300: Engine controller idle validation switch 1 fill switch
1: Idle validation switch: When detected 1: Forward clutch fill switch: ON
2: (Unused) 2: Reverse clutch fill switch: ON
3: (Unused) 3: 1st clutch fill switch: ON
4: (Unused) 4: 2nd clutch fill switch: ON
5: (Unused) 5: 3rd clutch fill switch: ON
6: (Unused) 6: (Unused)
44 D275A-5R
31521: Input state of steering controller fill switch 40906: Transmission controller input signal 2
1: Left brake fill switch: ON 1: Automatic gear shift-down switch: ON
2: Left clutch fill switch: ON 2: Neutral switch: ON
3: (Unused) 3: Neutral switch: OFF
4: (Unused) 4: Shift mode switch: ON
5: Right clutch fill switch: ON 5: Shift mode switch: OFF
6: Right brake fill switch: ON 6: (Unused)
a Items 2 and 5 are for optional specifications.
40905: Transmission controller input signal 1

1: Gear shift-up switch: OFF 40907: Transmission controller operation input signal
2: Gear shift-up switch: ON 1: ACC signal
3: Gear shift-down switch: OFF 2: (Unused)
4: Gear shift-down switch: ON 3: R signal
5: Parking brake switch: FREE 4: (Unused)
6: Parking brake switch: LOCK 5: (Unused)
8: (Unused)
D275A-5R 45
40908: Input signal of transmission controller blade 40910: Steering controller switch input signal 1
lever oil pressure switch 1: (Unused)
1: Blade raise switch: ON 2: (Unused)
2: Blade lower switch: ON 3: (Unused)
4: (Unused) 5: Parking brake lever switch: FREE
5: Blade left tilt switch: ON 6: Parking brake lever switch: LOCK
6: Blade right tilt switch: ON 7: (Unused)
8: (Unused)
a This item is for optional specifications.
40911: Steering controller switch input signal 2

1: Buzzer cancel switch: T position (Right)
40909: Transmission controller ON/OFF output 2: Buzzer cancel switch: U position (Left)
signal 2 3: Information switch: > position (Right)
1: (Unused) 4: Information switch: < position (Left)
2: (Unused) 5: Service switch: ON
3: (Unused) 6: Pivot turn mode switch: ON
4: Back-up alarm relay: ON 7: (Unused)
5: Neutral safety relay: ON 8: (Unused)
6: Lockup solenoid: ON
7: (Unused)
8: (Unused)
46 D275A-5R
40913: Steering controller switch input signal 5 40915: Steering controller ON/OFF output signal 2
1: ACC signal: ON 1: Pre-lubrication motor relay drive: ON
2: Pre-lubricating oil pressure switch: ON 2: Engine ACC cut relay drive: (ON)
3: R signal 3: (Unused)
5: Fan reverse mode switch: ON 5: (Unused)
6: Fan clean mode switch: ON 6: (Unused)
a Items 2 and 5 are for optional specifications. a This item is for optional specifications.
40914: Output signal of steering controller ON/OFF 43502: Warm-up operation cancel flag
1: (Unused) 1: Warm-up operation cancel flag: ON
2: Snap shot signal: ON 2: (Unused)
3: Fan reverse solenoid: ON 3: (Unused)
5: Battery relay drive output: ON 5: (Unused)
6: Sudden stop prevention valve: ON 6: (Unused)
a Item 2 is for optional specifications.
D275A-5R 47
60400: Steering controller switch input signal 6 70304: Transmission controller ON/OFF output signal
1: (Unused) 1: Dual tilt solenoid: ON
2: C-signal: ON 2: Pitch solenoid: ON
3: Engine low idle: ON 3: (Unused)
4: Engine stop signal: ON 4: (Unused)
5: Hydraulic oil level switch signal: ON 5: (Unused)
6: Pre-lubrication motor drive signal: ON 6: (Unused)
a Items 3 and 6 are for optional specifications.
70305: Input signal of ripper lever oil pressur

70300: Input signal of transmission controller blade switch
lever knob switch 1: (Unused)
1: Blade lever tilt switch: Single tilt 2: Ripper lift RAISE oil pressure switch:
2: Blade lever tilt switch: Dual tilt ON (Operated)
3: Blade lever pitch switch: When ON 3: Ripper lift LOWER oil pressure switch:
4: Blade lever pitch switch: When OFF ON (Operated)
5: (Unused) 4: Ripper lift TILT-IN oil pressure switch:
6: (Unused) ON (Operated)
7: (Unused) 5: Ripper lift TILT-OUT oil pressure switch:
8: (Unused) ON (Operated)
6: (Unused)
7: (Unused)
8: (Unused)
a Item 5 is for the optional specification.
48 D275A-5R
99907: Lockup condition

1: Forward clutch outputing
2: Reverse clutch outputing
3: 1st clutch outputing
4: 2nd clutch outputing
5: 3rd clutch outputing
6: Modulating
7: Lockup clutch outputing
8: Neutral
D275A-5R 49
11. Dual display monitoring mode 2) Selecting and entering monitored items
(11-DUAL DISPLAY MONITORING MODE) i) On the code input screen, input the 5-
In this mode, 2 monitored items can be dis- digit codes of the items to be moni-
played simultaneously. tored to the upper and lower lines by
a Note that only codes and monitoring infor- operating information switch (5), shift-
mation are displayed in this mode since up switch (6), and shift-down switch
the usable display columns are limited. (7).
(Item names and units cannot be dis- q [ > ]: Move cursor to right.
played.) q [ < ]: Move cursor to left.
q [UP]: Increase number.
1) Selecting and executing mode q [DOWN]: Decrease number.
i) Select "Dual display monitoring mode" ii) After inputting the codes, display the
on the mode selection screen. m on i to r in g s c r e en b y op er a ti n g
a If the mode is selected, code buzzer cancel switch (4).
(dR) is displayed on gear speed q [U]: Enter input code.
displayed.
ii) Display the monitoring code input
switch (4).
Serial No.: 35001 – 35004
a If the input codes are normal, the

mon itor in g s cr een sh own at
appears.
50 D275A-5R
a If the input codes are abnormal, 4) When operating machine in monitoring

the code input screen appears mode
again after the screen shown at If the parking brake lever is set in the
right. FREE position, gear speed display section
parking brake lever to the FREE posi-
cedure.
Serial No.: 35001 – 35004
3) Contents of display on monitoring screen

(Right figure shows examples)
[1] Code 1
[2] Information 1
[3] Code 2
[4] Information 2
a For the details, see the "Monitoring
mode table". Serial No.: 35005 and up
D275A-5R 51
D275A-5R Bulldozer
© 2008 KOMATSU
All Rights Reserved
52 D275A-5R
SEN02755-01
D275A-5R

D275A-5R 35001 and up

Adjustment method when controller has been replaced ................................................................................. 2
Method of starting use of KOMTRAX terminal ................................................................................................ 4
Indication by KOMTRAX terminal lamps......................................................................................................... 7
Preparation work for troubleshooting for electric system .............................................................................. 10
Handling of optional devices ......................................................................................................................... 13
Pm Clinic service .......................................................................................................................................... 14
D275A-5R 1
Adjustment method when

controller has been replaced 1
a After the machine is assembled or transmis-
s i on c o ntr o ll e r o r s t ee ri n g c on tr ol l er i s
replaced, adjust the system according to the
k If the system is not adjusted, the machine
may not operate normally and may move
suddenly. Accordingly, be sure to adjust it.
a Precautions for replacing a controller:
If a controller is replaced, the memory of the oil
and filter maintenance mode is reset. Accord-
ingly, take a record of the next replacement
periods of the oils and filters.
a Precautions for replacing a controller: 4. Adjusting transmission controller
Stop the machine on a save place, turn the Select Transmission controller specification set
starting switch OFF, check that the battery relay (0003) and adjust the transmission controller.
is turned OFF, wait for about 1 minute, and then a Execute this code only when the steering
replace the controller. controller is also replaced.
a The control is still operating for a while after
the starting switch is turned OFF and the bat-
tery relay is turned OFF. Accordingly, do not
remove the controller just after the battery
relay is turned OFF.
1. Controller initial setting

After replacing controller, turn the switch ON
temporarily (ACC position) and after approx.
10 seconds, turn the switch OFF.
q After turning the switch OFF, the controller
is initialized. Therefore leave it for approx.
1 minute after turning the switch OFF
even if the battery relay shuts down.
a When the starting switch is turned ON for
the first time, an error (CALL E04) may be 5. Turning power on again
displayed. You may continue the work, Turn the starting switch off (battery relay off)
however. and leave it for 1 minute. Then turn the starting
switch on, then reset the monitor panel in the
2. Setting system in service mode "Adjustment Mode" of the service mode.
After step 1, turn the starting switch ON again
and set the monitor panel in the "Adjustment 6. Adjusting machine specification
mode" of the service mode. Select Machine specification set (0004) and
a For details of the operation in the service adjust the machine specification.
mode, see the special functions section of
machine monitor (EMMS).
3. Adjusting steering controller

Select Steering controller specification set
(0002) and adjust the steering controller.
a Execute this code only when the transmis-
sion controller is also replaced.
2 D275A-5R
7. Adjusting brake potentiometer 10. Turning power on again

Select Brake potentiometer initial set (0005) Turn the starting switch OFF (battery relay off)
and adjust the brake potentiometer. and after leaving it for 1 minute, turn it ON
again.
11. Checking failure codes

1) Set the monitor panel in the “Electrical
system failure code display mode” of the
service mode.
2) Check if any active failure codes exist. If
not, delete all the failure codes recorded.
a If any active failure codes exist, elimi-
nate the cause of the incident by trou-
bleshooting, then carry out steps 10
and 11 again.
a Precautions after replacing controller:
If any controller is replaced, the ser-
vice meter in the oil and filter mainte-
8. Adjusting pitch angle sensor nance mode is reset to 0.
Select the initial setting (0009) of the pitch As a result, the replacement period
angle sensor and adjust the pitch angle sen- displayed on the monitor panel may
sor. be different from the actual operating
hours. To solve this problem, deter-
mine the first replacement periods of
the oils and filters after the replace-
ment of the controller according to the
replacement periods recorded before
the replacement of the controller.
12. Setting maintenance interval time

Set the replacement interval time of the charge
filter to "0" in the maintenance interval time
change mode.
9. KOMTRAX system set

Set KOMTRAX system using Adjustment
mode (0021).
(If not, take care that default is not-equipped
set.)
D275A-5R 3
Method of starting use of 6) Disconnect inspection connector 1 and

KOMTRAX terminal 1 wait for 5 seconds.
If KOMTRAX terminal is installed when machine

is delivered:
a If the KOMTRAX terminal is installed (as stan-
dard) when the machine is delivered, carry out
1. Notification of machine name, machine

model, and serial No.
Notify the responsible person for use of
KOMTRAX of the name, model, and serial No.
of the machine.
2. Registration of machine
Using the KOMTRAX client personal com- 7) Turn the starting switch ON and wait for 5
puter, the responsible person for use of seconds. [Dot (a) blinks on and off]
KOMTRAX must register the machine. q Blinking of dot (a): When the terminal
a For the procedure, see "Manual for respon- detects insert or removal of the con-
sible person for use of KOMTRAX". nector, dot (a) blinks on and off.
a The above is all of the necessary work. 8) Disconnect inspection connector 2 and
wait for 5 seconds. [Dot (a) blinks on and
If KOMTRAX terminal is installed after machine off]
is delivered: 9) Reconnect inspection connector 1 and
a If the KOMTRAX terminal is installed (retrofit- wait for 5 seconds. [Dot (a) blinks on and
ted) after the machine is delivered, carry out off]
the following procedure. 10) Reconnect inspection connector 2 and
wait for 5 seconds. [Dot (a) blinks on and
1. Inspection of machine for starting use of off]
KOMTRAX a Perform steps 7) to 10) in 30 seconds.
1) Move the machine to a place with good Monitor panel
visibility of upper direction.
2) Switch the machine monitor display to
"Adjust mode" enter "Setting KOMTRAX
specification", and enable the KOMTRAX
function.
q Adjust code: 0021
q Specification: ACTIVE
3) Switch the machine monitor display to
"Monitoring mode" and enter "KOMTRAX
LED display".
a Refer to "Special functions of monitor
panel (EMMS)" for the operating method.
4) Turn the starting switch OFF and wait for
at least 5 seconds, and then go to the next
step.
a After the starting switch is turned
OFF, the machine monitor keeps dis-
playing.
5) Visually check that inspection connectors
1 and 2 are connected.
q Inspection connector 1:
T0F (female) and T0M (male)
q Inspection connector 2:
T1F (female) and T1M (male)
4 D275A-5R
KOMTRAX terminal a If [B: GPS position data detection

trouble] is indicated, check if there is
any abnormality on the GPS antenna
or cable. If there is any abnormality,
repair it and start from procedure 1)
again.
a If [C: Reception trouble] is indicated,
check if there is any abnormality on
the appearance of the communication
antenna or cable. If there is any
abnormality, repair it then repeat from
procedure 1) again.
a If [D: GPS position data detection trou-
ble and reception trouble] is indicated,
check if there is any abnormality on
11) Check that display (b) on the machine the GPS antenna/cable or communi-
monitor or KOMTRAX terminal is dis- cation antenna/cable. If there is any
played normally. abnormality, repair it and start from
a The normal display shows "d" o "0" procedure 1) again.
o "–" repeatedly for 30 seconds on a If [E: Network trouble] is indicated,
the monitor panel after 10) is finished. check the display of [LED-C4] refer-
a Move on to the next step if you can ring to "Lamp display of KOMTRAX
check that the display is [normal]. terminal". If the CAN is not recog-
a If the display is [abnormal], start from nized, check the CAN harness of the
procedure 1) again. KOMTRAX terminal, and then if there
is any abnormality, repair it and start
from procedure 1) again.
12) Turn the starting switch to the START

position and hold it for at least 5 seconds
to ensure that the engine does not start,
and then return the starting switch to the
ON position.
a If the engine starts up or the starting
switch is turned off, start from proce-
dure 1) again.
13) Turn the starting switch to the START
position again and check that the engine
starts.
14) Check that display (b) on the machine
monitor or KOMTRAX terminal is dis-
played normally.
a Move on to the next step if you can
check that the display is [A: normal].
(It takes from 90 seconds to 15 min-
utes before the display turns normal.)
D275A-5R 5
15) Turn the starting switch to the OFF posi- 2. Application for start of use
tion. a Before applying for start of use, be sure to
16) After 5 seconds, check that the 7-segment finish the inspection of the machine for
lamp indicates "Normal". starting use.
a If "Normal" is indicated, the inspection 1) Notify the following data of the machine
for starting use is finished. inspected for start of use to the responsi-
a If "Abnormal" is indicated, the inspec- ble person for use of KOMTRAX.
tion for starting use is not finished (1) Data of machine inspected for start of
normally. In this case, repeat the use (Machine name, machine moni-
above procedure from step 1). tor, and serial No.)
(2) Part No. and serial No. of KOMTRAX
terminal
(3) Service meter reading when KOMTRAX
terminal is installed (Unit: 0.1 h)
17) Turn the buzzer cancel switch clockwise

to finish the "KOMTRAX LED display"
mode.
a The battery relay is turned OFF and
the power is turned OFF.
2) Using the KOMTRAX client personal com-

puter, the responsible person for use of
KOMTRAX must register the machine.
a For the procedure, see "Manual for
responsible person for use of
KOMTRAX".
a The above is all of the necessary
work.
6 D275A-5R
Indication by KOMTRAX terminal lamps 1
LEDs for CPU 7-segment lamp and dot for CPU

1. LED-C1 (R signal and ACC signal) 7. 7-segment lamp (Number of males which are
2. LED-C2 (Condition of starting output) not sent yet)
3. LED-C3 (Condition of S-NET and C signal) 8. Dot (Measuring condition of GPS)
4. LED-C4 (Condition of CAN)
5. LED-C5 (Download writing condition)
6. LED-C6 (Download writing condition)
D275A-5R 7
The KOMTRAX system indicates the information in the system and contents of processing with the LED dis-
play unit at the top of the KOMTRAX terminal. Accordingly, if the system seems to have a trouble, carry out
the following checks.
q Check of antennas
q Check of terminal LEDs
Before using the KOMTRAX system, you must complete application for start of use and inspection of the
machine for starting use.
Check of antennas
a Before checking the indication of the LED unit, check that the communication antenna and GPS
antenna are free from abnormality.
q The communication antenna must not be off the position and must not be broken.
q The communication antenna cable must not be disconnected and must be connected to the KOMTRAX
terminal normally.
q The GPS antenna must not be off the position and must not be broken.
q The GPS antenna cable must not be disconnected and must be connected to the KOMTRAX terminal
normally.
Check of terminal LEDs

1. Contents of indication of LEDs for CPU
a When checking the indication of the LEDs, turn the starting switch to the ON or START position or run
the engine.
No. LED Name/Function Indication (*1) Contents of indication
ON Starting switch ACC signal: ON, Alternator R signal: ON
Starting switch ACC Quick blink Starting switch ACC signal: OFF, Alternator R signal: ON
1 LED-C1 signal and alternator
R signal Slow blink Starting switch ACC signal: ON, Alternator R signal: OFF
OFF Starting switch ACC signal: OFF, Alternator R signal: OFF
Condition of engine ON Engine control signal: ON
2 LED-C2
control signal OFF Engine control signal: OFF
ON S-NET: Connected, Starting switch C signal: OFF
Condition of S-NET Quick blink Starting switch C signal: ON
3 LED-C3 connection and start-
ing switch C signal Slow blink (Unused)
OFF S-NET: Disconnected, Starting switch C signal: OFF
ON CAN: Installed, (Fuel sensor: Not installed)
Condition of CAN Quick blink CAN: Installed, (Fuel sensor: Installed)
4 LED-C4
connection Slow blink CAN: Not installed, (Fuel sensor: Installed)
OFF CAN: Not installed, (Fuel sensor: Not installed)
Download writing mode (Special function of system
5 LED-C5 Condition of Either is ON
administrator)
download writing
6 LED-C6 Both are OFF Normal operation mode
*1: Types of blink and blinking interval

Quick blink: Blinking at intervals of about 1 second
Slow blink: Blinking at intervals of about 4 seconds
a The contents of the LED display can also be checked in the monitoring mode (ID: 20300) of the machine
monitor.
8 D275A-5R
2. Contents of indication of 7-segment lamp and dot for CPU

a When checking the indication of the LEDs, turn the starting switch to the ON position.
No. Indicator Name/Function Indication (*2) Contents of indication
Figure indicates number of mails which are not sent yet (When
Number of mails Lighting of 0 – 9 10 or more mails are not sent yet, 9 is indicated).
7-seg- Lighting indicates that satellite is captured.
which are not sent yet
7 ment
and satellite captur- Figure indicates number of mails which are not sent yet (When
lamp Quick blink of
ing condition 10 or more mails are not sent yet, 9 is indicated).
0–9
Quick blink indicates that satellite is not captured.
GPS has completed measuring (Position is recognized. See
ON
Measuring condition *3.)
8 Dot
of GPS GPS has not completed measuring (Position is not recognized.
OFF
See *3.)
*2: Types of blink and blinking interval

Quick blink: Blinking at intervals of about 0.5 seconds
Slow blink: Blinking at intervals of about 2.0 seconds
*3: Remarks on measuring condition of GPS
Even in an outdoor place where the radio waves are strong enough, it may take more than 1 minute to
complete measurement after the starting switch is turned ON. If the radio waves are very weak or no
radio waves are received, the GPS cannot measure the position.
a The contents of the 7-segment and dot display can also be checked in the monitoring mode (ID: 20300)
of the machine monitor.
D275A-5R 9
Preparation work for 3) Insert or connect T-adapters in or to con-

troubleshooting for electric n ec to r s S 01 , S 0 2, S 03, a nd S 04 o f
machine monitor (2).
system 1
a When carrying out troubleshooting for an elec-
tric circuit related to the machine monitor,
engine controller, transmission controller, or
steering controller, expose the related connec-
tors according to the following procedure.
1. Machine monitor
1) Remove cover (1).
2) Remove the 2 mounting bolts and pull out
machine monitor (2) toward the operator’s
seat.
Serial No.: 35001 – 35004
2. Engine controller
1) Open left engine side cover (3) and
remove cover (4).
2) Remove the cover (5).
10 D275A-5R
3)Insert or connect troubleshooting T-adapt- 3. Transmission controller

ers in or to connectors EGC1, EGC2 and 1) Slide the operator's seat to the front end
EGC3 of engine controller (6). and fold the seat back forward.
a Since connectors EGC1 and EGC2 are 2) Remove cover (7).
fixed with screws, loosen those screws
before disconnecting.
a When connecting connectors EGC1 and
EGC2, tighten the screws to the specified
torque.
3 Screw: 3 ± 1 Nm {0.3 ± 0.1 kgm}
3) Insert or connect T-adapters in or to con-

nectors TMCN1, TMCN2, and TMCN3 of
transmission controller (8).
a If the connectors cannot be discon-
nected and connected easily, remove
the controller from the floor frame.
k In order to prevent malfunction a Since the connectors are secured
and mistaken system error warn- with screws, loosen those screws
ing, be sure to completely remove before disconnecting.
foreign object (b) such as sand, a When connecting the connectors,
dust, water, etc., from inside of tighten the screws to the specified
controller side connector (a) with torque.
3 Screw: 2.82 Nm {0.288 kgm}
air blow etc., before connecting to
harness connector.
D275A-5R 11
4. Steering controller 5. KOMTRAX terminal

1) Slide the operator's seat to the front end 1) Slide the operator's seat to the front end
and fold the seat back forward. and fold the seat back forward.
2) Remove cover (7). 2) Remove cover (10) from the right rear of
the operator's seat.
3) Insert or connect T-adapters in or to con-

nectors STCN1, STCN2, and STCN3 of 3) Insert or connect a troubleshooting T-
transmission controller (9). adapter in or to connector KOM1 of
a If the connectors cannot be discon- KOMTRAX terminal (11).
nected and connected easily, remove a If it is difficult to disconnect and con-
the controller from the floor frame. nect the connector, remove the termi-
a Since the connectors are secured nal from the floor frame.
with screws, loosen those screws a Since the connector is fixed with
before disconnecting. screws, loosen those screws before
a When connecting the connectors, disconnecting.
tighten the screws to the specified a When connecting the connector,
torque. tighten the screws to the specified
3 Screw: 2.82 Nm {0.288 kgm} torque.
3 Screw: 2.82 Nm {0.288 kgm}
12 D275A-5R
Handling of optional devices 1 4. Taking out C signal of starting switch

If the C signal (starting signal) of the starting
a This machine has connectors to install optional
switch is necessary to an optional device such
devices in its fuse box. When installing any
as the pre-lubricator, take it out through the fol-
optional device, receive the necessary signals
lowing connector pin.
and power through those connectors without
q CN-PRS (2-pole heavy duty wire connec-
modifying the wiring harness.
tor)
a Remove the connector installed when the
1. Taking out ACC signal of starting switch
machine is shipped and connect pin (1) to
If the ACC signal (ON signal) of the starting
the starting signal to be output finally by
switch is necessary to an optional device such
the optional device and connect pin (2) to
as the turbocharger timer, take it out through
the starting switch signal to be input to the
the following connector pin.
optional device.
q Pin (B) of CN-ESD (3-pole heavy duty wire
connector)
5. Taking out external power source
a A 20-A fuse is installed on the upstream
If an external power source is necessary, take
side of this connector pin.
it through the following connectors.
q CN-800, CN-810 (Plug connectors)
2. Inputting engine stop signal
q CN-801, CN-811 (Plug connectors)
When it is required to stop the engine with an
a A 20-A fuse is installed on the upstream
optional engine emergency stop function etc.
side of each of these connectors.
while the starting switch is in the ON position,
a CN-800 and CN-801 are prepared in the
utilize the circuit of the following connectors
fuse box and CN-810 and CN-811 are pre-
and pins.
pared on the outside of the floor.
q Pin (A) of CN-ESD (3-pole heavy duty wire
connector)
a Before using, be sure to notify the Service
Section.
3. Inputting engine low-idle command

When it is required to keep the engine speed
at low idle with an optional engine protection
function etc., utilize the circuit of the following
connectors and pins.
q Pin (C) of CN-ESD (3-pole heavy duty wire
connector)
a Before using, be sure to notify the Service
Section.
D275A-5R 13
Pm Clinic service 1
Model Serial No. Service meter
D275A-5R h
User name Date of clinic Serviceman

/ /
Specifications
Blade Attachment Shoe width
T Semi U blade T Multi-shank ripper T 610 mm
T U blade T Variable giant ripper T 710 mm
T Dual tilt blade T Counterweight ( kg) T 760 mm
T T T
Operating conditions
Quarry, mine Construction Type of soil (specific gravity) Type of work
T Construction, civil engi-
T Coal T Rock T Dozing %
neering
T Gold T Roads T Gravel T Side cutting %
T Limestone T Tunnels T Sand T Ripping %
T T T Clay T Travel %
Existence of abnormalities
Oil, coolant level check
T Engine coolant level When necessary
T Engine oil level T Power train T Damper case
T Hydraulic oil level T Final drive T( )
Ambient temperature Height above sea level

Max.
°C m
Min.
Operator's opinion
Visual check results
Failure code history

[ ] h [ ] h
Content: Content:
[ ] h [ ] h
Content: Content:
a Engine coolant temperature: Max. range a Power train oil temperature: Max. range
Serial No.: 35001 – 35004 Serial No.: 35005 and up Serial No.: 35001 – 35004 Serial No.: 35005 and up
14 D275A-5R
Check positions/Method 1
D275A-5R 15
16 D275A-5R
D275A-5R 17
Pm Clinic check sheet Serial No
D275A-5R
Work order No. Date Service meter Serviceman
h
Item Measurement conditions Unit Standard value for new machine Service limit value Test results Pass Fail
Low idle 650 - 750 650 - 750
High idle Deceleration pedal depressed 850 - 950 850 - 950
Engine speed High idle (Deceleration cut-off mode) rpm 2,150 - 2,250 2,150 - 2,250
Torque converter stall 1,570 - 1,670 Min. 1,510
Torque converter stall + work equipment relief 1,530 - 1,630 Min. 1,450
kPa Max. 2.94 3.92
Blow-by pressure Torque converter stall {mmH2O} {Max. 300} {400}
Engine
SAE0W30E0S
High idle SAE5W40E0S Min. 0.34 0.21
SAE10W30DH {Min. 3.5} {2.1}
Engine oil MPa
SAE15W40DH {kg/cm2}
pressure
SAE30DH Oil Min. 0.10 0.08
Low idle Oil temperature: {Min. 1.0} {0.8}
Min. 80
kPa Min. 116 99
Boost pressure Torque converter stall {mmHg} {Min. 870} {740}
Exhaust temperature Torque converter stall Max. 670 720
Max. 0.2 Max. 0.2
Torque converter
Inlet oil pressure {Max. 2} {Max. 2}

Transmission: Low idle
Max. 0.2 Max. 0.2
Outlet oil pressure Neutral MPa {Max. 2} {Max. 2}
Oil temperature: {kg/cm2} 0.49 - 1.0 0.49 - 1.0
Inlet oil pressure {5 - 10} {5 - 10}
70-90 High idle
0.39 - 0.59 0.39 - 0.59
Outlet oil pressure {4 - 6} {4 - 6}
Low idle 2.74 - 3.14 Min. 2.65

{28 - 32} {Min. 27}
Main relief pressure
3.04 - 3.43 Min. 2.94
Transmission: High idle {31 - 35} {Min. 30}
Neutral Low idle
Lubricating oil
pressure (Reference) 0.05 - 0.29 0.05 - 0.29
Transmission
High idle {0.5 - 3.0} {0.5 - 3.0}

MPa 2.84 - 3.14 Min. 2.65
F clutch pressure Transmission: F3 Low idle {29 - 32} {Min. 27}
{kg/cm2}
R clutch pressure 2.84 - 3.14 Min. 2.65
Transmission: R3 Low idle {29 - 32} {Min. 27}
2.84 - 3.14 Min. 2.65
1st clutch pressure Transmission: F1 Low idle {29 - 32} {Min. 27}
2.84 - 3.14 Min. 2.65
2nd clutch pressure Transmission: F2 Low idle {29 - 32} {Min. 27}
2.84 - 3.14 Min. 2.65
3rd clutch pressure Transmission: F3 Low idle {29 - 32} {Min. 27}
Steering clutch & brake
Left clutch pressure 1.57 - 1.96 1.47 - 2.06

{16 - 20} {15 - 21}
Engine at low idle
Left brake pressure 2.84 - 3.14 Min. 2.26
Transmission: MPa {29 - 32} {Min. 23}
Neutral {kg/cm2} 1.57 - 1.96 1.47 - 2.06
Left clutch pressure {16 - 20} {15 - 21}
Engine at high idle
Left brake pressure 3.14 - 3.43 Min. 2.45
{32 - 35} {Min. 25}
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".
(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.
18 D275A-5R
Pm Clinic check sheet Serial No
D275A-5R
h
1.57 - 1.96 1.47 - 2.06
Right clutch pressure {16 - 20} {15 - 21}
Steering clutch & brake
Engine at low idle

2.84 - 3.14 Min. 2.26
Right brake pressure {29 - 32} {Min. 23}
Transmission: MPa
Neutral {kg/cm2} 1.57 - 1.96 1.47 - 2.06
Right clutch pressure {16 - 20} {15 - 21}
Engine at high idle
Right brake pressure 3.14 - 3.43 Min. 2.45
{32 - 35} {Min. 25}
Brake performance Engine at high idle, F2, brake actuated Machine must not move
Ripper lift 26.1 - 28.8 26.1 - 28.8
relief {266 - 294} {266 - 294}
Hydraulic components
Low idle
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 26.1 - 28.8 26.1 - 28.8
High idle {266 - 294} {266 - 294}
(single tilt only)
Control circuit basic 3.43 - 3.92 3.23 - 3.92
pressure Lever: Neutral {35 - 40} {33 - 40}
Low idle 8 - 15 20
Blade RAISE
High idle 3-5 6

Low idle 3-5 7
Single tilt (left right)
High idle 2.3 - 3.3 3.5
Sec.
Low idle 5-8 10
Dual tilt (left right)
High idle 2.3 - 3.3 3.5
Low idle 8 - 14 17
Ripper tilt (in out)
High idle 3-4 4.5
Hydraulic drift
Hydraulic oil temperature
Blade lift drift level Engine stopped Max. 150 Max. 300
mm/15 min.
Ripper lift drift level Max. 80 Max. 160
Min rotation speed
Low idle Fan 100% speed 420 - 480
mode
Fan speed rpm
Fan
Max rotation speed

Fan 100% speed 1,250 - 1,350 1,200
High idle mode
Fan 100% speed MPa 17.17 - 20.60 17.17 - 20.60
Fan oil pressure {kg/cm2} {175 - 210} {175 - 210}
mode
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
D275A-5R 19
Pm Clinic undercarriage check sheet Serial No
D275A-5R
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
20 D275A-5R
Undercarriage troubleshooting report (Normal)
(Program form No.: SELA195001)
Y Komatsu
Undercarriage Inspection Customer name:
Address:
Model D275A-5R 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 l M
1.3 RH 260.60 263.60
LH 166.0 148.0
H
RH 166.0 148.0
LINK HEIGHT1.3
New Turned
BUSHING d1 LH 90.5 82.0
New Turned
d
D is the smallest d RH 90.5 82.0
of d1,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
4 RH 255.0 195.0
D=2(h1-h2)
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:
D275A-5R 21
Undercarriage troubleshooting report (Impact)
(Program form No.: SELA195001)
Y Komatsu
Undercarriage Inspection Customer name:
Address:
Model D275A-5R 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 l M
1.3 RH 260.60 263.60
LH 166.0 148.0
H
RH 166.0 148.0
LINK HEIGHT1.3
New Turned
BUSHING d1 LH 90.5 84.5
New Turned
d
D is the smallest d RH 90.5 84.5
of d1,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
4 RH 255.0 195.0
D=2(h1-h2)
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:
22 D275A-5R
D275A-5R 23
D275A-5R Bulldozer
© 2008 KOMATSU
All Rights Reserved
24 D275A-5R
SEN02756-01
D275A-5R

D275A-5R 35001 and up
40 Troubleshooting 1
Failure code table and fuse locations
Failure codes table.......................................................................................................................................... 2
Fuse locations............................................................................................................................................... 10
D275A-5R 1
SEN02756-01 40 Troubleshooting
Failure codes table 1

Failure Trouble Applicable Action History Reference
code equipment code classification manual
1500L0 Transmission clutch dual engagement TM CALL E03 Electrical
system
15SAL1 Forward clutch oil pressure 1 TM CALL E03 Electrical
system
Electrical
15SALH Forward clutch oil pressure 2 TM CALL E03 system
Electrical
15SBL1 Reverse clutch oil pressure 1 TM CALL E03 system
Electrical
15SBLH Reverse clutch oil pressure 2 TM CALL E03 system
15SEL1 1st clutch oil pressure 1 TM CALL E03 Electrical
system
15SELH 1st clutch oil pressure 2 TM CALL E03 Electrical
system
15SFL1 2nd clutch oil pressure 1 TM CALL E03 Electrical
system
15SFLH 2nd clutch oil pressure 2 TM CALL E03 Electrical
system
Electrical
15SGL1 3rd clutch oil pressure 1 TM CALL E03 system
Electrical
15SGLH 3rd clutch oil pressure 2 TM CALL E03 system
Electrical
2201L1 Right steering clutch oil pressure 1 ST CALL E04 system
2201LH Right steering clutch oil pressure 2 ST CALL E04 Electrical
system
2202L1 Left steering clutch oil pressure 1 ST CALL E04 Electrical
system
2202LH Left steering clutch oil pressure 2 ST CALL E04 Electrical Troubleshooting
system by failure code,
Electrical Part 1
2300NR Brake thermal load ST — system SEN02758-01
Electrical
2301L1 Right steering brake oil pressure 1 ST CALL E04 system
Electrical
2301LH Right steering brake oil pressure 2 ST CALL E04 system
2301NR Right steering brake thermal load ST — Electrical
system
2302L1 Left steering brake oil pressure 1 ST CALL E04 Electrical
system
2302LH Left steering brake oil pressure 2 ST CALL E04 Electrical
system
Electrical
2302NR Left steering brake thermal load ST — system
Mechanical
6001ZK Failure code for design — — system
Mechanical
A000NS Engine overheat — — system
AA10NX Air cleaner clogging MON — Mechanical
system
AB00MA Battery charge abnormal MON — Mechanical
system
B@BAZG Eng oil press low ENG — Mechanical
system
Mechanical
B@BAZK Eng oil level low MON — system
Mechanical
B@BCNS Eng coolant overheat ENG — system
Mechanical
B@BCZK Radiator coolant level low MON — system
2 D275A-5R

B@BEBF Water gets mixed with fuel — — Mechanical
system
Mechanical
B@BFZK Fuel level abnormal reduction MON — system
Mechanical
B@CENS Torque converter oil overheat MON — system
Mechanical Troubleshooting
B@CHZG HSS charge oil pressure reduction MON — system by failure code,
Mechanical Part 1
B@CHZK Power train oil level reduction — — SEN02758-01
system
B@GAZK Battery electrolyte level reduction — — Mechanical
system
B@HANS Hyd oil overheat MON — Mechanical
system
Mechanical
B@HAZK Hydraulic oil level reduction — — system
Electrical
CA111 EMC critical internal failure ENG CALL E04 system
Electrical
CA115 Eng Ne and Bkup speed sens error ENG CALL E04 system
Electrical
CA122 Chg air (boost) press sensor high error ENG CALL E03 system
CA123 Chg air (boost) press sensor low error ENG CALL E03 Electrical
system
CA131 Throttle sensor high error ENG CALL E03 Electrical
system
CA132 Throttle sensor low error ENG CALL E03 Electrical
system
Electrical
CA135 Eng oil press sensor high error ENG E02 system
Electrical
CA141 Eng oil press sensor low error ENG E02 system
Electrical
CA144 Coolant temp sens high error ENG E02 system
CA145 Coolant temp sens low error ENG E02 Electrical
system
CA153 Chg air (boost) temp sensor high error ENG E01 Electrical
system Troubleshooting
CA154 Chg air (boost) temp sensor low error ENG E01 Electrical by failure code,
system Part 2
Electrical SEN02759-01
CA187 Sens supply 2 volt low error ENG CALL E03 system
Electrical
CA221 Ambient press sens high error ENG CALL E03 system
Electrical
CA222 Ambient press sens low error ENG CALL E03 system
CA227 Sens supply 2 volt high error ENG CALL E03 Electrical
system
CA234 Eng overspeed ENG — Electrical
system
CA238 Ne speed sens supply volt error ENG CALL E03 Electrical
system
Electrical
CA263 Fuel temp sensor high error ENG E01 system
Electrical
CA265 Fuel temp sensor low error ENG E01 system
Electrical
CA271 PCV1 short error ENG CALL E03 system
CA272 PCV1 open error ENG CALL E03 Electrical
system
CA273 PCV2 short error ENG CALL E03 Electrical
system
D275A-5R 3

CA274 PCV2 open error ENG CALL E03 Electrical
system
Electrical
CA322 Inj #1 open/short error ENG CALL E03 system
Electrical
Electrical
CA325 Inj #6 open/short error ENG CALL E03 Electrical
system
system
system
Electrical
CA342 Calibration code incompatibility ENG CALL E04 system
Electrical
CA351 Injectors drive circuit error ENG CALL E03 system
Electrical Troubleshooting
CA352 Sens supply 1 volt low error ENG CALL E03 system by failure code,
Electrical Part 2
CA386 Sens supply 1 volt high error ENG CALL E03 system SEN02759-01
CA441 Battery voltage low error ENG CALL E04 Electrical

system
CA442 Battery voltage high error ENG CALL E04 Electrical
system
CA449 Rail press very high error ENG CALL E03 Electrical
system
Electrical
CA451 Rail press sensor high error ENG CALL E03 system
Electrical
CA452 Rail press sensor low error ENG CALL E03 system
Electrical
CA553 Rail press high error ENG E02 system
CA554 Rail press sensor in range error ENG CALL E03 Electrical
system
CA559 No-pressure feed by supply pump 1 ENG E02 Electrical
system
CA689 Eng Ne speed sensor error ENG CALL E03 Electrical
system
Electrical
CA731 Eng Bkup speed sens phase error ENG CALL E03 system
Electrical
CA757 All continuous data lost error ENG CALL E04 system
Electrical
CA778 Eng Bkup speed sensor error ENG CALL E03 system
CA1633 KOMNET datalink timeout error ENG CALL E03 Electrical
system
CA2185 Throt sens sup volt high error ENG CALL E03 Electrical
CA2186 Throt sens sup volt low error ENG CALL E03 Electrical by failure code,
system Part 3
CA2249 No-pressure feed by supply pump 2 ENG CALL E03 system
Electrical
CA2555 Intake air heater relay open error ENG E01 system
Electrical
CA2556 Intake air heater relay short error ENG E01 system
D110KA Battery relay holding disconnection ST — Electrical
system
D110KB Battery relay drive short circuit ST — Electrical
system
4 D275A-5R

D130KA Neutral safety relay disconnection TM E02 Electrical
system
Electrical
D130KB Neutral safety relay short circuit TM E02 system
Electrical
D161KA Back-up alarm relay disconnection TM E01 system
D161KB Back-up alarm relay short circuit TM E01 system by failure code,
Electrical Part 3
D190KA Engine controller ACC signal cut relay ST — SEN02760-00
system
D190KB Engine controller ACC signal cut relay short ST — Electrical
system
D811KR KOMTRAX controller CAN defective communication ST — Electrical
system
Machine monitor CAN communication defective Electrical
DAFRKR communication MON CALL E03 system
Electrical
DAQ0KT Transmission controller internal abnormality TM E01 system
Transmission controller main source voltage reduc- Electrical
DAQ1KK tion TM CALL E04 system
Electrical
DAQ2KK Transmission controller load voltage reduction TM CALL E04 system
DAQ5KK Transmission controller sensor 5 V power source TM CALL E03 Electrical
(1) power supply source voltage reduction system
DAQ6KK Transmission controller sensor 24 V power supply TM E01 Electrical
source voltage reduction system
DAQ7KK Transmission controller sensor 5 V power supply TM CALL E03 Electrical
source (2) power source voltage reduction system
Transmission controller type collation (Type select Electrical
DAQ9KQ signal inconsistency) TM CALL E04 system
Transmission controller CAN defective communica- Electrical
DAQRKR tion (Abnormality in objective component system) ST CALL E03 system
Transmission controller S-NET defective communi- Electrical
DAQSKR cation (Abnormality in objective component system) TM E01 system
DB2RKR Engine controller CAN defective communication ST CALL E03 Electrical
system
DB30KT Steering controller abnormality in controller ST E01 Electrical
DB31KK Steering controller main power supply source volt- ST CALL E04 Electrical by failure code,
age reduction system Part 4
Load power source of steering controller power Electrical SEN02761-00
DB32KK source voltage drop ST CALL E04 system
Steering controller sensor 5 V power source (1) Electrical
DB35KK power source voltage drop ST CALL E03 system
Steering controller sensor 24 V power supply Electrical
DB36KK source voltage reduction ST CALL E03 system
DB37KK Steering controller sensor 5 V power source (2) ST CALL E03 Electrical
power source voltage drop system
DB39KQ Steering controller type collation (Type select signal ST CALL E04 Electrical
inconsistency) system
DB3RKR Steering controller CAN defective communication TM CALL E03 Electrical
(Abnormality in objective component system) system
Steering controller S-NET defective communication Electrical
DB3SKR (Abnormality in objective component system) ST E01 system
Electrical
DD12KA Shift up switch disconnection TM E02 system
Electrical
DD12KB Shift up switch short circuit TM E02 system
DD13KA Shift down switch disconnection TM E02 Electrical
system
DD13KB Shift down switch short circuit TM E02 Electrical
system
D275A-5R 5

DD14KA Parking brake lever switch disconnection TM CALL E03 Electrical
system
Electrical
DD14KB Parking brake lever switch short circuit TM E03 system
Electrical
DDB9L4 Reverse switch disagreement TM CALL E03 system
Electrical
DDK3L4 Forward switch disagreement TM CALL E03 system
DDK5KA Gearshift switch disconnection TM E02 Electrical
system
DDK5KB Gearshift switch short circuit TM E02 Electrical
system
DDN7KA Blade pitch switch disconnection TM E02 Electrical
system
Electrical
DDN7KB Blade pitch switch short circuit TM E02 system
Electrical
DDN9KA Blade tilt switch disconnection TM E01 system
DDN9KB Blade tilt switch short circuit TM E01 system by failure code,
Ripper lift raise oil pressure switch is kept ON for Electrical Part 4
DDNBLD long time TM — system SEN02761-00
DDNCLD Ripper lift lower oil pressure switch is kept ON for TM — Electrical
long time system
DDNDLD Ripper lift tilt-in oil pressure switch is kept ON for TM — Electrical
long time system
DDQ2KA Parking brake lever switch disconnection TM CALL E03 Electrical
system
Electrical
DDQ2KB Parking brake lever switch short circuit ST CALL E03 system
Electrical
DDQ2L4 Parking brake lever switch disagreement ST CALL E03 system
Electrical
DDT5KA Neutral switch disconnection TM CALL E04 system
DDT5KB Neutral switch short circuit TM CALL E04 Electrical
system
DDT5KQ Lever specification selection (Model selection signal TM CALL E04 Electrical
disagreement) system
DGS1KX Hydraulic oil temperature sensor input signal is out TM — Electrical
of normal range system
Electrical
DGT1KA Power train oil temp sensor disconnection TM E01 system
Electrical
DGT1KX Power train oil temp sensor out of signal range MON E01 system
Work equipment pump oil pressure sensor short cir- Electrical
DH21KB cuit ST E01 system
DH22KA Work equipment pump oil pressure sensor discon- TM — Electrical
nection system
DH22KB Work equipment pump oil pressure sensor short cir- TM — Electrical
cuit system Troubleshooting
DK10KA Fuel control dial disconnection ST CALL E03 Electrical by failure code,
system Part 5
DK10KB Fuel control dial short circuit ST CALL E03 system
Electrical
DK30KA Steering potentiometer (1) disconnection ST CALL E03 system
Electrical
DK30KB Steering potentiometer (1) short circuit ST CALL E03 system
DK30KX Steering potentiometer (1) out of input signal range ST CALL E04 Electrical
system
DK30KZ Steering potentiometer (1) disconnection or short ST CALL E04 Electrical
circuit system
6 D275A-5R

DK30L8 Steering potentiometer (1) analog signals do not ST CALL E03 Electrical
agree system
Electrical
DK31KA Steering potentiometer (2) disconnection ST CALL E03 system
Electrical
DK31KB Steering potentiometer (2) short circuit ST CALL E03 system
Electrical
DK40KA Brake potentiometer disconnection ST CALL E03 system
DK40KB Brake potentiometer short circuit ST CALL E03 Electrical
system
DK55KX Directional potentiometer out of input signal range TM CALL E04 Electrical
system
DK55KZ Directional potentiometer disconnection or short cir- TM CALL E04 Electrical
cuit system
Directional potentiometer analog signals do not Electrical
DK55L8 agree TM CALL E03 system
Electrical
DK56KA F-R potentiometer (1) disconnection TM CALL E03 system
Electrical
DK56KB F-R potentiometer (1) short circuit TM CALL E03 system
Electrical
DK57KA F-R potentiometer (2) disconnection TM CALL E03 system
DK57KB F-R potentiometer (2) short circuit TM CALL E03 Electrical
system
DK60KA Acceleration sensor disconnection ST E01 Electrical Troubleshooting
system by failure code,
Electrical Part 5
DK60KB Acceleration sensor short circuit ST E01 SEN02762-00
system
Electrical
DKH1KA Pitch angle sensor disconnection ST CALL E03 system
Electrical
DKH1KB Pitch angle sensor short circuit ST CALL E03 system
Electrical
DKH1KX Pitch angle sensor out of input signal range TM E01 system
DLT3KA Transmission out-speed sensor disconnection TM E01 Electrical
system
DLT3KB Transmission out-speed sensor abnormal TM E01 Electrical
system
DV00KB Caution buzzer short circuit MON — Electrical
system
Electrical
DW59KA Blade dual selector solenoid disconnection TM E01 system
Electrical
DW59KB Blade dual selector solenoid short circuit TM E01 system
Electrical
DW59KY Blade dual selector solenoid hot short TM E01 system
DW5AKA Blade pitch selector solenoid disconnection TM E02 Electrical
system
DW5AKB Blade pitch selector solenoid short circuit TM E02 Electrical
system
DW5AKY Blade pitch selection solenoid hot short circuit TM E02 Electrical
system
Electrical
DW7BKA Fan rev EPC disconnection ST E01 system
Electrical
DW7BKB Fan rev EPC short circuit ST E01 system Troubleshooting
Electrical by failure code,
DW7BKY Fan reverse solenoid hot short circuit ST E02 system Part 6
DWN3KA Sudden stop prevention solenoid disconnection ST CALL E04
system
DWN3KB Sudden stop prevention solenoid short circuit ST CALL E04 Electrical
system
D275A-5R 7

DWN3KY Sudden stop prevention solenoid hot short circuit ST CALL E04 Electrical
system
Electrical
DWN5KA Fan pump solenoid disconnection TM E01 system
Electrical
DWN5KB Fan pump solenoid short circuit TM E01 system
Electrical
DWN5KY Fan pump solenoid hot short circuit TM E02 system
DXH4KA 1st clutch ECMV disconnection TM CALL E03 Electrical
system
DXH4KB 1st clutch ECMV short circuit TM CALL E03 Electrical
system
DXH4KY 1st clutch ECMV hot short circuit TM CALL E03 Electrical
system
Electrical
DXH5KA 2nd clutch ECMV disconnection TM CALL E03 system
Electrical
DXH5KB 2nd clutch ECMV short circuit TM CALL E03 system
Electrical
DXH5KY 2nd clutch ECMV hot short circuit TM CALL E03 system
Electrical
DXH6KA 3rd clutch ECMV disconnection TM CALL E03 system
DXH6KB 3rd clutch ECMV short circuit TM CALL E03 Electrical
system
DXH6KY 3rd clutch ECMV hot short circuit TM E03 Electrical
system
DXH7KA Reverse clutch ECMV disconnection TM CALL E03 Electrical
system
Electrical
DXH7KB Reverse clutch ECMV short circuit TM CALL E03 system Troubleshooting
Electrical by failure code,
DXH7KY R clutch ECMV hot short circuit TM CALL E03 system Part 6
DXH8KA Forward clutch ECMV disconnection TM CALL E03 system
DXH8KB Forward clutch ECMV short circuit TM CALL E03 Electrical
system
DXH8KY F clutch ECMV hot short circuit TM CALL E03 Electrical
system
DXH9KA Right steering clutch ECMV disconnection ST CALL E03 Electrical
system
Electrical
DXH9KB Right steering clutch ECMV short circuit ST CALL E03 system
Electrical
DXH9KY Right steering clutch ECMV hot short ST CALL E04 system
Electrical
DXHAKA Left steering clutch ECMV disconnection ST CALL E03 system
DXHAKB Left steering clutch ECMV short circuit ST CALL E03 Electrical
system
DXHAKY Left steering clutch ECMV hot short ST CALL E04 Electrical
system
DXHBKA Right brake ECMV disconnection ST CALL E04 Electrical
system
Electrical
DXHBKB Right brake ECMV short circuit ST CALL E04 system
Electrical
DXHBKY Right brake ECMV hot short circuit ST CALL E04 system
Electrical
DXHCKA Left brake ECMV disconnection ST CALL E04 system
DXHCKB Left brake ECMV short circuit ST CALL E04 Electrical
system
DXHCKY Left brake ECMV hot short circuit ST CALL E04 Electrical
system
8 D275A-5R
a The items in this table are arranged in the order of the failure codes.
a A component in charge is a controller or the machine monitor in charge of the system check.
MON : Machine monitor
ENG : Engine controller
TM : Transmission controller
ST : Steering controller
a The failure codes having no numbers in the action code column are not displayed on the ordinary
screen when abnormality related to them occurs. They are simply recorded in the fault history of the
service menu (Electrical equipment system or mechanical equipment system).
a The history classification column shows in which system each failure is classified, the electrical equip-
ment system or mechanical equipment system, when it is recorded in the failure history.
a Blinking and lighting of failure code
q Blinking : The trouble has not been repaired.
q Lighting : The trouble has been repaired.
D275A-5R 9
Fuse locations 1
Connection table of circuit breakers and fuse boxes
a This connection table shows the devices to which each power supply of the fuse box supplies power (An
accessory power supply is a device which supplies power while the starting switch is in the ON position
and an unswitched power supply is a device which supplies power while the starting switch is in the OFF
and ON positions).
a When carrying out troubleshooting related to the electrical system, you should check the circuit breakers
and fuses to see if the power is supplied normally.
< CAB specification >
Circuit breakers
Breaker capacity
Breaker No. Conector No. Destination of power
(A)
1 CB105H 105 Electrical intake air heater relay
2 B7L 30 Engine controller
3 F96 105 Main power supply
4 F32 30 Unswitched power supply
5 CB1 20 Steering controller
6 CB2 20 Machine monitor
7 CB3 20 Transmission controller
8 CB4 20 Air conditioner
9 CB5 20 Head lamp
10 CB6 20 Unswitched power supply of starting switch
Fuse box FS11, FS12

Fuse capacity
Fuse No. Power source Destination of power
(A)
1 Accessory power supply 20 —
2 20 Unswitched power supply of controller
3 Unswitched power supply 20 Unswitched power supply of cab
4 10 Unswitched power supply of 12 volt converter
5 Accessory power supply 20 Power supply of 12 volt converter
Fuse box FS21, FS22

Fuse capacity
(A)
1 5 Backup alarm
2 20 Pin puller, Pre-heat, Air suspension seat
3 Accessory power supply 20 Additional heater
4 20 Working lamp
5 20 Rear lamp
10 D275A-5R
Fuse box FS31, FS32

Fuse capacity
(A)
1 5 Engine controller ACC
2 20 Horn
3 Accessory power supply 20 Spare power supply 1
4 20 Spare power supply 2
5 20 Spare ACC signal
D275A-5R 11
Locations of circuit breakers (Breaker No. 1 – 4) (In battery room)
Locations of circuit breakers (Breaker No. 5 – 10) and fuse boxes FS11, FS12, FS21, FS22, FS31, and
FS32 (Operator's seat on left side forward front under)
12 D275A-5R
Fuse box
Fuse capacity
(A)
1 10 Radio, Cigarette lighter, Room lamp
2 10 Rear wiper
3 10 Right wiper
4 10 Front wiper
5 Accessory power supply 10 Left wiper
6 20 Additional rear lamp
7 20 Additional head lamp, Revolving warning lamp
8 — Spare
9 — Spare
10 Unswitched power supply 10 Radio memory
Location of fuse box (In operator's cab)
D275A-5R 13
< Non CAB specification >

Circuit breakers
Breaker capacity
Breaker No. Conector No. Destination of power
(A)
1 CB105H 105 Electrical intake air heater relay
2 B7L 30 Unswitched power supply of engine controller
3 F96 105 Main power supply
4 F32 30 Unswitched power supply
Fuse box FS11, FS12

Fuse capacity
(A)
1 Accessory power supply 20 —
2 20 Unswitched power supply of controller
3 Unswitched power supply 20 Unswitched power supply of cab
4 10 Unswitched power supply of 12 volt converter
5 Accessory power supply 20 Power supply of 12 volt converter
Fuse box FS21, FS22

Fuse capacity
(A)
1 5 Backup alarm
2 20 Pin puller, Pre-heat, Air suspension seat
3 Accessory power supply 20 Additional heater
4 20 Working lamp
5 20 Rear lamp
14 D275A-5R
Fuse box FS31, FS32

Fuse capacity
(A)
1 5 Engine controller ACC
2 20 Horn
3 Accessory power supply 20 Spare power supply 1
4 20 Spare power supply 2
5 20 Spare ACC signal
Fuse box FS41, FS42

Fuse capacity
(A)
1 20 Machine monitor
2 20 Steering controller
Accessory power supply
3 20 Transmission controller
4 20 Head lamp
5 Unswitched power supply 20 Unswitched power supply of starting switch
D275A-5R 15
Locations of circuit breakers (Breaker No. 1 – 4) (In battery room)
Locations of fuse boxes FS11, FS12, FS21, FS22, FS31, F32, F41, and FS42 (Operator's seat on left
side forward front under)
16 D275A-5R
Reset method for main power supply circuit Reset method for circuit breaker
breaker Turn the starting switch to the OFF position and
Turn the starting switch to the OFF position to turn push in reset button (5) which was pushed out
the electric circuit OFF, wait for 5 – 10 minutes, and when the electric circuit was turned OFF.
press reset buttons (1) – (4). a If the reset button is pushed out again soon
a Check by the operating effort of each reset but- after it is pushed in, carry out troubleshooting
ton that the circuit is reset. and repair the faulty part.
a If the electric circuit is turned OFF, the operat-
ing effort of the reset button is heavier than
when the electric circuit is turned ON.
a Do not hold down the reset button.
a If the starting motor still does not run after the
reset operation, carry out troubleshooting and
repair the faulty part.
D275A-5R 17
D275A-5R Bulldozer
© 2008 KOMATSU
All Rights Reserved
18 D275A-5R
SEN02757-01
D275A-5R

D275A-5R 35001 and up
General information on troubleshooting
Points to remember when troubleshooting ..................................................................................................... 2
Sequence of events in troubleshooting........................................................................................................... 3
Check before troubleshooting ......................................................................................................................... 4
Classification and procedures for troubleshooting .......................................................................................... 5
Contents of troubleshooting table ................................................................................................................... 8
Connection table for connector pin numbers ................................................................................................ 10
T-branch box and T-branch adapter table ..................................................................................................... 46
D275A-5R 1
Points to remember when troubleshooting 1

k Stop the machine in a level place, and check that the lock pin, blocks, and parking brake are
securely fitted.
k When carrying out the operation with 2 or more workers, keep strictly to the agreed signals, and
do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause
burns, so wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k 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 testing 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 pre-
vent 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 symp-
toms.
1. When carrying out troubleshooting, do not 4) Other maintenance items can be checked
hurry to disassemble the components. externally, so check any item that is con-
If components are disassembled immediately sidered to be necessary.
any failure occurs:
q Parts that have no connection with the fail- 4. Confirming failure
ure or other unnecessary parts will be dis- Confirm the extent of the failure yourself, and
assembled. judge whether to handle it as a real failure or
q It will become impossible to find the cause as a problem with the method of operation, etc.
of the failure. a When operating the machine to reenact
It will also cause a waste of manhours, parts, the troubleshooting symptoms, do not
or oil or grease, and at the same time, will also carry out any investigation or measure-
lose the confidence of the user or operator. For ment that may make the problem worse.
this reason, when carrying out troubleshooting, 5. Troubleshooting
it is necessary to carry out thorough prior Use the results of the investigation and inspec-
investigation and to carry out troubleshooting tion in Items 2 – 4 to narrow down the causes
in accordance with the fixed procedure. of failure, then use the troubleshooting table or
2. Points to ask user or operator troubleshooting flowchart to locate the position
of the the failure exactly.
1) Have any other problems occurred apart
a The basic procedure for troubleshooting is
from the problem that has been reported?
as follows.
2) Was there anything strange about the
1] Start from the simple points.
machine before the failure occurred?
2] Start from the most likely points.
3) Did the failure occur suddenly, or were
there problems with the machine condition 3] Investigate other related parts or
before this? information.
4) Under what conditions did the failure 6. Measures to remove root cause of failure
occur? Even if the failure is repaired, if the root cause
5) Had any repairs been carried out before of the failure is not repaired, the same failure
the failure? When were these repairs car- will occur again.To prevent this, always investi-
ried out? gate why the problem occurred. Then, remove
6) Has the same kind of failure occurred the root cause.
before?
3. Check before troubleshooting
1) Is there any sign of irregularities of the
machine?
2) Make checks before starting day's work.
3) Make checks of other items.
2 D275A-5R
Sequence of events in troubleshooting 1
D275A-5R 3
Check before troubleshooting 1

Item Criterion Remedy
1. Check of level and type of fuel — Add fuel
2. Check of fuel for foreign matter — Clean and drain
3. Check of hydraulic oil level Between H – L Add oil
4. Check of damper case oil level Between H – L Add oil
Lubricating
5. Check of power train oil level Between H – L Add oil
oil/Coolant
6. Check of level and type of engine oil (in oil pan) Between H – L Add oil
7. Check of coolant level (in sub tank) Between FULL - LOW Add coolant
8. Check of dust indicator for clogging Out of red range Clean or replace
9. Check of brake pedal stroke — Adjust
Hydraulic/ 1. Check for abnormal noise/smell — Repair

Mechanical 2. Check for oil leakage — Repair
equipment 3. Bleeding air — Bleed air
1. Check of battery terminals and wiring for loose-
— Retighten or replace
ness and corrosion
2. Check of alternator terminals and wiring for
looseness and corrosion
3. Check of starting motor terminals and wiring for
looseness and corrosion
4. Check of battery voltage (with engine stopped) 20 – 30 V Charge or replace
5. Check of electrolyte level Between H – L Add or replace
6. Check of wires for discoloration, burn, and
Electrical — Repair or replace
removal of cover
equipment
7. Check for released wire clamp and drooping wire — Repair
8. Check of wires for wetness (Check connectors
— Dry
and terminals for wetness, in particular)
9. Check circuit breaker for turning OFF and fuse
— Replace
for disconnection and corrosion
10. Check of alternator voltage After operating for several
Replace
(while engine speed is at middle or higher) minutes: 27.5 – 29.5 V
11. Check of battery relay for operating sound
— Replace
(when starting switch is turned ON or OFF)
4 D275A-5R
Classification and procedures for troubleshooting 1

Classification for troubleshooting
Type Contents
Display of code Troubleshooting by failure code
E mode Troubleshooting for electrical system
H mode Troubleshooting for hydraulic and mechanical system
S mode Troubleshooting for engine
Procedure for troubleshooting

If a phenomenon looking like a trouble occurs in the machine, select a proper troubleshooting No. according
to the following procedure, and then go to the corresponding troubleshooting section.
1. Procedure for troubleshooting to be taken when action code and failure code are displayed on
machine monitor:
If a action code and a failure code are displayed on the machine monitor, carry out the troubleshooting
for the corresponding "Display of code" according to the displayed failure code.
2. When electrical system failure code or mechanical system failure code is recorded in fault his-
tory:
If a action code and a failure code are not displayed on the machine monitor, check for a mechanical
system failure code and an electrical system failure code with the fault history function of the machine
monitor.
If a failure code is recorded, carry out troubleshooting for the corresponding "Display of code" accord-
ing to that code.
a If an electrical system failure code is recorded, delete all the codes and reproduce them, and then
see if the trouble is still detected.
a A failure code of the mechanical system cannot be deleted.
a If a trouble is displayed in the air conditioner fault history or heater fault history by the fault history
function, carry out the corresponding troubleshooting in "E mode".
3. When action code or failure code is not displayed and no failure code is recorded in fault
history:
If a action code or a failure code is not displayed on the machine monitor and no failure code is recorded
in the fault history, a trouble that the machine cannot find out by itself may have occurred in the electrical
system or hydraulic and mechanical system.
In this case, check the phenomenon looking like a trouble again and select the same phenomenon from
the table of "Phenomena looking like troubles and troubleshooting Nos.", and then carry out trouble-
shooting corresponding to that phenomenon in the "E mode", "H mode", or "S mode".
D275A-5R 5
Phenomena looking like troubles and troubleshooting Nos.

Troubleshooting
No. Phenomena looking like troubles Display
E mode H mode S mode
of code
Phenomena related to action code/failure code
1 Action code and failure code are displayed on machine monitor
Accord-
When fault history is checked, failure code is displayed in mechanical
2 ing to dis-
system fault history
played
When fault history is checked, failure code is displayed in electrical code
3
system fault history
When fault history is checked, failure code is displayed in air conditioner
4 E-26
or heater fault history
Phenomena related to engine
5 Starting performance of engine is poor S-1
6 Engine does not start E-1 S-2
7 Engine does not pick up smoothly S-3
8 Engine stops during operation S-4
9 Engine does not rotate smoothly S-5
10 Engine lack output (or lacks power) S-6
11 Exhaust gas is black (incomplete combustion) S-7
12 Oil consumption is excessive (or exhaust gas is blue) S-8
13 Oil becomes dirty quickly S-9
14 Fuel consumption is excessive S-10
15 Oil is in coolant (or coolant spurts back or coolant level goes down) S-11
16 Oil pressure drops S-12
17 Oil level rises (Entry of coolant or fuel) S-13
18 Coolant temperature becomes too high (Overheating) S-14
19 Abnormal noise is made S-15
20 Vibration is excessive S-16
21 Air cannot be bled from fuel circuit S-17
22 The preheater does not operate (Manual preheating function) E-2
Phenomena related to power train
23 No travel power (No drawbar pull) H-1
24 Machine does not move (At 2nd or 3rd speed) H-2
25 Machine does not move in any speed range H-3
26 Machine travels only in one direction forward or in reverse H-4
When gear is shifted or travel direction is changed, large time lag is
27 H-5
made
28 Steering is not possible H-6
29 Steering is possible only on one side H-7
30 Steering overrun occurs H-8
31 Brake does not work H-9
32 Overheat of power train oil temperature H-10
Phenomena related to work equipment
33 All work equipment speeds are slow H-11
34 Work equipment does not move H-12
35 Blade lift speed is slow or lacks power H-13
36 Blade tilt speed is slow or lacks power H-14
37 Ripper lift speed is slow or lacks power H-15
38 Ripper tilt speed is slow or lacks power H-16
6 D275A-5R
Troubleshooting
No. Phenomena looking like troubles Display
E mode H mode S mode
of code
39 Excessive hydraulic drift of blade lift H-17
40 Excessive hydraulic drift of blade tilt H-18
41 Excessive hydraulic drift of ripper lift H-19
Ripper pin puller cylinder does not work (Giant ripper attachment
42 H-20
machine)
43 Blade pitch does not work (Dual tilt attachment machine) H-21
44 Abnormal sound comes out from around work equipment pump H-22
Fan speed is abnormal (Sound and/or vibration of fan are/is abnormally
45 H-23
large or engine overheats)
Phenomena related to machine monitor
46 The ripper pin puller cylinder does not operate E-3
The machine monitor does not come on at all when the starting switch is
47 E-4
turned ON
When the starting switch is turned ON, the machine monitor completely
48 E-5
remains lighted and does not go out
49 When the starting switch is turned ON, the basic check items flash E-6
50 While the engine is operating, any caution item flashes E-7
51 While the engine is operating, the emergency warning item flashes E-8
While the preheater is operating, the preheating pilot lamp does not
52 E-9
come on
At the selecting time of dual tilt, the dual/single tilt selector lamp does
53 E-10
not come on (Dual tilt-mounted machine)
54 The engine coolant temperature gauge does not indicate normally E-11
55 Indication of the power train temperature gauge is abnormal E-12
56 The hydraulic oil temperature gauge does not indicate normally E-13
57 Indication of the fuel gauge is abnormal E-14
58 Indications of gear speed and engine speed are abnormal E-15
59 Indication of the shift mode service meter is abnormal E-16
60 The switch module cannot be operated E-17
61 The warning lamp does not flash or does not go out E-18
62 The alarm buzzer does not sound or does not stop E-19
63 Auto shift down is not possible or is not released E-20
64 The alarm buzzer cannot be cancelled E-21
66 The operator mode cannot be operated E-22
67 The service mode cannot be operated E-23
68 The back-up alarm does not sound E-24
The night light, the headlamp, the working lamp and the rear lamp on
69 E-25
the panel do not come on
70 The air conditioner does not operate E-26
Other phenomena
71 KOMTRAX system does not operate normally E-27
72 Fan does not reverse E-28
73 Gear cannot be shifted E-29
74 Electric priming pump does not operate or does not stop automatically E-30
D275A-5R 7
Contents of troubleshooting table 1

a The following information is summarized in the troubleshooting table and the related electrical circuit
diagram. Before carrying out troubleshooting, understand that information fully.
Action code Failure code
Machine Names of the failure symptoms displayed in the failure history
Machine monitor Trouble
monitor on the machine monitor
display
display
Contents of
State where the machine monitor or controller detects the trouble
trouble
Action of
Action to be taken to protect the system and equipment when the machine monitor or control-
machine moni-
ler detects a trouble
tor or controller
Problem that
Problem that appears as an abnormality in the machine by the action (above) taken by monitor
appears on
or controller
machine
Related
Information related to troubles occurred or troubleshooting
information
Cause Standard value in normal state/Remarks on troubleshooting

<Described contents>
• Standard value when normal required to judge the possi-
ble cause
• Remarks required to judge whether any cause is right or
1 not
<Symptoms of defective harness>

• Disconnection in wiring
The connector connection is defective or the wiring har-
ness is disconnected.
• Defective grounding
A harness not connected to GND (ground) circuit comes
into contact with the GND (ground) circuit.
• Hot short defect
A harness not connected to the electric power supply
2 (24V) circuit comes into contact with the electric power
supply (24V) circuit.
• Short circuit
Possible causes Cause by which a trouble is A harness abnormally comes into contact with a harness
and standard assumed to be detected of separate circuit.
value in normal (The order number indicates
state a serial number, not a priority <Points to remember when troubleshooting>
sequence.) (1) Method of indicating connector numbers and handling T-
adapter
For troubleshooting, insert or connect the T- adapter as
3 described below unless especially specified.
• When “male“or “female“ is not indicated for a connec-
tor number, disconnect the connector, and insert the T-
adapter in both the male and female.
• When “male“or “female“ is indicated for a connector
number, disconnect the connector, and insert the T-
adapter in only either the male or female.
(2) Pin number description sequence and tester lead han-
dling
For troubleshooting, connect the plus (+) and minus (-)
leads of the tester as described below unless especially
4 specified.
• Connect the plus (+) lead to a pin number or harness
indicated in the front.
• Connect the minus (-) lead to a pin number or harness
indicated in the rear.
8 D275A-5R
Circuit diagram related
This drawing is a part of the electric circuit diagram related to trouble-

shooting.
• Connector No.: Indicates (Model - Number of pins) and (Color).
• “Connector No. and pin No.“ from each branching/merging point:
Shows the ends of branch or source of merging within the parts of the
same wiring harness.
• Arrow ( ): Roughly shows the location on the machine.
D275A-5R 9
Connection table for connector pin numbers 1

(Rev. 2007.10)
a The terms of male and female refer to the pins, while the terms of male housing and female housing
refer to the mating portion of the housing.
10 D275A-5R
D275A-5R 11
12 D275A-5R
D275A-5R 13
14 D275A-5R
D275A-5R 15
16 D275A-5R
D275A-5R 17
18 D275A-5R
D275A-5R 19
20 D275A-5R
D275A-5R 21
22 D275A-5R
D275A-5R 23
24 D275A-5R
D275A-5R 25
26 D275A-5R
D275A-5R 27
28 D275A-5R
D275A-5R 29
30 D275A-5R
D275A-5R 31
32 D275A-5R
D275A-5R 33
34 D275A-5R
D275A-5R 35
36 D275A-5R
D275A-5R 37
38 D275A-5R
D275A-5R 39
40 D275A-5R
D275A-5R 41
42 D275A-5R
D275A-5R 43
44 D275A-5R
D275A-5R 45
T-branch box and T-branch adapter table 1

(Rev. 2008.02)
a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal
column indicates a part number of harness checker assembly.
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
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
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37 q
799-601-3200 T-box (for MS) 37 q
799-601-3380 Plate for MS (14-pin) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3510 Adapter for BENDIX (MS) 5 MS-5S q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
799-601-2750 Adapter for ECONO 2 ECONO2P q q
799-601-2810 Adapter for DLI 8 DLI-8P q q
799-601-2840 Extension cable (ECONO type) 12 ECONO12P q q q
799-601-2850 Case q
799-601-4350 T-box (for DRC60, ECONO) 60 q
799-601-4360 Case q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7050 Adapter for SWP 6 SW6P q q q
799-601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 — q q
799-601-7090 Adapter for M 2 M2P q q q q
46 D275A-5R
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
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
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol

799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for S 8 S8P q q q q
799-601-7150 Adapter for S (White) 10 S10P q q q q
799-601-7160 Adapter for S (Blue) 12 S12P q q q
799-601-7170 Adapter for S (Blue) 16 S16P q q q q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 — q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 — q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q q q
799-601-9030 Adapter for DT 3 DT3 q q
799-601-9040 Adapter for DT 4 DT4 q q q q
799-601-9050 Adapter for DT 6 DT6 q q
799-601-9060 Adapter for DT (Gray) 8 DT8GR q q
799-601-9070 Adapter for DT (Black) 8 DT8B q q
799-601-9080 Adapter for DT (Green) 8 DT8G q q
799-601-9090 Adapter for DT (Brown) 8 DT8BR q q
799-601-9110 Adapter for DT (Gray) 12 DT12GR q q
799-601-9120 Adapter for DT (Black) 12 DT12B q q
799-601-9130 Adapter for DT (Green) 12 DT12G q q
799-601-9140 Adapter for DT (Brown) 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9310 Plate for HD30 (24-pin) q q q
D275A-5R 47
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
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
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-9320 T-box (for ECONO) 24 q q q

799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL 3 A3 q q
Adapter for oil pressure
Socket for engine (CRI-T2)
799-601-9430* 2 P q q
Socket for engine (CRI-T3) PCV
799-601-9440* Socket for engine (CRI-T2) 3 1,2,3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540* 2 A q q
Socket for engine (CRI-T3) TIM
795-799-5460 Cable for engine (HPI-T2) 3 — q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q
799-601-4140 3 FCIG q q
Atmosphere pressure
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
799-601-4160 2 4160 q q
Oil pressure switch
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
799-601-4190* 3 1,2,3L q q
Commonrail pressure
799-601-4230* 4 1,2,3,4C q q
Air intake pressure/temperature
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1,2,3A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1,2,3B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1,2,3,G q q
799-601-4340* 2 2,PA q q
Pump actuator
Socket for engine (CRI-T3)(95)
799-601-4380* 4 1,2,3,4T q
Air intake pressure/temperature
799-601-4260 Adapter for controller (ENG) 4 DTP4 q q
799-601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4390* Socket for controller (95 ENG) 60 — q
799-601-4280 Box for controller (PUMP) 121 — q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
799-601-9890 Multi-adapter for DT2-4 and DTM2 3, — q
4
“*” Shows not T-adapter but socket.
48 D275A-5R
D275A-5R 49
D275A-5R Bulldozer
© 2008 KOMATSU
All Rights Reserved
50 D275A-5R
SEN02758-01
D275A-5R

D275A-5R 35001 and up
Troubleshooting by failure and error
codes, Part 1
Failure code [1500L0] Transmission clutch dual engagement........................................................................ 3
Failure code [15SAL1] Forward clutch oil pressure 1 ..................................................................................... 4
Failure code [15SALH] Forward clutch oil pressure 2..................................................................................... 6
Failure code [15SBL1] Reverse clutch oil pressure 1 ..................................................................................... 8
Failure code [15SBLH] Reverse clutch oil pressure 2 .................................................................................. 10
Failure code [15SEL1] 1st clutch oil pressure 1............................................................................................ 12
Failure code [15SELH] 1st clutch oil pressure 2 ........................................................................................... 13
Failure code [15SFL1] 2nd clutch oil pressure 1........................................................................................... 14
Failure code [15SFLH] 2nd clutch oil pressure 2 .......................................................................................... 15
Failure code [15SGL1] 3rd clutch oil pressure 1........................................................................................... 16
Failure code [15SGLH] 3rd clutch oil pressure 2 .......................................................................................... 17
Failure code [2201L1] Right steering clutch oil pressure 1 ........................................................................... 18
Failure code [2201LH] Right steering clutch oil pressure 2 .......................................................................... 20
Failure code [2202L1] Left steering clutch oil pressure 1 ............................................................................. 22
D275A-5R 1
Failure code [2202LH] Left steering clutch oil pressure 2 ............................................................................. 24

Failure code [2300NR] Brake thermal load ................................................................................................... 26
Failure code [2301L1] Right steering brake oil pressure 1............................................................................ 28
Failure code [2301LH] Right steering brake oil pressure 2 ........................................................................... 30
Failure code [2301NR] Right steering brake thermal load ............................................................................ 32
Failure code [2302L1] Left steering brake oil pressure 1 .............................................................................. 34
Failure code [2302LH] Left steering brake oil pressure 2 ............................................................................. 36
Failure code [2302NR] Left steering brake thermal load............................................................................... 38
Failure code [6001ZK] Failure code for design ............................................................................................. 38
Failure code [A000NS] Engine overheat....................................................................................................... 39
Failure code [AA10NX] Air cleaner clogging ................................................................................................. 40
Failure code [AB00MA] Battery charge abnormal......................................................................................... 42
Failure code [B@BAZG] Eng oil press low ................................................................................................... 44
Failure code [B@BAZK] Eng oil level low ..................................................................................................... 45
Failure code [B@BCNS] Eng coolant overheat ............................................................................................ 46
Failure code [B@BCZK] Radiator coolant level low...................................................................................... 46
Failure code [B@BEBF] Water gets mixed with fuel ..................................................................................... 47
Failure code [B@BFZK] Fuel level abnormal reduction ................................................................................ 47
Failure code [B@CENS] Torque converter oil overheat................................................................................ 48
Failure code [B@CHZG] HSS charge oil pressure reduction ....................................................................... 49
Failure code [B@CHZK] Power train oil level reduction................................................................................ 49
Failure code [B@GAZK] Battery electrolyte level reduction.......................................................................... 50
Failure code [B@HANS] Hyd oil overheat .................................................................................................... 50
Failure code [B@HAZK] Hydraulic oil level reduction ................................................................................... 51
2 D275A-5R
Failure code [1500L0] Transmission clutch dual engagement 1

Action code Failure code Transmission clutch dual engagement
Trouble
CALL E03 1500L0 (Transmission controller system)
• Of the failure codes related to the transmission clutch, the following codes were displayed at the
same time. (Gear speed is limited.)
(1) Either [DXH4KA] or [DXH4KB] and either [DXH5KA] or [DXH5KB]
• Of the failure codes related to the transmission clutch, the following codes were displayed at the
same time. (Machine can not travel.)
(2) Either [DXH8KA] or [DXH8KB] and either [DXH7KA] or [DXH7KB]
Contents of
(3) Either of [DXH6KA] or [DXH6KB] and (1) above
trouble
(4) [15SALH] and [15SBLH]
(5) Either [15SAL1] or [DXH8KY] and either [15SBL1] or [DXH7KY]
(6) [15SELH], [15SFLH], and [15SGLH]
(7) Either [15SEL1] or [DXH4KY] and either [15SFL1] or [DXH5KY]
(8) Either [15SEL1] or [DXH4KY] and either [15SGL1] or [DXH6KY]
(9) Either [15SFL1] or [DXH5KY] and either [15SGL1] or [DXH6KY]
Action of • Flashes warning lamp and turns on alarm buzzer.
controller • Limits operation of engine and transmission.
• The auto shift down function does not start.
Problem that
• Once machine is stopped, engine speed is limited to medium (half).
appears on
• Once machine is stopped, traveling is limited to specific gear speeds.
machine
• Machine cannot travel.
Related
• Duplication of failure code: Engine start + travel
information

Possible causes Confirm the failure 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], [DXH4KY], [DXH5KA], [DXH5KB], [DXH5KY], [DXH6KA], [DXH6KB],
[DXH6KY], [DXH7KA], [DXH7KB], [DXH7KY], [DXH8KA], [DXH8KB], [DXH8KY]
D275A-5R 3
Failure code [15SAL1] Forward clutch oil pressure 1 1

Action code Failure code Forward clutch oil pressure 1 (Command current is OFF but fill sig-
Trouble nal is ON)
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. (Prevention of double engagement)
controller
• Limits operation of engine and transmission.
Problem that
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 real-time monitoring
Related
mode. (Code 31520: Transmission controller fill switch input state)
information
• Method of reproducing failure code: Engine start + Neutral running

a Prepare with starting switch OFF, then start the engine for trou-
bleshooting.
Defective forward clutch fill FFT (male) PCCS lever Resistance
1
switch (Internal short)
Between (1) – N Min. 1 Mz
chassis ground F (Forward) Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshoot-
Defective harness grounding without turning starting switch ON.
Possible causes
2 ing (Contact with ground cir-
and standard Wiring harness between TMCN1 (female) Resis-
cuit) Max. 1 Mz
value in normal (5) – FFT (female) (1) with chassis ground tance
state
bleshooting.
Defective transmission con- TMCN1 PCCS lever Voltage
3
troller
Between (5) – N 5 – 11 V
chassis ground F (Forward) Max. 1 V
When no fault is detected in the electric system, the hydraulic pres-
Defective hydraulic pressure
4 sure system is assumed to be abnormal. Carry out the related trou-
system
bleshooting (H mode).
4 D275A-5R
D275A-5R 5
Failure code [15SALH] Forward clutch oil pressure 2 1

Action code Failure code Forward clutch oil pressure 2 (Command current is ON but fill sig-
Trouble nal is OFF)
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. (Prevention of double engagement)
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 real-time monitoring
Related
information
• Method of reproducing failure code: Engine start + Forward running

bleshooting.
Defective forward clutch fill
1 switch (Internal disconnec- FFT (male) PCCS lever Resistance
tion in wiring) Between (1) – N Min. 1 Mz
chassis ground F (Forward) Max. 1 z
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
Possible causes ness (Disconnection in wiring ing without turning starting switch ON.
2
and standard or defective contact in con- Wiring harness between TMCN1 (female) Resis-
value in normal nector) Max. 1 z
(5) – FFT (female) (1) tance
state
bleshooting.
3
troller
Between (5) – N 5 – 11 V
chassis ground F (Forward) Max. 1 V
system
6 D275A-5R
D275A-5R 7
Failure code [15SBL1] Reverse clutch oil pressure 1 1

Action code Failure code Reverse clutch oil pressure 1 (Command current is OFF but fill sig-
Trouble nal is ON)
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. (Prevention of double engagement)
controller
Problem that
appears on
• Once machine is stopped, running is limited to R1.
machine
• The input state (ON/OFF) from the reverse clutch fill switch can be checked in real-time monitoring
Related
information

bleshooting.
Defective reverse clutch fill FRT (male) PCCS lever Resistance
1
Between (1) – N Min. 1 Mz
chassis ground R (Reverse) Max. 1 z
Possible causes
cuit) Min. 1 Mz
value in normal (24) – FFT (female) (1) with chassis ground tance
state
bleshooting.
3
troller
Between (24) – N 5 – 11 V
chassis ground R (Reverse) Max. 1V
system
8 D275A-5R
D275A-5R 9
Failure code [15SBLH] Reverse clutch oil pressure 2 1

Action code Failure code Reverse clutch oil pressure 2 (Command current is ON but fill sig-
Trouble nal is OFF)
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. (Prevention of double engagement)
controller
Problem that
appears on
• Once machine is stopped, running is limited to F1.
machine
• The input state (ON/OFF) from the reverse clutch fill switch can be checked in real-time monitoring
Related
information
• Method of reproducing failure code: Engine start + Reverse running

bleshooting.
Defective reverse clutch fill
1 switch (Internal disconnec- FRT (male) PCCS lever Resistance
tion in wiring) Between (1) – N Min. 1 Mz
chassis ground R (Reverse) Max. 1 z
2
(24) – FRT (female) (1) tance
state
bleshooting.
3
troller
Between (24) – N 5 – 11 V
chassis ground R (Reverse) Max. 1 V
system
10 D275A-5R
D275A-5R 11
Failure code [15SEL1] 1st clutch oil pressure 1 1

Action code Failure code 1st clutch oil pressure 1 (Command current is OFF but fill signal is
Trouble ON)
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
Action of • Flashes caution lamp and turns on caution buzzer.
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 real-time monitoring
Related
mode. (Code 31520: Transmission fill switch input state)
information
• Method of reproducing failure code: Engine start + F2 or R2 running

bleshooting.
Defective 1st clutch fill switch F1T (male) PCCS lever Resistance
1
(Internal short)
Between (1) – Other than F1/R1 Min. 1 Mz
chassis ground F1 • R1 Max. 1 z
Possible causes
cuit) Min. 1 Mz
value in normal (23) – F1T (female) (1) with chassis ground tance
state
bleshooting.
3
troller
Between (23) – Other than F1/R1 5 – 11 V
chassis ground F1 • R1 Max. 1 V
system
12 D275A-5R
Failure code [15SELH] 1st clutch oil pressure 2 1

Action code Failure code 1st clutch oil pressure 2 (Command current is ON but fill signal is
Trouble OFF)
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.
appears on • Once machine is stopped, engine speed is limited to medium (half).
machine • Once machine is stopped, running is limited to F2 and R2.
• The input state (ON/OFF) from the 1st clutch fill switch can be checked in real-time monitoring
Related
information

bleshooting.
Defective 1st clutch fill switch
1 (Internal disconnection in F1T (male) PCCS lever Resistance
wiring) Between (1) – Other than F1/R1 Min. 1 Mz
2
value in normal nector) Min. 1 Mz
(23) – F1T (female) (1) tance
state
bleshooting.
3
troller
system
D275A-5R 13
Failure code [15SFL1] 2nd clutch oil pressure 1 1

Action code Failure code 2nd clutch oil pressure 1 (Command current is OFF but fill signal is
Trouble ON)
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 real-time monitoring
Related
information

bleshooting.
Defective 2nd clutch fill F2T (male) PCCS lever Resistance
1
Possible causes
cuit) Min. 1 Mz
state
bleshooting.
3
troller
system
14 D275A-5R
Failure code [15SFLH] 2nd clutch oil pressure 2 1

Action code Failure code 2nd clutch oil pressure 2 (Command current is ON but fill signal is
Trouble OFF)
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 real-time monitoring
Related
information

bleshooting.
Defective 2nd clutch fill F2T (male) PCCS lever Resistance
1
2
value in normal nector) Max. 1 Mz
state
bleshooting.
3
troller
system
D275A-5R 15
Failure code [15SGL1] 3rd clutch oil pressure 1 1

Action code Failure code 3rd clutch oil pressure 1 (Command current is OFF but fill signal is
Trouble ON)
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 real-time monitoring
Related
information

bleshooting.
Defective 3rd clutch fill F3T (male) PCCS lever Resistance
1
Possible causes
cuit) Max. 1 Mz
state
bleshooting.
3
troller
system
16 D275A-5R
Failure code [15SGLH] 3rd clutch oil pressure 2 1

Action code Failure code 3rd clutch oil pressure 2 (Command current is ON but fill signal is
Trouble OFF)
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 real-time monitoring
Related
information

bleshooting.
Defective 3rd clutch fill F3T (male) PCCS lever Resistance
1
2
state
bleshooting.
3
troller
system
D275A-5R 17
Failure code [2201L1] Right steering clutch oil pressure 1 1

Action code Failure code Right steering clutch oil pressure 1 (Command current is OFF but
Trouble fill signal is ON)
CALL E04 2201L1 (Steering controller system)
Contents of
• The fill switch signal is not set off at output stop of the right steering clutch solenoid circuit.
trouble
controller • Limits operation of engine, transmission, and brake.
Problem that • Once machine is stopped, engine speed is limited to medium (half).
appears on • Once machine is stopped, it never runs.
machine • Auto-shift down function does not work.
• The input state (ON/OFF) from the right steering clutch fill switch can be checked in real-time moni-
Related
toring mode. (Code 31521: Steering fill switch input state)
information
• Method of reproducing failure code: Engine start

a Prepare with starting switch OFF. Engine start for troubleshoot-
ing.
Defective right steering
1 clutch fill switch FRC (male) PCCS lever Resistance
(Internal short) Between (1) – N (Neutral) Min. 1 Mz
chassis ground Right max. steering Max. 1 z
Possible causes Defective harness grounding ing without turning starting switch ON.
2
and standard (Contact with ground circuit) Wiring harness between STCN3 (female) Resis-
value in normal Min. 1 Mz
(39) – FRC (female) (1) with chassis ground tance
state
ing.
3 Defective steering controller STCN3 PCCS lever Voltage
Between (39) – N (Neutral) 5 – 11 V
chassis ground Right max. steering Max. 1 V
system
18 D275A-5R
D275A-5R 19
Failure code [2201LH] Right steering clutch oil pressure 2 1

Action code Failure code Right steering clutch oil pressure 2 (Command current is ON but fill
Trouble signal is OFF)
CALL E04 2201LH (Steering controller system)
Contents of
• The fill switch signal is not set off at output to the right steering clutch solenoid circuit.
trouble
• The input state (ON/OFF) from the right steering clutch fill switch can be checked in real-time moni-
Related toring mode. (Code 31521: Steering fill switch input state)
information • Method of reproducing failure code: Engine start + Parking brake lever release + PCCS lever oper-
ate (right steering)

ing.
1 clutch fill switch FRC (male) PCCS lever Resistance
chassis ground Right max. steering Max. 1 z
2
and standard or defective contact in con- Wiring harness between STCN2 (female) Resis-
(39) – FRC (female) (1) tance
state
ing.
chassis ground Right max. steering Max. 1 V
system
20 D275A-5R
D275A-5R 21
Failure code [2202L1] Left steering clutch oil pressure 1 1

Action code Failure code Left steering clutch oil pressure 1 (Command current is OFF but fill
Trouble signal is ON)
Contents of
• The fill switch signal is not set off at output stop of the left steering clutch solenoid circuit.
trouble
• The input state (ON/OFF) from the left steering clutch fill switch can be checked in real-time moni-
Related
information

ing.
Defective left steering clutch
1 fill switch FLC (male) PCCS lever Resistance
chassis ground Left max. steering Max. 1 z
Possible causes Defective harness grounding ing without turning starting switch ON.
2
and standard (Contact with ground circuit) Wiring harness between STCN3 (female) Resis-
(29) – FLC (female) (1) with chassis ground tance
state
ing.
chassis ground Left max. steering Max. 1 V
system
22 D275A-5R
D275A-5R 23
Failure code [2202LH] Left steering clutch oil pressure 2 1

Action code Failure code Left steering clutch oil pressure 2 (Command current is ON but fill
Contents of
• The fill switch signal is not set off at output to the left steering clutch solenoid circuit.
trouble
• The input state (ON/OFF) from the left steering clutch fill switch can be checked in real-time moni-
Related toring mode. (Code 31521: Steering fill switch input state)
information • Method of reproducing failure code: Engine start + Parking brake lever release + PCCS lever oper-
ate (left steering)

ing.
1 fill switch FLC (male) PCCS lever Resistance
chassis ground Left max. steering Max. 1 z
2
(29) – FLC (female) (1) tance
state
ing.
chassis ground Left max. steering Max. 1 V
system
24 D275A-5R
D275A-5R 25
Failure code [2300NR] Brake thermal load 1

Action code Failure code Brake thermal load
Trouble
— 2300NR (Steering controller system)
Contents of • Steering controller judged from pitch angle, travel speed, continuous pedal brake operation time,
trouble etc. that brake was heating abnormally.
Action of
• None in particular.
controller
Problem that
appears on
machine
Related
information
Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard Improper braking during downslope travel (e.g. Continous downhill travel with brake pedal
1
value in normal pressed)
state 2 Defective steering controller When the operation in cause 1 is not performed
26 D275A-5R
D275A-5R 27
Failure code [2301L1] Right steering brake oil pressure 1 1

Action code Failure code Right steering brake oil pressure 1 (Command current is OFF but
Trouble fill signal is ON)
Contents of
• The fill switch signal is not set off at output stop of the right steering brake solenoid circuit.
trouble
Problem that
appears on
• Once machine is stopped, it never runs.
machine
• The input state (ON/OFF) from the right steering brake fill switch can be checked in real-time moni-
Related
information

a Prepare with starting switch OFF. Engine start + Pivot turn
switch ON + Forward for troubleshooting.
Defective right steering FRB (male) PCCS lever Resistance
1 brake fill switch
(Internal short) N (Neutral) Max. 1 z
Between (1) –
chassis ground Right steering stroke
Min. 1 Mz
end
Possible causes
and standard Wiring harness between STCN2 (female) Resis-
cuit) Max. 1 Mz
value in normal (25) – FRB (female) (1) with chassis ground tance
state
STCN2 PCCS lever Voltage
3 Defective steering controller
N (Neutral) Max. 1 V
Between (25) –
5 – 11 V
end
system
28 D275A-5R
D275A-5R 29
Failure code [2301LH] Right steering brake oil pressure 2 1

Action code Failure code Right steering brake oil pressure 2 (Command current is ON but fill
Contents of
• The fill switch signal is not set off at output to the right steering brake solenoid circuit.
trouble
Problem that
appears on
machine
• The input state (ON/OFF) from the right steering brake fill switch can be checked in real-time moni-
Related
information
• Method of reproducing failure code: Engine start + Parking brake release

Defective right steering FRB (male) PCCS lever Resistance
1 clutch fill switch
Between (1) –
Min. 1 Mz
end
2
(25) – FRB (female) (1) tance
state
Between (25) –
5 – 11 V
end
system
30 D275A-5R
D275A-5R 31
Failure code [2301NR] Right steering brake thermal load 1

Action code Failure code Right steering brake thermal load (Abnormal heating)
Trouble
Contents of • Steering controller judged from pitch angle, travel speed and continuous right steering operation
trouble time that right steering brake was heating abnormally.
Action of
controller
Problem that
appears on
machine
Related
information

and standard 1 Improper steering during downslope travel (e.g. Continuous downhill travel with right steering ON)
value in normal
32 D275A-5R
D275A-5R 33
Failure code [2302L1] Left steering brake oil pressure 1 1

Action code Failure code Left steering brake oil pressure 1 (Command current is OFF but fill
Trouble signal is ON)
Contents of
• The fill switch signal is not set off at output stop of the left steering brake solenoid circuit.
trouble
Problem that
appears on
machine
• The input state (ON/OFF) from the left steering brake fill switch can be checked in real-time moni-
Related
information

Defective left steering clutch FRB (male) PCCS lever Resistance
1 fill switch
Between (1) –
chassis ground Left steering stroke
Min. 1 Mz
end
Possible causes
and standard Wiring harness between STCN2 (female) Resis-
cuit) Max. 1 Mz
value in normal (35) – FLB (female) (1) with chassis ground tance
state
Between (35) –
5 – 11 V
end
system
34 D275A-5R
D275A-5R 35
Failure code [2302LH] Left steering brake oil pressure 2 1

Action code Failure code Left steering brake oil pressure 2 (Command current is ON but fill
Contents of
• The fill switch signal is not set on at output stop of the left steering brake solenoid circuit.
trouble
Problem that
appears on
machine
• The input state (ON/OFF) from the left steering brake fill switch can be checked in real-time moni-
Related
information
• Method of reproducing failure code: Engine start + Parking brake release

Defective left steering brake FLB (male) PCCS lever Resistance
1 fill switch
Between (1) –
Min. 1 Mz
end
2
(35) – FLB (female) (1) tance
state
Between (35) –
5 – 11 V
end
system
36 D275A-5R
D275A-5R 37
Failure code [2302NR] Left steering brake thermal load 1

Action code Failure code Left steering brake thermal load (Abnormal heating)
Trouble
Contents of • Steering controller judged from pitch angle, travel speed and continuous left steering operation time
trouble that left steering brake was heating abnormally.
Action of
controller
Problem that
appears on
machine
Related
information

and standard 1 Improper steering during downslope travel (e.g. Continuous downhill travel with left steering ON)
value in normal
Failure code [6001ZK] Failure code for design 1

Action code Failure code
Trouble Failure code for design
— 6001ZK
Contents of
trouble
Action of
controller
Problem that
appears on • None in particular.
machine
Related • Since this failure code is for design, it does not occur actually. It appears in mechanical system fail-
information ure code list, however.
38 D275A-5R
Failure code [A000NS] Engine overheat 1

Action code Failure code Engine overheat
Trouble
— A000NS (Mechanical system)
Contents of
• Engine overheat caution lamp turned on during engine is running.
trouble
Action of
machine monitor
Problem that
machine
Related • Since above caution lamp is not set on this machine, above failure code does not occur. Above fail-
information ure code is listed up in mechanical system failure code table, however.
D275A-5R 39
Failure code [AA10NX] Air cleaner clogging 1

Action code Failure code Air cleaner clogging
Trouble
— AA10NX (Mechanical system)
Contents of
• While engine was running, clogging of air cleaner was detected.
trouble
Action of
controller
Problem that
appears on • If machine is used as it is, engine output may lower or engine may be damaged.
machine
Related • Method of reproducing failure code: Start engine.
information • Air cleaner clogging caution symbol on machine monitor blinks and this failure code is recorded.

Clogged air cleaner
1 a Air cleaner may be clogged. Check and clean or replace it.
(When system is normal)
a Prepare with starting switch OFF, then start engine and carry
out troubleshooting.
Defective air cleaner clog-
2 ging switch (Internal discon- AF1 (male) Air cleaner Resistance
nection) Normal Max. 1 z
Between (1) – (2)
Clogged Min. 1 Mz
Possible causes
and standard
Disconnection in wiring har- ing without turning starting switch ON.
value in normal
state ness (Disconnection in wiring Wiring harness between S03 (female) (13) – Resis-
3 Max. 1 z
or defective contact in con- AF1 (female) (1) tance
nector) Wiring harness between AF1 (female) (2) – Resis-
Max. 1 z
chassis ground tance
4 Defective machine monitor S03 Air cleaner Voltage
Between (13) – Normal Max. 1 V
chassis ground Clogged 20 – 30 V
40 D275A-5R
D275A-5R 41
Failure code [AB00MA] Battery charge abnormal 1

Action code Failure code Battery charge abnormal
Trouble
— AB00MA (Mechanical system)
Contents of
• While engine was running, charge circuit from alternator detected voltage reduction.
trouble
Action of
• Blinks warning lamp.
controller
Problem that
appears on • If machine is used as it is, battery may not be charged.
machine
• Battery voltage can be checked with real-time monitoring mode.
Related (Code: 03200 Battery power supply)
information • Method of reproducing failure code: Start engine.
• Charge level caution symbol on machine monitor blinks and this failure code is recorded.

Possible causes Defective charge by battery Phenomenon seems to have caused battery charge trouble. Find
1
and standard (When system is normal) and stop it and repair damaged part.
value in normal If cause 1 is not detected, charge level monitor system may be
state Defective charge level moni-
2 defective. Carry out "E-7 While the engine is operating, any cau-
tor system
tion item flashes" in E mode.
42 D275A-5R
D275A-5R 43
Failure code [B@BAZG] Eng oil press low 1

Action code Failure code Eng oil press low
Trouble
— B@BAZG (Mechanical system)
Contents of
• The engine oil pressure abnormality takes place during the engine running.
trouble
Action of • Flashes warning lamp and turns on alarm buzzer. (Function of machine monitor)
controller • Limits operation of engine.
Problem that • If the machine is operated in such a condition, the engine output may decrease and the engine may
appears on be damaged.
machine • After warning, engine speed is limited to medium (half).
• The engine oil pressure caution symbol on the machine monitor flashes and this failure code is
Related
recorded.
information
• Duplication of failure code: Start the engine.

It can be suspected that the problem causing the detection of
Reduction of engine oil
engine oil pressure reduction is currently occurring or occurred in
Possible causes 1 pressure
the past. Investigate the cause and damage condition, and correct
and standard (When system is normal)
it.
value in normal
state If cause 1 is not detected, engine oil sensor system may be detec-
Defective engine oil pressure tive.
2
sensor system Carry out troubleshooting for the failure codes [CA135] and
[CA141].
44 D275A-5R
Failure code [B@BAZK] Eng oil level low 1

Action code Failure code Eng oil level low
Trouble
— B@BAZK (Mechanical system)
Contents of • The signal circuit of the engine oil level switch is opened (disconnected from grounding) while the
trouble engine is stopped.
Action of
controller
Problem that
appears on • If machine is operated as it is, engine may be damaged.
machine
Related • Method of reproducing failure code: Start engine.
information • Engine oil level caution symbol on machine monitor blinks and this failure code is recorded.
a This failure code is not used in this machine.

It is listed in the mechanical system failure code table, however.
D275A-5R 45
Failure code [B@BCNS] Eng coolant overheat 1

Action code Failure code Eng coolant overheat
Trouble
— B@BCNS (Mechanical system)
Contents of • While engine was running, engine coolant temperature sensor signal circuit detected that engine
trouble coolant was overheated.
controller • Limits engine operation.
Problem that
• If machine is used as it is, engine output may lower or engine may be damaged.
appears on
• After alarm is made, engine speed is limited to medium (half) at certain rate.
machine
• Engine coolant temperature sensor signal is input to engine controller and then transmitted to
machine monitor through communication system.
• Engine coolant temperature can be checked with real-time monitoring mode.
Related
(Code: 04104 Engine coolant temperature)
information
• Method of reproducing failure code: Start engine.
• Engine coolant temperature caution symbol on machine monitor blinks and this failure code is
recorded.

Possible causes Overheated engine coolant Check engine coolant for overheating. If it is overheated, remove
1
and standard (When system is normal) cause.
value in normal If cause 1 is not detected, engine coolant temperature sensor may
state Defective engine coolant
2 be defective. Carry out troubleshooting for failure codes [CA144]
temperature sensor system
and [CA145].
Failure code [B@BCZK] Radiator coolant level low 1

Action code Failure code Radiator coolant level low
Trouble
— B@BCZK (Mechanical system)
Contents of • While starting switch was ON (and engine was stopped) or engine was running, radiator coolant
trouble level switch signal circuit detected that radiator coolant level was low (sensor contact was open).
Action of
controller
Problem that
appears on • If machine is used as it is, engine may overheat.
machine
Related
• Engine radiator coolant level caution symbol on machine monitor blinks and this failure code is
information
recorded.

Possible causes Low coolant level Phenomenon seems to have caused radiator sub tank coolant
1
and standard (When system is normal) level reduction. Find and stop it and repair damaged part.
value in normal If cause 1 is not detected, radiator coolant level monitor may be
state Defective radiator coolant
2 defective. Carry out "E-6 When the starting switch is turned ON,
level monitor system
the basic check items flash" in E mode.
46 D275A-5R
Failure code [B@BEBF] Water gets mixed with fuel 1

Action code Failure code Water gets mixed with fuel
Trouble
— B@BEBF (Mechanical system)
Contents of
• Water gets mixed with fuel and water separator caution lamp turned on.
trouble
Action of
controller
Problem that
machine
Related • This failure code is not displayed since caution lamp related above item is not set on this machine.
information It is listed in the mechanical system failure code table, however.
Failure code [B@BFZK] Fuel level abnormal reduction 1

Action code Failure code Fuel level abnormal reduction
Trouble
— B@BFZK (Mechanical system)
Contents of
• Fuel level is low and fuel level caution lamp is lighting.
trouble
Action of
controller
Problem that
machine
D275A-5R 47
Failure code [B@CENS] Torque converter oil overheat 1

Action code Failure code Torque converter oil overheat
Trouble
— B@CENS (Mechanical system)
Contents of • While engine was running, torque converter oil overheated and torque converter oil temperature
trouble caution lamp blinked.
Action of
controller
Problem that
appears on • If machine is used as it is, power train components may be damaged.
machine
• Torque converter oil temperature can be checked with real-time monitoring mode.
(Code: 30100 Torque converter oil temperature)
Related
information
• Torque converter oil temperature caution lamp on machine monitor blinks and this failure code is
recorded.

Overheated torque con-
Possible causes Check torque converter oil for overheating. If it is overheated,
1 verter oil (When system is
and standard remove cause.
normal)
value in normal
state Defective torque converter If cause 1 is not detected, torque converter oil temperature sensor
2 oil temperature sensor sys- system may be defective. Carry out troubleshooting for failure
tem code [DGT1KA] or [DGT1KX].
48 D275A-5R
Failure code [B@CHZG] HSS charge oil pressure reduction 1

Action code Failure code HSS charge oil pressure reduction
Trouble
— B@CHZG (Mechanical system)
Contents of • While engine was running, HSS charge oil pressure decreased and HSS charge oil pressure cau-
trouble tion lamp blinked.
Action of
controller
Problem that
machine
Failure code [B@CHZK] Power train oil level reduction 1

Action code Failure code Power train oil level reduction
Trouble
— B@CHZK (Mechanical system)
Contents of
• Power train oil level caution lamp turned on during engine is running.
trouble
Action of
controller
Problem that
machine
D275A-5R 49
Failure code [B@GAZK] Battery electrolyte level reduction 1

Action code Failure code Battery electrolyte level reduction
Trouble
— B@GAZK (Mechanical system)
Contents of
• Battery electrolyte level reduce and battery electrolyte level reduction lamp blinked.
trouble
Action of
controller
Problem that
machine
Failure code [B@HANS] Hyd oil overheat 1

Action code Failure code Hyd oil overheat
Trouble
— B@HANS (Mechanical system)
Contents of • While engine was running, hydraulic oil overheated and hydraulic oil temperature caution lamp
trouble blinked.
Action of
controller
Problem that
appears on • If machine is used as it is, work equipment and HSS circuit components may be damaged.
machine
• Hydraulic oil temperature can be checked with real-time monitoring mode.
Related (Code: 04401 Hyd oil temperature)
information • Method of reproducing failure code: Start engine.
• Hydraulic oil temperature caution lamp on machine monitor blinks and this failure code is recorded.

Possible causes Overheated hydraulic oil Check hydraulic oil for overheating. If it is overheated, remove
1
and standard (When system is normal) cause.
value in normal If cause 1 is not detected, hydraulic oil temperature gauge system
state Defective hydraulic oil tem-
2 may be defective. Carry out troubleshooting for "E-13 The hydrau-
perature gauge system
lic oil temperature gauge does not indicate normally" in E mode.
50 D275A-5R
Failure code [B@HAZK] Hydraulic oil level reduction 1

Action code Failure code Hydraulic oil level reduction
Trouble
— B@HAZK (Mechanical system)
Contents of
• While engine was running, hydraulic oil level reduce and hydraulic oil level caution lamp blinked.
trouble
Action of
controller
Problem that
machine
D275A-5R 51
D275A-5R Bulldozer
© 2008 KOMATSU
All Rights Reserved
52 D275A-5R
SEN02759-01
D275A-5R

D275A-5R 35001 and up
codes, Part 2
Failure code [CA111] EMC critical internal failure ........................................................................................... 4
Failure code [CA115] Eng Ne and Bkup speed sens error ............................................................................. 6
Failure code [CA122] Chg air (boost) press sensor high error ....................................................................... 8
Failure code [CA123] Chg air (boost) press sensor low error....................................................................... 10
Failure code [CA131] Throttle sensor high error........................................................................................... 12
Failure code [CA132] Throttle sensor low error ............................................................................................ 14
Failure code [CA135] End oil press sensor high error .................................................................................. 16
Failure code [CA141] Eng oil press sensor low error.................................................................................... 18
Failure code [CA144] Coolant temp sens high error..................................................................................... 20
Failure code [CA145] Coolant temp sens low error ...................................................................................... 22
Failure code [CA153] Chg air (boost) temp sensor high error ...................................................................... 24
Failure code [CA154] Chg air (boost) temp sensor low error........................................................................ 26
Failure code [CA187] Sens supply 2 volt low error ....................................................................................... 26
Failure code [CA221] Ambient press sens high error ................................................................................... 28
D275A-5R 1
Failure code [CA222] Ambient press sens low error..................................................................................... 30

Failure code [CA227] Sens supply 2 volt high error...................................................................................... 32
Failure code [CA234] Eng overspeed ........................................................................................................... 34
Failure code [CA238] Ne speed sens supply volt error................................................................................. 36
Failure code [CA263] Fuel temp sensor high error ....................................................................................... 38
Failure code [CA265] Fuel temp sensor low error......................................................................................... 40
Failure code [CA271] PCV1 short error ........................................................................................................ 41
Failure code [CA272] PCV1 open error ........................................................................................................ 42
Failure code [CA273] PCV2 short error ........................................................................................................ 43
Failure code [CA274] PCV2 open error ........................................................................................................ 44
Failure code [CA322] Inj #1 open/short error ................................................................................................ 45
Failure code [CA342] Calibration code incompatibility.................................................................................. 51
Failure code [CA351] Injectors drive circuit error .......................................................................................... 52
Failure code [CA352] Sens supply 1 volt low error ....................................................................................... 54
Failure code [CA386] Sens supply 1 volt high error...................................................................................... 56
Failure code [CA441] Battery voltage low error ............................................................................................ 58
Failure code [CA442] Battery voltage high error ........................................................................................... 58
Failure code [CA449] Rail press very high error ........................................................................................... 59
Failure code [CA451] Rail press sensor high error ....................................................................................... 60
Failure code [CA452] Rail press sensor low error......................................................................................... 62
Failure code [CA553] Rail press high error ................................................................................................... 62
Failure code [CA554] Rail press sensor in range error ................................................................................. 63
Failure code [CA559] No-pressure feed by supply pump 1 .......................................................................... 64
Failure code [CA689] Eng Ne speed sensor error ........................................................................................ 68
2 D275A-5R
D275A-5R 3
Failure code [CA111] EMC critical internal failure 1

Action code Failure code EMC critical internal failure
Trouble
CALL E04 CA111 (Engine controller system)
Contents of
• Trouble occurred in engine controller.
trouble
Action of
controller
Problem that
appears on • Engine runs normally but may stop during operation or may not be able to start.
machine
Related • Source voltage of engine controller can be checked with real-time monitoring mode.
information (Code: 03203 Engine controller power supply voltage)

Defective circuit breaker If circuit breaker is turned OFF, circuit probably has ground fault.
1
(CB7) (See cause 3.)
ing without turning starting switch ON.
Disconnection in wiring har- Wiring harness between EGC3 (female) (3), Resis-
Max. 1 z
ness (Disconnection in wiring (4) – CB7 (B7L) tance
2
or defective contact in con- Wiring harness between CB7 (B7S) – termi- Resis-
nector) Max. 1 z
nal BRB tance
Wiring harness between EGC3 (female) (1), Resis-
Max. 1 z
(2) – chassis ground (GND11) tance
Possible causes
and standard
value in normal
state Wiring harness between EGC3 (female) (3), Resis-
Min. 1 Mz
Ground fault in wiring har- (4) – CB7 (B7L) and chassis ground tance
3 ness (Contact with ground Wiring harness between CB7 (B7S) – termi- Resis-
circuit) Min. 1 Mz
nal BRB and chassis ground tance
Wiring harness between EGC3 (female) (1),
Resis-
(2) – chassis ground (GND11) and chassis Min. 1 Mz
tance
ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
4 Defective engine controller EGC3 Starting switch Voltage
Between (3), (4) –
ON 20 – 30 V
(1), (2)
4 D275A-5R
D275A-5R 5
Failure code [CA115] Eng Ne and Bkup speed sens error 1

Action code Failure code Eng Ne and Bkup speed sens error
Trouble
Contents of
• Trouble occurred in Ne speed sensor circuit and Bkup speed sensor circuit simultaneously.
trouble
Action of
controller
Problem that
• Engine cannot be started (if engine has been stopped).
appears on
• Engine stops (if engine has been running).
machine
Related
information

Defective Ne speed sensor Ne speed sensor system may be defective. Carry out trouble-
1
system shooting for code [CA689].
Defective Bkup speed sen- Bkup speed sensor system may be defective. Carry out trouble-
2
sor system shooting for code [CA778].
Possible causes Defective mount of Ne speed Check mount of Ne speed sensor directly for defect (defective
3
and standard sensor installation of sensor, internal trouble of flywheel, etc.)
value in normal Defective mount of Bkup Check mount of Bkup speed sensor directly for defect (defective
state 4
speed sensor installation of sensor, internal trouble of supply pump, etc.)
Defective connection (Wrong Check Ne speed sensor and Bkup speed sensor directly for defec-
5
connection) of sensor tive connection (wrong connection).
If causes 1 – 5 are not detected, engine controller may be defec-
6 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
6 D275A-5R
D275A-5R 7
Failure code [CA122] Chg air (boost) press sensor high error 1
Action code Failure code Chg air (boost) press sensor high error
Trouble
Contents of
• Signal voltage in charge (boost) pressure sensor circuit is abnormally high.
trouble
Action of
• Fixes charge (boost) pressure (400 kPa {4.08 kg/cm2}) and continues operation.
controller
Problem that
appears on • Acceleration performance of engine lowers or black smoke is produced more during acceleration.
machine
Related • State of charge pressure sensor can be checked with real-time monitoring mode.
information (Code: 36500 Boost pressure)

Defective sensor power sup- If code [CA187] or [CA227] is indicated, carry out troubleshooting
1
ply system for it first.
or start engine and carry out troubleshooting.
Defective charge (boost) PIM Voltage
2 pressure sensor (Internal Between (1) – (3) Power supply 4.75 – 5.25 V
trouble)
Pressure sensor voltage is measured with wiring harness con-
nected. Accordingly, if voltage is abnormal, check wiring harness
and controller, too, for another cause of trouble, and then judge.
Disconnection in wiring har- Wiring harness between EGC1 (female) Resis-
Max. 1 z
ness (Disconnection in wiring (37) – PIM (female) (1) tance
3
or defective contact in con- Wiring harness between EGC1 (female) Resis-
nector) Max. 1 z
(47) – PIM (female) (3) tance
Wiring harness between EGC1 (female) Resis-
Max. 1 z
(44) – PIM (female) (2) tance
Possible causes a Prepare with starting switch OFF, then carry out troubleshoot-
and standard ing without turning starting switch ON.
value in normal Wiring harness between EGC1 (female) Resis-
Ground fault in wiring har- Min. 1 Mz
state (37) – PIM (female) (1) and chassis ground tance
4 ness (Contact with ground
circuit) Wiring harness between EGC1 (female) Resis-
Min. 1 Mz
(47) – PIM (female) (3) and chassis ground tance
Min. 1 Mz
(44) – PIM (female) (2) and chassis ground tance
Wiring harness between EGC1 (female)
Resis-
(37) – PIM (female) (1) and between EGC1 Min. 1 Mz
tance
Short circuit in wiring har- (female) (47) – PIM (female) (3)
5 ness (with another wiring Wiring harness between EGC1 (female)
harness) Resis-
tance
(female) (44) – PIM (female) (2)
Chassis ground between EGC1 (female)
Resis-
tance
(female) (44) – PIM (female) (2)
6 Defective engine controller
EGC1 Voltage
Between (37) – (47) Power supply 4.75 – 5.25 V
8 D275A-5R
D275A-5R 9
Failure code [CA123] Chg air (boost) press sensor low error 1
Action code Failure code Chg air (boost) press sensor low error
Trouble
Contents of
• Signal voltage in charge (boost) pressure sensor circuit is abnormally low.
trouble
Action of
• Fixes charge (boost) pressure (400 kPa {4.08 kg/cm2}) and continues operation.
controller
Problem that
appears on • Acceleration performance of engine lowers or black smoke is produced more during acceleration.
machine
Related • State of charge pressure sensor can be checked with real-time monitoring mode.
information (Code: 36500 Boost pressure)

and standard
value in normal Carry out troubleshooting for failure code [CA122].
state
10 D275A-5R
D275A-5R 11
Failure code [CA131] Throttle sensor high error 1

Action code Failure code Throttle sensor high error
Trouble
Contents of
• Signal voltage in decelerator pedal potentiometer circuit is abnormally high.
trouble
Action of
• Sets throttle position with fuel control dial signal and continues operation.
controller
Problem that
appears on • Engine speed may not be controlled.
machine
Related • State of decelerator pedal optimum operation range signal can be checked with real-time monitor-
information ing mode. (Code: 31703 Decelerator potentiometer voltage)

Defective sensor power sup- If code [CA2185] or [CA2186] is indicated, carry out troubleshoot-
1
ply system ing for it first.
Defective fuel control dial DCL (male) Resistance

2
(Internal trouble) Between (B) – (C) 1.5 – 2.5 kz
Between (A) – (B) 0 – 3 kz
Between (A) – (C) 0 – 3 kz
Disconnection in wiring har- Wiring harness between EGC2 (female) (9) Resis-
Max. 1 z
ness (Disconnection in wiring – DCL (female) (A) tance
3
Possible causes or defective contact in con- Wiring harness between EGC2 (female) Resis-
nector) Max. 1 z
and standard (22) – DCL (female) (B) tance
state Max. 1 z
(23) – DCL (female) (C) tance
Wiring harness between EGC2 (female) (9) Resis-
– DCL (female) (A) and chassis ground tance
Min. 1 Mz
(22) – DCL (female) (B) and chassis ground tance
Min. 1 Mz
(23) – DCL (female) (C) and chassis ground tance
5 Defective engine controller EGC2 Voltage
Between (9) – (23) Signal 0.5 – 4.5 V
12 D275A-5R
D275A-5R 13
Failure code [CA132] Throttle sensor low error 1

Action code Failure code Throttle sensor low error
Trouble
Contents of
• Signal voltage in decelerator pedal potentiometer circuit is abnormally low.
trouble
Action of
• Sets throttle position with fuel control dial signal and continues operation.
controller
Problem that
machine
Related • State of decelerator pedal optimum operation range signal can be checked with real-time monitor-
information ing mode. (Code: 31703 Decelerator potentiometer voltage)

and standard
state
14 D275A-5R
D275A-5R 15
Failure code [CA135] End oil press sensor high error 1

Action code Failure code End oil press sensor high error
Trouble
E02 CA135 (Engine controller system)
Contents of
• Signal voltage in engine oil pressure sensor circuit is abnormally high.
trouble
Action of
• Sets engine oil pressure to default value (250 {2.55 kg/cm2}) and continues operation.
controller
Problem that
appears on • Starting performance of the engine lowers during low temperature.
machine
Related • State of engine oil pressure sensor can be checked with real-time monitoring mode.
information (Code: 37201 End oil press sense volt)

1
POIL Voltage
Defective engine oil pressure
2 Between (1) – (2) Power supply 4.75 –5.25 V
sensor (Internal trouble)
Sensor voltage is measured with wiring harness connected.
Accordingly, if voltage is abnormal, check wiring harness and con-
troller, too, for another cause of trouble, and then judge.
Max. 1 z
ness (Disconnection in wiring (37) – POIL (female) (1) tance
3
nector) Max. 1 z
(47) – POIL (female) (2) tance
Max. 1 z
(13) – POIL (female) (3) tance
and standard
state (37) – POIL (female) (1) and chassis ground tance
Min. 1 Mz
(47) – POIL (female) (2) and chassis ground tance
Min. 1 Mz
(13) – POIL (female) (3) and chassis ground tance
Resis-
(37) – POIL (female) (1) and between EGC1 Min. 1 Mz
tance
Short circuit in wiring har- (female) (47) – POIL (female) (2)
harness) Resis-
tance
(female) (13) – POIL (female) (3)
Resis-
tance
(female) (13) – POIL (female) (3)
EGC1 Voltage
16 D275A-5R
D275A-5R 17
Failure code [CA141] Eng oil press sensor low error 1

Action code Failure code Eng oil press sensor low error
Trouble
Contents of
• Signal voltage in engine oil pressure sensor circuit is abnormally low.
trouble
Action of
• Sets engine oil pressure to default value (250 kPa {2.55 kg/cm2}) and continues operation.
controller
Problem that
appears on • Starting performance of the engine lowers during low temperature.
machine
Related • State of engine oil pressure sensor can be checked with real-time monitoring mode.
information (Code: 37201 Eng oil press sens volt)

and standard
state
18 D275A-5R
D275A-5R 19
Failure code [CA144] Coolant temp sens high error 1

Action code Failure code Coolant temp sens high error
Trouble
Contents of
• Signal voltage in engine coolant temperature sensor circuit is abnormally high.
trouble
Action of
• Fixes engine coolant temperature (90°C) and continues operation.
controller
Problem that
appears on • Startability of engine lowers at low temperature.
machine
Related • State of engine coolant temperature sensor can be checked with real-time monitoring mode.
information (Code: 04105 Coolant temp sens volt)

TWTR (male) Coolant temperature Resistance
Defective engine coolant 0°C 30 – 37 kz
1 temperature sensor (Internal
25°C 9.3 – 10.7 kz
trouble)
Between (A) – (B) 50°C 3.2 – 3.8 kz
80°C 1.0 – 1.3 kz
95°C 700 – 800 z
ness (Disconnection in wiring Wiring harness between EGC1 (female) Resis-
2 Max. 1 z
Possible causes or defective contact in con- (15) – TWTR (female) (A) tance
and standard nector) Wiring harness between EGC1 (female) Resis-
value in normal Max. 1 z
(38) – TWTR (female) (B) tance
state
Ground fault in wiring har- ing without turning starting switch ON.
3 ness (Contact with ground Wiring harness between EGC1 (female)
circuit) Resis-
(15) – TWTR (female) (A) and chassis Min. 1 Mz
tance
ground
EGC1 (female) Coolant temperature Resistance
0°C 30 – 37 kz
25°C 9.3 – 10.7 kz
Between (15) – (38) 50°C 3.2 – 3.8 kz
80°C 1.0 – 1.3 kz
95°C 700 – 800 z
20 D275A-5R
D275A-5R 21
Failure code [CA145] Coolant temp sens low error 1

Action code Failure code Coolant temp sens low error
Trouble
Contents of
• Signal voltage in engine coolant temperature sensor circuit is abnormally low.
trouble
Action of
• Fixes engine coolant temperature (90°C) and continues operation.
controller
Problem that
machine
Related • State of engine coolant temperature sensor can be checked with real-time monitoring mode.
information (Code: 04105 Coolant temp sens volt)

and standard
state
22 D275A-5R
D275A-5R 23
Failure code [CA153] Chg air (boost) temp sensor high error 1
Action code Failure code Chg air (boost) temp sensor high error
Trouble
Contents of
• Signal voltage in charge (boost) temperature sensor circuit is abnormally high.
trouble
Action of
• Fixes charge (boost) temperature (intake air temperature) (70°C) and continues operation.
controller
Problem that
machine
Related • State of charge temperature sensor signal can be checked with real-time monitoring mode.
information (Code: 18501 Boost temperature sensor voltage)

Intake air
TIM (male) Resistance
temperature
Defective charge (boost) 0°C 29 – 36 kz
1 temperature sensor (Internal
25°C 9 – 11 kz
trouble) Between (A) – (B)
40°C 4.9 – 5.8 kz
100°C 600 – 700 z
Between (A) –
All range Min. 1 Mz
chassis ground
Possible causes
and standard 2 Max. 1 z
or defective contact in con- (23) – TIM (female) (A) tance
value in normal
nector) Wiring harness between EGC1 (female) Resis-
state Max. 1 z
(47) – TIM (female) (B) tance
Min. 1 Mz
(23) – TIM (female) (A) and chassis ground tance
Intake air
EGC1 (female) Resistance
temperature
4 Defective engine controller 0°C 29 – 36 kz
25°C 9 – 11 kz
Between (23) – (47)
40°C 4.9 – 5.8 kz
100°C 600 – 700 z
24 D275A-5R
D275A-5R 25
Failure code [CA154] Chg air (boost) temp sensor low error 1
Action code Failure code Chg air (boost) temp sensor low error
Trouble
Contents of
• Signal voltage in charge (boost) temperature sensor circuit is abnormally low.
trouble
Action of
• Fixes charge (boost) temperature (intake air temperature) (70°C) and continues operation.
controller
Problem that
machine
Related • State of charge temperature sensor signal can be checked with real-time monitoring mode.
information (Code: 18501 Boost temperature sensor voltage)

and standard
state
Failure code [CA187] Sens supply 2 volt low error 1

Action code Failure code Sens supply 2 volt low error
Trouble
Contents of
• Signal voltage in sensor power supply 2 (5 V) circuit is abnormally low.
trouble
• Operates Bkup speed sensor with signals of Ne speed sensor.
Action of • Sets oil pressure sensor to default value (250 kPa {2.55 kg/cm2}) and continues operation.
controller • Sets ambient pressure sensor to default value (52.44 kPa {0.53 kg/cm2}) and continues operation.
• Fixes charge (boost) pressure sensor value (400 kPa {4.08 kg/cm2}) and continues operation.
Problem that
appears on • Engine output drops.
machine
Related
information

and standard
state
26 D275A-5R
D275A-5R 27
Failure code [CA221] Ambient press sens high error 1

Action code Failure code Ambient press sens high error
Trouble
Contents of
• Signal voltage in ambient pressure sensor circuit is abnormally high.
trouble
Action of
• Sets ambient pressure to default value (52.44 kPa {0.53 kg/cm2}) and continues operation.
controller
Problem that
machine
Related • State of ambient pressure sensor signal can be checked with real-time monitoring mode.
information (Code: 37401 Ambient press sens volt)

1
PAMB Voltage
Defective ambient pressure Between (1) – (3) Power supply 4.75 – 5.25 V
2
sensor (Internal trouble) Between (2) – (3) Signal 0.3 – 4.7 V
Max. 1 z
ness (Disconnection in wiring (37) – PAMB (female) (1) tance
3
nector) Max. 1 z
(38) – PAMB (female) (3) tance
Max. 1 z
– PAMB (female) (2) tance
Possible causes
and standard
value in normal Wiring harness between EGC1 (female) (37) Resis-
state – PAMB (female) (1) and chassis ground tance
circuit) Wiring harness between EGC1 (female) (38) Resis-
Min. 1 Mz
– PAMB (female) (3) and chassis ground tance
Min. 1 Mz
– PAMB (female) (2) and chassis ground tance
Resis-
(37) – PAMB (female) (1) and between Min. 1 Mz
tance
Short circuit in wiring har- EGC1 (female) (38) - PAMB (female) (3)
harness) Resis-
tance
EGC1 (female) (3) – PAMB (female) (2)
Resis-
tance
EGC1 (female) (3) – PAMB (female) (2)
a repare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.
6 Defective engine controller EGC1 Voltage
Between (37) – (38) 4.75 – 5.25 V
Between (3) – (38) 0.3 – 4.7 V
28 D275A-5R
D275A-5R 29
Failure code [CA222] Ambient press sens low error 1

Action code Failure code Ambient press sens low error
Trouble
Contents of
• Signal voltage in ambient pressure sensor circuit is abnormally low.
trouble
Action of
• Sets ambient pressure to default value (52.44 kPa {0.53 kg/cm2}) and continues operation.
controller
Problem that
machine
Related • State of ambient pressure sensor signal can be checked with real-time monitoring mode.
information (Code: 37401 Ambient press sens volt)

and standard
state
30 D275A-5R
D275A-5R 31
Failure code [CA227] Sens supply 2 volt high error 1

Action code Failure code Sens supply 2 volt high error
Trouble
Contents of
• Signal voltage in sensor power supply 2 (5 V) circuit is abnormally high.
trouble
• Operates Bkup speed sensor with signals of Ne speed sensor.
Action of • Sets oil pressure sensor to default value (250 kPa [2.55 kg/cm2}) and continues operation.
controller • Sets ambient pressure to default value (52.44 kPa {0.53 kg/cm2}) and continues operation.
• Fixes charge (boost) pressure sensor value (400 kPa [4.08 kg/cm2}) and continues operation.
Problem that
machine
Related
information

1 Defective related system If another failure code is indicated, carry out troubleshooting for it.
Bkup speed sensor G connector
Disconnect devices
at right in order. If Oil pressure sensor POIL connector
Defective sensor (Internal
2 "E" of failure code Ambient pressure
trouble) PAMB connector
disappears when a sensor
device is discon- Charge (boost)
nected, that device PIM connector
pressure sensor
has trouble in it.
Resistor RES connector
3 Max. 1 z
or defective contact in con- (37) – each sensor (female) tance
Possible causes nector) Wiring harness between EGC1 (female) Resis-
and standard Max. 1 z
(47) – each sensor (female) tance
value in normal
state
Ground fault in wiring har- Resis-
(37) – each sensor (female) and chassis Min. 1 Mz
4 ness (Contact with ground tance
ground
circuit)
Resis-
(47) – each sensor (female) and chassis Min. 1 Mz
tance
ground
Short circuit in wiring har- ing without turning starting switch ON.
harness) Resis-
(37) – each sensor (female) and between Min. 1 Mz
tance
EGC1 (female) (47) – each sensor (female)
EGC1 Voltage
Between (37) – (47) 4.75 – 5.25 V
32 D275A-5R
D275A-5R 33
Failure code [CA234] Eng overspeed 1

Action code Failure code Eng overspeed
Trouble
— CA234 (Engine controller system)
Contents of
• Engine speed is above operating range.
trouble
Action of
• Limits fuel injection rate until engine speed lowers to operating range.
controller
Problem that
appears on • Engine speed fluctuates.
machine
Related • Engine speed can be checked with real-time monitoring mode.
information (Code: 01000 Engine speed)

Possible causes
and standard Way of use of machine may be improper. Teach proper way of use
2 Improper way of use
value in normal to operator.
state If causes 1 – 2 are not detected, engine controller may be defec-
out.)
34 D275A-5R
D275A-5R 35
Failure code [CA238] Ne speed sens supply volt error 1

Action code Failure code Ne speed sens supply volt error
Trouble
Contents of
• Trouble occurred in Ne speed sensor power supply (5 V) circuit.
trouble
Action of
• Controls Ne speed sensor with signals of Bkup speed sensor.
controller
Problem that
• Running engine stops (when Bkup speed sensor is also abnormal).
appears on
• Stopped engine cannot be started (when Bkup speed sensor is also abnormal).
machine
Related
information

Disconnect devices
Defective Ne speed sensor at right in order. If
1 "E" of failure code
(Internal trouble) Engine Ne
disappears when a NE connector
speed sensor
device is discon-
nected, that device
has trouble in it.
2 Max. 1 z
or defective contact in con- (16) – NE (female) (1) tance
Possible causes
Max. 1 z
and standard (48) – NE (female) (2) tance
value in normal a Prepare with starting switch OFF, then carry out troubleshoot-
state ing without turning starting switch ON.
Ground fault in wiring har-
3 ness (Contact with ground Min. 1 Mz
(16) – NE (female) (1) and chassis ground tance
circuit)
Min. 1 Mz
harness) Resis-
(16) – NE (female) (1) and between EGC1 Min. 1 Mz
tance
(female) (48) – NE (female) (2)
EGC1 Voltage
Between (16) – (48) 4.75 – 5.25 V
36 D275A-5R
D275A-5R 37
Failure code [CA263] Fuel temp sensor high error 1

Action code Failure code Fuel temp sensor high error
Trouble
Contents of
• Signal voltage in fuel temperature sensor circuit is abnormally high.
trouble
Action of
• Fixes fuel temperature (90 °C) and continues operation.
controller
Problem that
appears on
machine
Related • State of fuel temperature sensor signal can be checked with real-time monitoring mode.
information (Code: 14201 Fuel temp sens volt)

TFUEL (male) Fuel temperature Resistance
Defective fuel temperature 0°C 30 – 37 kz

1
sensor (Internal trouble) 25°C 9.3 – 10.7 kz
Between (A) – (B) 50°C 3.2 – 3.8 kz
80°C 1.0 – 1.3 kz
95°C 700 – 800 z
Possible causes 2 Max. 1 z
or defective contact in con- (30) – TFUEL (female) (A) tance
and standard nector)
Max. 1 z
state (47) – TFUEL (female) (B) tance
Min. 1 Mz
– TFUEL (female) (A) and chassis ground tance
EGC1 (female) Fuel temperature Resistance
0°C 30 – 37 kz
25°C 9.3 – 10.7 kz
Between (30) – (47) 50°C 3.2 – 3.8 kz
80°C 1.0 – 1.3 kz
95°C 700 – 800 z
38 D275A-5R
D275A-5R 39
Failure code [CA265] Fuel temp sensor low error 1

Action code Failure code Fuel temp sensor low error
Trouble
Contents of
• Signal voltage in fuel temperature sensor circuit is abnormally low.
trouble
Action of
• Fixes fuel temperature (90°C) and continues operation.
controller
Problem that
appears on
machine
Related
information

and standard
state
40 D275A-5R
Failure code [CA271] PCV1 short error 1

Action code Failure code PCV1 short error
Trouble
Contents of
• There is short circuit in PCV1 circuit of supply pump.
trouble
Action of
controller
Problem that
appears on
machine
Related • While engine is running normally, pulse voltage of about 24 V is applied to PCV1 (1). This pulse
information voltage cannot be measured with circuit tester.

Defective supply pump PCV1 (male) Resistance
1
PCV1 (Internal short circuit) Between (1) – (2) 2.3 – 5.3 z
Between (1), (2) –
Min. 1 Mz
chassis ground
– PCV1 (female) (1) and chassis ground tance
circuit)
Possible causes
and standard Min. 1 Mz
value in normal
state a Prepare with starting switch OFF, then turn starting switch ON
Hot short (Short circuit with Wiring harness between EGC1 (female) (4)
3 Voltage Max. 1 V
24V circuit) in wiring harness – PCV1 (female) (1) and chassis ground
Wiring harness between EGC1 (female) (5)
Voltage Max. 1 V
– PCV1 (female) (2) and chassis ground
Between (4) – (5) 2.3 – 5.3 z
Between (4), (5) –
Min. 1 Mz
chassis ground
D275A-5R 41
Failure code [CA272] PCV1 open error 1

Action code Failure code PCV1 open error
Trouble
Contents of
• There is disconnection in PCV1 circuit of supply pump.
trouble
Action of
controller
Problem that
appears on
machine

1 PCV1 (Internal disconnec-
tion) Between (1) – (2) 2.3 – 5.3 z
Between (1), (2) –
Min. 1 Mz
chassis ground
Disconnection in wiring har-
ness (Disconnection in wiring Wiring harness between EGC1 (female) (4) Resis-
2 Max. 1 z
or defective contact in con- – PCV1 (female) (1) tance
Possible causes nector)
– PCV1 (female) (2) tance
value in normal
state a Prepare with starting switch OFF, then carry out troubleshoot-
circuit)
Min. 1 Mz
Between (4) – (5) 2.3 – 5.3 z
Between (4), (5) –
Min. 1 Mz
chassis ground
42 D275A-5R
Failure code [CA273] PCV2 short error 1

Action code Failure code PCV2 short error
Trouble
Contents of
• There is short circuit in PCV2 circuit of supply pump.
trouble
Action of
controller
Problem that
appears on
machine

1
PCV2 (Internal short circuit) Between (1) – (2) 2.3 – 5.3 z
Between (1), (2) –
Min. 1 Mz
chassis ground
circuit)
Possible causes
and standard Min. 1 Mz
value in normal
Hot short (Short circuit with Wiring harness between EGC1 (female) (9)
3 Voltage Max. 1 V
24V circuit) in wiring harness – PCV2 (female) (1) and chassis ground
Wiring harness between EGC1 (female) (10)
Voltage Max. 1 V
– PCV2 (female) (2) and chassis ground
Between (9) – (10) 2.3 – 5.3 z
Between (9), (10) –
Min. 1 Mz
chassis ground
D275A-5R 43
Failure code [CA274] PCV2 open error 1

Action code Failure code PCV2 open error
Trouble
Contents of
• There is disconnection in PCV2 circuit of supply pump.
trouble
Action of
controller
Problem that
appears on
machine

1 PCV2 (Internal disconnec-
tion) Between (1) – (2) 2.3 – 5.3 z
Between (1), (2) –
Min. 1 Mz
chassis ground
ness (Disconnection in wiring Wiring harness between EGC1 (female) (9) Resis-
2 Max. 1 z
or defective contact in con- – PCV2 (female) (1) tance
(10) – PCV2 (female) (2) tance
value in normal
circuit)
Min. 1 Mz
Between (9) – (10) 2.3 – 5.3 z
Between (9), (10) –
Min. 1 Mz
chassis ground
44 D275A-5R
Failure code [CA322] Inj #1 open/short error 1

Action code Failure code Inj #1 open/short error
Trouble
Contents of
• There is disconnection or short circuit in injector #1 circuit.
trouble
Action of
controller
Problem that
• Output drops.
appears on
• Rotation is unstable.
machine
Related • While engine is running, pulse voltage of about 65 V is applied to PCV1 (1) (if normal) and it cannot
information be measured with circuit tester.

Defective injector #1 (Inter- CN1 (male) Resistance
1
nal trouble) Between (1) – (2) 0.4 – 1.1 z
Between (1), (2) –
Min. 1 Mz
chassis ground
2 Max. 1 z
or defective contact in con- (45) – CN1 (female) (1) tance
(53) – CN1 (female) (2) tance
value in normal
(45) – CN1 (female) (1) and chassis ground tance
circuit)
Min. 1 Mz
Between (45) – (53) 0.4 – 1.1 z
Between (45), (53) –
Min. 1 Mz
chassis ground
D275A-5R 45

Trouble
Contents of
trouble
Action of
controller
Problem that
• Output drops.
appears on
machine

1
Between (1), (2) –
Min. 1 Mz
chassis ground
2 Max. 1 z
value in normal
circuit)
Min. 1 Mz
Between (46) – (60) 0.4 – 1.1 z
Between (46), (60) –
Min. 1 Mz
chassis ground
46 D275A-5R

Trouble
Contents of
trouble
Action of
controller
Problem that
• Output drops.
appears on
machine

1
Between (1), (2) –
Min. 1 Mz
chassis ground
2 Max. 1 z
value in normal
circuit)
Min. 1 Mz
Between (55) – (52) 0.4 – 1.1 z
Between (55), (52) –
Min. 1 Mz
chassis ground
D275A-5R 47

Trouble
Contents of
trouble
Action of
controller
Problem that
• Output drops.
appears on
machine

1
Between (1), (2) –
Min. 1 Mz
chassis ground
2 Max. 1 z
value in normal
circuit)
Min. 1 Mz
Between (57) – (59) 0.4 – 1.1 z
Between (57), (59) –
Min. 1 Mz
chassis ground
48 D275A-5R

Trouble
Contents of
trouble
Action of
controller
Problem that
• Output drops.
appears on
machine

1
Between (1), (2) –
Min. 1 Mz
chassis ground
2 Max. 1 z
value in normal
circuit)
Min. 1 Mz
Between (54) – (51) 0.4 – 1.1 z
Between (54), (51) –
Min. 1 Mz
chassis ground
D275A-5R 49

Trouble
Contents of
trouble
Action of
controller
Problem that
• Output drops.
appears on
machine

1
Between (1), (2) –
Min. 1 Mz
chassis ground
2 Max. 1 z
value in normal
circuit)
Min. 1 Mz
Between (56) – (58) 0.4 – 1.1 z
Between (56), (58) –
Min. 1 Mz
chassis ground
50 D275A-5R
Failure code [CA342] Calibration code incompatibility 1

Action code Failure code Calibration code incompatibility
Trouble
Contents of
• Incompatibility occurred in engine controller data.
trouble
Action of
controller
Problem that
appears on • Engine continues operation normally, but it may stop during operation or may not be able to start.
machine
Related
information

and standard
state
D275A-5R 51
Failure code [CA351] Injectors drive circuit error 1

Action code Failure code Injectors drive circuit error
Trouble
Contents of
• Trouble occurred in injector drive circuit.
trouble
Action of
• Limits engine output and continues operation (Limits common rail pressure).
controller
Problem that
machine

If another failure code (failure code of trouble in injector system) is
1 Defective related system
indicated, carry out troubleshooting for it.
Defective circuit breaker If circuit breaker is turned OFF, circuit probably has ground fault
2
(CB30 or CB8) (See cause 4).
Disconnection in wiring har- Wiring harness between EGC3 (female) (3), Resis-
Max. 1 z
ness (Disconnection in wiring (4) – CB7 (B7L) tance
3
or defective contact in con- Wiring harness between CB7 (B7S) – termi- Resis-
nector) Max. 1 z
nal BRB tance
Possible causes Wiring harness between EGC3 (female) (1), Resis-
Max. 1 z
and standard (2) – chassis ground (GND11) tance
Wiring harness between EGC3 (female) (3), Resis-
Min. 1 Mz
Ground fault in wiring har- (4) – CB8 (2) and chassis ground tance
4 ness (Contact with ground Wiring harness between CB7 (B7S) – termi- Resis-
circuit) Min. 1 Mz
nal BRB and chassis ground tance
Wiring harness between EGC3 (female) (1),
Resis-
(2) – chassis ground (GND11) and chassis Min. 1 Mz
tance
ground
EGC3 Voltage
Between (3), (4) – (1), (2) 20 – 30 V
52 D275A-5R
D275A-5R 53
Failure code [CA352] Sens supply 1 volt low error 1

Action code Failure code Sens supply 1 volt low error
Trouble
Contents of
• Signal voltage in sensor power supply 1 (5 V) circuit of engine controller is abnormally low.
trouble
Action of
• Limits common rail pressure sensor output and continues operation (Limits common rail pressure).
controller
Problem that
machine
Related
information

and standard
state
54 D275A-5R
D275A-5R 55
Failure code [CA386] Sens supply 1 volt high error 1

Action code Failure code Sens supply 1 volt high error
Trouble
Contents of
• Signal voltage in sensor power supply 1 (5 V) engine controller circuit is abnormally high.
trouble
Action of
• Limits common rail pressure sensor output and continues operation (Limits common rail pressure).
controller
Problem that
machine
Related
information

Disconnect devices
Defective sensor (Internal at right in order. If
trouble) Common rail
disappears when a PFUEL connector
pressure sensor
device is discon-
nected, that device
has trouble in it.
3 Max. 1 z
or defective contact in con- (33) – PFUEL (female) (1) tance
Possible causes Max. 1 z
and standard (47) – PFUEL (female) (3) tance
Ground fault in wiring har- Resis-
(33) – PFUEL (female) (1) and chassis Min. 1 Mz
ground
circuit)
Resis-
(47) – PFUEL (female) (3) and chassis Min. 1 Mz
tance
ground
harness) Resis-
(33) – PFUEL (female) (1) and between Min. 1 Mz
tance
EGC1 (female) (47) – PFUEL (female) (3)
EGC1 Voltage
Between (33) – (47) 4.75 – 5.25 V
56 D275A-5R
D275A-5R 57
Failure code [CA441] Battery voltage low error 1

Action code Failure code Battery voltage low error
Trouble
Contents of
• Power supply circuit voltage of engine controller is abnormally low.
trouble
Action of
controller
Problem that
machine

and standard
state
Failure code [CA442] Battery voltage high error 1

Action code Failure code Battery voltage high error
Trouble
Contents of
• Power supply circuit voltage of engine controller is abnormally high.
trouble
Action of
controller
Problem that
machine

and standard
state
58 D275A-5R
Failure code [CA449] Rail press very high error 1

Action code Failure code Rail press very high error
Trouble
Contents of
• Common rail pressure sensor circuit detected abnormally high pressure (level 2).
trouble
Action of
controller
Problem that
machine
Related • Common rail pressure can be checked with real-time monitoring mode.
information (Code: 36400 Rail pressure)

and standard
state
D275A-5R 59
Failure code [CA451] Rail press sensor high error 1

Action code Failure code Rail press sensor high error
Trouble
Contents of
• Signal voltage in common rail pressure sensor circuit is abnormally high.
trouble
Action of
controller
Problem that
machine
Related • State of common rail pressure sensor signal can be checked with real-time monitoring mode.
information (Code: 36401 Rail pressure sens volt)

1
PFUEL Voltage
Defective common rail pres- Between (1) – (3) Power supply 4.75 – 5.25 V
2
sure sensor (Internal trouble) Between (2) – (3) Signal 0.25 – 4.6 V
Max. 1 z
ness (Disconnection in wiring (33) – PFUEL (female) (1) tance
3
nector) Max. 1 z
(25) – PFUEL (female) (2) tance
Possible causes Wiring harness between EGC1 (female) Resis-
(47) – PFUEL (female) (3) tance
value in normal
– PFUEL (female) (1) and chassis ground tance
Min. 1 Mz
Min. 1 Mz
Resis-
tance
Short circuit in wiring har- EGC1 (female) (25) – PFUEL (female) (2)
harness) Resis-
tance
Resis-
tance
60 D275A-5R
Possible causes a Prepare with starting switch OFF, then turn starting switch ON
and standard or start engine and carry out troubleshooting.
value in normal 6 Defective engine controller EGC1 Voltage
state Between (33) – (47) 4.75 – 5.25 V
Between (25) – (47) 0.25 – 4.6 V
D275A-5R 61
Failure code [CA452] Rail press sensor low error 1

Action code Failure code Rail press sensor low error
Trouble
Contents of
• Signal voltage in common rail pressure sensor circuit is abnormally low.
trouble
Action of
controller
Problem that
machine

and standard
state
Failure code [CA553] Rail press high error 1

Action code Failure code Rail press high error
Trouble
Contents of
• Common rail pressure sensor circuit detected abnormally high pressure (level 1).
trouble
Action of
controller
Problem that
machine

2 Use of improper fuel Check fuel used directly (for high viscosity).
Defective electrical system of Common rail pressure sensor may have electric trouble. Carry out
3
Possible causes common rail pressure sensor troubleshooting for failure code [CA451].
and standard Defective mechanical system
value in normal 4 of common rail pressure sen- Check mechanical system of common rail pressure sensor directly.
state sor
Check overflow valve directly for broken spring, worn seat, and
5 Defective overflow valve
stuck ball.
6 Clogging of overflow piping Check overflow piping directly for clogging.
7 Defective pressure limiter Check pressure limiter directly for mechanical defect.
62 D275A-5R
Failure code [CA554] Rail press sensor in range error 1

Action code Failure code Rail press sensor in range error
Trouble
Contents of
• In-range error occurred in common rail pressure sensor circuit.
trouble
Action of
controller
Problem that
machine

and standard
value in normal Carry out troubleshooting for Failure code [CA451].
state
D275A-5R 63
Failure code [CA559] No-pressure feed by supply pump 1 1

Action code Failure code No-pressure feed by supply pump 1
Trouble
Contents of
• Supply pump does not feed fuel (level 1).
trouble
Action of
• Limits common rail pressure.
controller
Problem that
machine

2 Use of improper fuel Check fuel used directly for improper quality.
a For contents of troubleshooting, see "Note 1". For check of
pressure in fuel low-pressure circuit, see Testing and adjusting,
"Testing fuel pressure".
Defective low-pressure cir-
3 Pressure in fuel
cuit device
low-pressure circuit 0.15 – 0.3 MPa
(At high idle or under the load {1.5 – 3.0 kg/cm2}
equivalent to rating (Stalling))
4 Clogging of filter/strainer a For contents of troubleshooting, see "Note 2".
Defective electrical system of Supply pump PCV may have electric trouble. Carry out trouble-
5
supply pump PCV shooting for following codes; [CA271], [CA272], [CA273], [CA274].
Defective common rail pres- Common rail pressure sensor may be defective. Check wiring har-
Possible causes 6
sure sensor ness for damage.
and standard
value in normal a For testing of leakage from pressure limiter, see Testing and
state adjusting, "Measuring fuel return rate and fuel leakage".
7 Defective pressure limiter Leakage from pressure limiter
(Operation equivalent to rated Max. 10 cc/min
operation (under stall load))
a For measuring of return (spill) limit from injector, see Testing
and adjusting, "Measuring fuel return rate and fuel leakage".
Speed in rated operation
Return (Spill) limit from injector
(stall load)
8 Defective injector 1,600 rpm 960 cc/min

1,700 rpm 1,020 cc/min
1,800 rpm 1,080 cc/min
1,900 rpm 1,140 cc/min
2,000 rpm 1,200 cc/min
9 Defective supply pump If causes 1 – 8 are not detected, supply pump may be defective.
<How to use check sheet>

Carry out the above troubleshooting and take a record of the contents of the attached "Check sheet for rail
pressure low error".
64 D275A-5R
Note 1: When low-pressure circuit is defective, check the following:

q Fuel level
q Clogged fuel tank breather
q Water separator/Prefilter filled with water
q Clogged fuel filter
q Clogged screen in water separator
q Stuck or worn feed pump, clogged filter
q Leaked or clogged low-pressure fuel pipe
q Bypass valve malfunction, defective assembly of other parts (See Fig.1.)
q Clogged fuel filter
q Fuel in oil pan (fuel leakage in head cover)
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
q Overflow valve (1): Spring is seen through both holes.
q Bypass valve (2): Spring is seen through hole on nut side.
q Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
q Fuel filter: Replace. (Replace both prefilter and main filter.)
q Water separator: Disassemble and check. If screen (4) is clogged, clean it. (See Fig. 2.)
q Gauze filter: Disassemble and check. Clean, if clogged.
q Upstream strainer of gauze filter: Disassemble and check. Clean, if clogged.
D275A-5R 65
Check sheet for rail pressure low error
Model D275A-5R Work No.

Machine serial No. # Date of check / /
Engine SAA6D140E-5 Service meter h
Engine serial No. # Worker's name
A. Visual check Good NG

1 Fuel leakage to outside
2 Clogging of fuel tank breather
B. Check with machine monitor (02 Fault history, 01 monitoring, and 09 reduced cylinder mode operation) Good NG
3 Check of failure code / / / /
Check of monitoring information
Standard value Measured
Code Displayed item Checking condition ISO unit Good NG
(Reference value) value
Low idle r/min 650 – 750
High idle
01000 Engine speed r/min 2,150 – 2,250
(Decelerator cut mode)
Torque converter stall r/min 1,570 – 1,670
Final accelerator Low idle % 0
31706
position High idle % 100
Final fuel injection
18600 rate command Torque converter stall mg/st — — —
4 (by weight)
Final common rail
36200 Torque converter stall MPa — — —
pressure command
Common rail pres-
36400 Torque converter stall MPa — — —
sure
Low idle CA — — —
Final injection tim-
36300 High idle CA — — —
ing command
Torque converter stall CA — — —
36500 Boost pressure Torque converter stall kPa — — —
Engine coolant tem-
04104 Low idle °C — — —
perature
14200 Fuel temperature Low idle °C — — —
Check of reduced cylinder mode operation (Engine speed)
Setting Reduced cylinder Checking condition ISO unit Good NG
No. 1 cylinder Low idle r/min — — —
5 No. 2 cylinder Low idle r/min — — —
Reduce No. 3 cylinder Low idle r/min — — —
each
cylinder No. 4 cylinder Low idle r/min — — —
66 D275A-5R

C. Check of fuel circuit pressure Checking condition Unit Good NG
At high idle or under the
Fuel low-pressure circuit MPa 0.15 – 0.3
6 load equivalent to rating
pressure {kg/cm2} {1.5 – 3.0}
(Stalling)
D. Check of strainers and filters Good NG

7 Visual check of strainers
8 Visual check of gauze filter
9 Visual check of fuel filter
10 Visual check of bypass valve
E. Check of leakage and Standard value Measured

Checking condition Unit Good NG
return rate (Reference value) value
Leakage through pressure
11 Torque converter stal cc/min Max. 10
limiter
Torque converter stall
cc/min 960
1,600 rpm
cc/min 1,020
1,700 rpm
Torque converter stall Speed:
12 Return rate from injector cc/min 1,080
1,800 rpm Leakage
cc/min 1,140
1,900 rpm
cc/min 1,200
2,000 rpm
D275A-5R 67
Failure code [CA689] Eng Ne speed sensor error 1

Action code Failure code Eng Ne speed sensor error
Trouble
Contents of
• Trouble occurred in engine Ne speed sensor circuit.
trouble
Action of
• Operates with signals of Bkup speed sensor.
controller
Problem that
• Running engine stops (when Bkup speed sensor is also abnormal).
appears on
• Stopped engine cannot be started (when Bkup speed sensor is also abnormal).
machine
Related
information

Defective sensor power sup-
1 If code [CA238] is indicated, carry out troubleshooting for it first.
ply system
Max. 1 z
ness (Disconnection in wiring (16) – NE (female) (1) tance
2
nector) Max. 1 z
(48) – NE (female) (2) tance
Max. 1 z
(27) – NE (female) (3) tance
Min. 1 Mz
Min. 1 Mz
and standard (27) – NE (female) (3) and chassis ground tance
Resis-
tance
Short circuit in wiring har- (female) (48) – NE (female) (2)
harness) Resis-
tance
Resis-
tance
Defective mount of sensor or Check Ne speed sensor directly for defective mount (defective
5 defective rotation sensing clearance) or check rotation sensing part (flywheel) directly for
part defect.
If causes 1 – 5 are not detected, engine Ne speed sensor may be
Defective engine Ne speed
6 defective. (Since trouble is in system, troubleshooting cannot be
sensor
carried out.)
out.)
68 D275A-5R
D275A-5R 69
D275A-5R Bulldozer
© 2008 KOMATSU
All Rights Reserved
70 D275A-5R
SEN02760-00
D275A-5R

D275A-5R 35001 and up
codes, Part 3
Failure code [CA731] Eng Bkup speed sens phase error............................................................................... 3
Failure code [CA757] All continuous data lost error........................................................................................ 3
Failure code [CA778] Eng Bkup speed sensor error ...................................................................................... 4
Failure code [CA1633] KOMNET datalink timeout error ................................................................................. 6
Failure code [CA2185] Throt sens sup volt high error .................................................................................... 8
Failure code [CA2186] Throt sens sup volt low error.................................................................................... 10
Failure code [CA2249] No-pressure feed by supply pump 2 ........................................................................ 10
Failure code [CA2555] Intake air heater relay open error ..............................................................................11
Failure code [CA2556] Intake air heater relay short error ............................................................................. 12
Failure code [D110KA] Battery relay holding disconnection ......................................................................... 14
Failure code [D110KB] Battery relay drive short circuit................................................................................. 16
Failure code [D130KA] Neutral safety relay disconnection........................................................................... 18
Failure code [D130KB] Neutral safety relay short circuit .............................................................................. 20
Failure code [D161KA] Back-up alarm relay disconnection.......................................................................... 22
D275A-5R 1
Failure code [D161KB] Back-up alarm relay short circuit.............................................................................. 24

Failure code [D190KA] Engine controller ACC signal cut relay .................................................................... 26
Failure code [D190KB] Engine controller ACC signal cut relay short ........................................................... 28
Failure code [D811KR] KOMTRAX controller CAN defective communication .............................................. 30
Failure code [DAFRKR] Machine monitor CAN communication defective communication........................... 32
2 D275A-5R
Failure code [CA731] Eng Bkup speed sens phase error 1

Action code Failure code Eng Bkup speed sens phase error
Trouble
Contents of
• Engine Bkup sensor circuit detected phase error.
trouble
Action of
• Controls with signals of engine Ne speed sensor.
controller
Problem that
• Running engine stops (when Ne speed sensor is also abnormal).
appears on
• Stopped engine cannot be started (when Ne speed sensor is also abnormal).
machine
Related
information

Possible causes
Defective engine Ne speed Engine Ne speed sensor may be defective. Carry out trouble-
and standard 1
sensor system shooting for failure code [CA689].
value in normal
state Defective engine Bkup Engine Bkup speed sensor may be defective. Carry out trouble-
2
speed sensor system shooting for failure code [CA778].
Failure code [CA757] All continuous data lost error 1

Action code Failure code All continuous data lost error
Trouble
Contents of
• All data in engine controller are lost.
trouble
Action of
controller
Problem that
machine
Related
information

and standard
state
D275A-5R 3
Failure code [CA778] Eng Bkup speed sensor error 1

Action code Failure code Eng Bkup speed sensor error
Trouble
Contents of
• Trouble occurred in engine Bkup speed sensor circuit.
trouble
Action of
• Operates with signals of Ne speed sensor.
controller
Problem that
• Running engine stops (when Ne speed sensor is also abnormal).
appears on
• Stopped engine cannot be started (when Ne speed sensor is also abnormal).
machine
Related
information

1
Max. 1 z
ness (Disconnection in wiring (37) – G (female) (1) tance
2
nector) Max. 1 z
(47) – G (female) (2) tance
Max. 1 z
(26) – G (female) (3) tance
(37) – G (female) (1) and chassis ground tance
Min. 1 Mz
(47) – G (female) (2) and chassis ground tance
Min. 1 Mz
and standard (26) – G (female) (3) and chassis ground tance
Resis-
(37) – G (female) (1) and between EGC1 Min. 1 Mz
tance
Short circuit in wiring har- (female) (47) – G (female) (2)
harness) Resis-
tance
(female) (26) – G (female) (3)
Resis-
tance
(female) (29) – G (female) (3)
Defective mount of sensor or Check Bkup speed sensor directly for defective mount (defective
5 defective rotation sensing clearance) or check rotation sensing part (in supply pump) directly
part for defect.
If causes 1 – 5 are not detected, engine Bkup speed sensor may
Defective engine Bkup
6 be defective. (Since trouble is in system, troubleshooting cannot
speed sensor
be carried out.)
out.)
4 D275A-5R
D275A-5R 5
Failure code [CA1633] KOMNET datalink timeout error 1

Action code Failure code KOMNET datalink timeout error
Trouble
Contents of • Trouble occurred in KOMNET (CAN) communication circuit between engine controller and machine
trouble monitor, transmission controller, and work equipment controller.
Action of
• Operates in default mode or maintains condition when abnormality occurs.
controller
Problem that
appears on
machine
Related
information

Wiring harness between S04 (female) (1),
(2) – STCN2 (female) (32), – TMCN2
Disconnection in wiring har- Resis-
(female) (32), – EGC2 (female) (46), – CA1 Max. 1 z
ness tance
(female) (A), – CT1 (female) (A) – SRV
1 (Disconnection in wiring or
(male) (3) – KOM1 (female) (8)
defective contact in connec-
tor) Wiring harness between S04 (female) (3),
Resis-
(female) (22) – EGC2 (female) (47) – CA1 Max. 1 z
tance
(female) (B), – CT1 (female) (B) – SRV
Short circuit of wiring harness between S04
(female) (1), (2) – STCN2 (female) (32), –
TMCN2 (female) (32) – EGC2 (female) (46), Resis-
Min. 1 Mz
Possible causes – CA1 (female) (A), – CT1 (female) (A) – tance
Short circuit with chassis
and standard SRV (male) (3) – KOM1 (female) (8) with
2 ground in wiring harness
value in normal chassis ground
(Contact with ground circuit)
state Short circuit of wiring harness between S04
TMCN2 (female) (22), – EGC2 (female) (47) Resis-
Min. 1 Mz
– CA1 (female) (B), – CT1 (female) (B) – tance
SRV (male) (10) – KOM1 (female) (7) with
chassis ground
TMCN2 (female) (32) – EGC2 (female) (46)
Voltage Max. 1 V
– CA1 (female) (A), – CT1 (female) (A) –
Hot short in wiring harness SRV (male) (3) – KOM1 (female) (8) with
3
(Contact with 24 V circuit) chassis ground
Voltage Max. 1 V
– CA1 (female) (B), – CT1 (female) (B) –
chassis ground
6 D275A-5R

Possible causes Defective CAN terminal ing without turning starting switch ON.
4
and standard resistance CA1 (male), CT1 (male) Resistance
value in normal Between (A) – (B) 100 – 140 z
state
Defective engine controller
5 tive. (Since trouble is in system, troubleshooting cannot be carried
or steering controller
out.)
D275A-5R 7
Failure code [CA2185] Throt sens sup volt high error 1

Action code Failure code Throt sens sup volt high error
Trouble
Contents of
• Signal voltage in throttle sensor power supply (5 V) circuit is abnormally high.
trouble
Action of
• Sets throttle position with signal of fuel control dial and continues operation.
controller
Problem that
machine
Related
information

Disconnect devices
Defective fuel control dial at right in order. If
(Internal trouble) Decelerator pedal
disappears when a DCL connector
potentiometer
device is discon-
nected, that device
has trouble in it.
2 Max. 1 z
or defective contact in con- (22) – DCL (female) (B) tance
Possible causes
Max. 1 z
and standard (23) – DCL (female) (C) tance
(22) – DCL (female) (B) and chassis ground tance
circuit)
Min. 1 Mz
(23) – DCL (female) (C) and chassis ground tance
harness) Resis-
(22) – DCL (female) (B) and between EGC2 Min. 1 Mz
tance
(female) (23) – DCL (female) (C)
EGC2 Voltage
Between (22) – (23) 4.75 – 5.25 V
8 D275A-5R
D275A-5R 9
Failure code [CA2186] Throt sens sup volt low error 1

Action code Failure code Throt sens sup volt low error
Trouble
Contents of
• Signal voltage in throttle sensor power supply (5 V) circuit of engine controller is abnormally low.
trouble
Action of
• Sets throttle position with signal of fuel control dial and continues operation.
controller
Problem that
machine
Related
information

and standard
state
Failure code [CA2249] No-pressure feed by supply pump 2 1

Action code Failure code No-pressure feed by supply pump 2
Trouble
Contents of
• Very low pressure error (level 2) occurred in supply pump.
trouble
Action of
• Limits common rail pressure.
controller
Problem that
machine
Related
information

and standard
state
10 D275A-5R
Failure code [CA2555] Intake air heater relay open error 1

Action code Failure code Intake air heater relay open error
Trouble
Contents of
• There is disconnection in intake air heater relay circuit.
trouble
Action of
controller
Problem that
appears on • Engine does not start easily at low temperature.
machine
Related • Engine coolant temperature can be checked with real-time monitoring mode.
information (Code: 04104 Coolant temperature)

and standard
value in normal Carry out troubleshooting failure code [CA2556].
state
D275A-5R 11
Failure code [CA2556] Intake air heater relay short error 1

Action code Failure code Intake air heater relay short error
Trouble
Contents of
• There is short circuit in intake air heater relay.
trouble
Action of
controller
Problem that
appears on • Engine does not start easily at low temperature.
machine
• Engine controller has automatic preheating function, which is turned ON when engine coolant tem-
Related perature is below -5 °C (for up to 30 seconds).
information • Engine coolant temperature can be checked with real-time monitoring mode.
(Code: 04104 Coolant temperature)

Defective intake air heater ing without turning starting switch ON.
1
relay (Internal trouble) PHR (male) Resistance
Between (1) – (2) 200 – 400 z
2 Max. 1 z
Possible causes or defective contact in con- (40) – PHR (female) (1) tance
and standard nector) Wiring harness between PHR (female) (2) – Resis-
Max. 1 z
value in normal chassis ground (GND03) tance
Min. 1 Mz
(40) – PHR (female) (1) and chassis ground tance
4 Defective engine controller EGC2 Coolant temperature Voltage
Between (40) – -5 °C or higher Max. 1 V
chassis ground Below -5 °C 20 – 30 V
12 D275A-5R
D275A-5R 13
Failure code [D110KA] Battery relay holding disconnection 1

Action code Failure code Battery relay holding disconnection
Trouble
– D110KA (Steering controller system)
Contents of
• Turns signal to battery relay holding circuit, no current flows.
trouble
Action of
• Turns signal to battery relay holding circuit OFF.
controller
Problem that
appears on • Problem may occur in writing data into ROM (non-volatile memory) of each controller.
machine
• State of battery relay holding circuit signal can be checked with real-time monitoring mode.
Related
(Code: 60600 BR hold relay)
information
• Method of reproducing failure code: Turn starting switch ON.

Defective battery relay (Inter- ing without turning starting switch ON.
1
nal disconnection) Battery relay Continuity
Between terminals SW – BRE There is continuity
ness (Disconnection in wiring Wiring harness between STCN3 (female) Resis-
2 Max. 1 z
Possible causes or defective contact in con- (4) – terminal SW tance
and standard nector) Wiring harness between terminal BRE and Resis-
chassis ground tance
state
3 ness (Contact with ground Wiring harness between STCN3 (female)
circuit) Resis-
(4) – terminal SW, terminal 260 or circuit Min. 1Mz
tance
branch end and chassis ground
STCN3 Continuity
Between (4) – chassis ground Continue
14 D275A-5R
D275A-5R 15
Failure code [D110KB] Battery relay drive short circuit 1

Action code Failure code Battery relay drive short circuit
Trouble
– D110KB (Steering controller system)
Contents of
• When signal was output to battery relay circuit, abnormal current flowed.
trouble
Action of
• Turns signal to battery relay holding circuit OFF.
controller
Problem that
appears on • Problem may occur in writing data into ROM (non-volatile memory) of each controller.
machine
• State of battery relay holding circuit signal can be checked with real-time monitoring mode.
Related
(Code: 60600 BR hold relay)
information

Defective battery relay (Inter- ing without turning starting switch ON.
1
nal short circuit) Battery relay Continuity/Resistance
Between terminals SW – BRE There is continuity
Possible causes
and standard Hot short (Short circuit with
2
value in normal 24V circuit) in wiring harness Wiring harness between STCN3 (female)
state (4) – terminal SW, terminal 260 or circuit Voltage Max. 1 V
branch end and chassis ground
3 Defective steering controller STCN3 Starting switch Voltage
Between (4) –
ON 10 – 20 V
chassis ground
16 D275A-5R
D275A-5R 17
Failure code [D130KA] Neutral safety relay disconnection 1

Action code Failure code Neutral safety relay disconnection
Trouble
E02 D130KA (Transmission controller system)
Contents of
• Neutral safety relay circuit voltage does not match controller output state.
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 real-time monitoring mode.
(Code 50900: Neutral safety relay drive voltage)
Related
• Method of reproducing failure code: Turn starting switch ON (+ Operate parking brake lever).
information
• This failure code detects abnormality in primary side (coil side) of neutral safety relay, but not in sec-
ondary side (contact side)

Defective neutral safety relay ing without turning starting switch ON.
1
(Internal disconnection) NSF (male) Resistance
Between (1) – (2) 200 – 400 z
Defective disconnection in ing without turning starting switch ON.
wiring harness (Disconnec- Wiring harness between TMCN2 (female) Resis-
2 Max. 1 z
tion in wiring or defective (8) – NSF (female) (2) tance
contact in connector) Wiring harness between NSF (female) (1) – Resis-
Max. 1 z
Possible causes terminal 270 tance
and standard a Prepare with starting switch OFF, then carry out troubleshoot-
value in normal ing without turning starting switch ON.
state
Short circuit of wiring harness between
Short circuit with chassis Resis-
TMCN2 (female) (8) – NSF (female) (2) with Min. 1 Mz
3 ground in wiring harness tance
chassis ground
Short circuit of wiring harness between NSF
Resis-
(female) 1 – terminal 270 with chassis Min. 1 Mz
tance
ground
Defective transmission con- TMCN2 Parking brake lever Voltage
4
troller
Between (8) – Lock position Max. 1 V
chassis ground Free position 20 – 30 V
18 D275A-5R
D275A-5R 19
Failure code [D130KB] Neutral safety relay short circuit 1

Action code Failure code Neutral safety relay short circuit
Trouble
E02 D130KB (Transmission controller system)
Contents of
• Abnormal current flowed in neutral safety relay circuit at the time of 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 real-time monitoring mode.
(Code 50900: Neutral safety relay drive voltage)
Related • Method of reproducing failure code: Turn starting switch ON and operate parking brake lever (Free
information position).
• This failure code detects abnormality in primary side (coil side) of neutral safety relay, but not in sec-
ondary side (contact side)

Defective neutral safety relay ing without turning starting switch ON.
1
(Internal short circuit) NSF (male) Resistance
Between (1) – (2) 200 – 400 z
Possible causes and carry out troubleshooting.
Hot short circuit in wiring har-
and standard
2 ness Short circuit of wiring harness between
value in normal
(Contact with 24V circuit) TMCN2 (female) (8) – NSF (female) (2) with Voltage Max. 1 V
state
chassis ground
Defective transmission con- TMCN2 Parking brake lever Voltage
3
troller
Between (8) – Lock position Max. 1 V
chassis ground Free position 20 – 30 V
20 D275A-5R
D275A-5R 21
Failure code [D161KA] Back-up alarm relay disconnection 1

Action code Failure code Back-up alarm relay disconnection
Trouble
E01 D161KA (Transmission controller system)
Contents of
• Backup alarm relay circuit voltage does not match controller output state.
trouble
Action of
• Turns output of back-up alarm relay circuit OFF.
controller
Problem that
appears on • Back-up alarm does not sound
machine
• Output state (voltage) to back-up alarm relay circuit can be checked with real-time monitoring
mode. (Code: 70400 Back alarm relay)
Related
• Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (R: Reverse).
information
• This failure code detects abnormality on primary side (coil side) of back-up alarm relay but does not
detect abnormality on secondary side (contact side).

1 Defective fuse (FS22) If fuse is broken, circuit probably has ground fault (See cause 4).
Defective back-up alarm ing without turning starting switch ON.
2
relay (Internal disconnection) BKAL (male) Resistance
Between (1) – (2) 200 – 400 z
ness (Disconnection in wiring Wiring harness between TMCN2 (female) Resis-
3 Max. 1 z
or defective contact in con- (18) – BKAL (female) (2) tance
nector) Wiring harness between BKAL (female) (1), Resis-
(3) – FS22 (1) tance
and standard
Ground fault in wiring har- Wiring harness between TMCN2 (female)
Resis-
4 ness (Contact with ground (18) – BKAL (female) (2) or circuit branch Min. 1 Mz
tance
circuit) end and chassis ground
Wiring harness between BKAL (female) (1), Resis-
Min. 1 Mz
(3) – FS22 (1) and chassis ground tance
Defective transmission con- PCCS lever
5 TMCN2 Voltage
troller (Directional)
22 D275A-5R
D275A-5R 23
Failure code [D161KB] Back-up alarm relay short circuit 1

Action code Failure code Back-up alarm relay short circuit
Trouble
E01 D161KB (Transmission controller system)
Contents of
• When circuit of back-up alarm relay was disconnected, abnormal current flowed.
trouble
Action of
• Turns output of back-up alarm relay circuit OFF.
controller
Problem that
appears on • Back-up alarm does not sound.
machine
• Output state (voltage) to back-up alarm relay circuit can be checked with real-time monitoring
mode. (Code: 70400 Back alarm relay)
Related
• Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (R: Reverse)
information
• This failure code detects abnormality on primary side (coil side) of back-up alarm relay but does not
detect abnormality on secondary side (contact side).

Defective back-up alarm ing without turning starting switch ON.
1
relay (Internal short circuit) BKAL (male) Resistance
Between (1) – (2) 200 – 400 z
Hot short (Short circuit with
and standard 2
24V circuit) in wiring harness Wiring harness between TMCN2 (female)
value in normal (18) – BKAL (female) (2) or circuit branch Voltage Max. 1 V
state end and chassis ground
Defective transmission con- PCCS lever
3 TMCN2 Voltage
troller (Directional)
24 D275A-5R
D275A-5R 25
Failure code [D190KA] Engine controller ACC signal cut relay 1

Action code Failure code Engine controller ACC signal cut relay
Trouble
– D190KA (Steering controller system)
Contents of
• Engine controller ACC signal cut relay circuit voltage does not match controller output state.
trouble
Action of
• Stops outputting signal to engine controller ACC signal cut relay.
controller
Problem that
appears on • Engine stop function of steering controller does not work.
machine
• Signal state of engine controller ACC signal cut relay circuit can be checked in real-time monitoring
mode. (Code: 60500 Engine controller ACC cut relay drive voltage)
Related
information
• This failure code detects abnormality on primary side (coil side) of ACC signal drive relay but does
not detect abnormality on secondary side (contact side).

1 Defective fuse FS3-1 If fuse is broken, circuit probably has ground fault etc.
Defective engine controller ing without turning starting switch ON.
2 ACC signal cut relay (Internal
ACT (male) Resistance
disconnection)
Between (1) – (2) 200 – 400 z
3 Max. 1 z
or defective contact in con- (8) – ACT (female) (2) tance
and standard Wiring harness between ACT (female) (1) – Resis-
Max. 1 z
value in normal KEY (female) (1) tance
Wiring harness between STCN2 (female) Resis-
(8) – ACT (female) (2) and chassis ground tance
circuit)
Wiring harness between ACT (female) (1) – Resis-
Min. 1 Mz
KEY (female) (1) tance
5 Defective Steering controller STCN2 (female) Starting switch Voltage
Between (8) –
ON Max. 1 V
chassis ground
26 D275A-5R
D275A-5R 27
Failure code [D190KB] Engine controller ACC signal cut relay short 1
Action code Failure code Engine controller ACC signal cut relay short
Trouble
– D190KB (Steering controller system)
Contents of • When ground circuit of engine controller ACC signal cut relay was disconnected, abnormal current
trouble flowed.
Action of
• Turns output of engine controller ACC signal cut relay circuit OFF.
controller
Problem that
appears on • Engine stop function of steering controller does not work.
machine
• State of engine controller ACC signal cut relay circuit signal can be checked with real-time monitor-
ing mode. (Code: 60500 Engine controller ACC cut relay drive voltage)
Related
information
• This failure code detects abnormality on primary side (coil side) of ACC signal drive relay but does
not detect abnormality on secondary side (contact side).

Defective engine controller ing without turning starting switch ON.
1 ACC signal cut relay (Internal
ACT (male) Resistance
short circuit)
Between (1) – (2) 200 – 400 z
and standard Hot short (Contact with 24V and carry out troubleshooting.
value in normal 2
circuit) in wiring harness Wiring harness between STCN2 (female) Resis-
state Max. 1 V
(8) – ACT (female) (2) and chassis ground tance
3 Defective steering controller STCN2 (female) Starting switch Voltage
Between (8) – chas-
ON Max. 1 V
sis ground
28 D275A-5R
D275A-5R 29
Failure code [D811KR] KOMTRAX controller CAN defective

communication 1
Action code Failure code KOMTRAX controller CAN defective communication
Trouble
– D811KR (Steering controller system)
Contents of
• Steering controller cannot recognize KOMTRAX controller in CAN communication circuit.
trouble
Action of
• None in particular
controller
Problem that
appears on • KOMTRAX LED information (Code: 20300) is not displayed in real-time monitoring mode.
machine
Related • Method of reproducing failure code: Turn starting switch ON and select code: 20300 in real-time
information monitoring mode.

ness tance
Resis-
tance
(female) (B) – CT1 (female) (B) – SRV
Min. 1 Mz
Min. 1 Mz
chassis ground
Voltage Max. 1 V
3
Voltage Max. 1 V
chassis ground
30 D275A-5R

4
state
If causes 1 – 4 are not detected, KOMTRAX controller or steering
Defective KOMTRAX con-
5 controller may be defective. (Since trouble is in system, trouble-
troller or steering controller
shooting cannot be carried out.)
D275A-5R 31
Failure code [DAFRKR] Machine monitor CAN communication defective

communication 1
Action code Failure code Machine monitor CAN communication defective communication
Trouble
CALL E03 DAFRKR (Machine monitor system)
Contents of
• Machine monitor cannot recognize steering controller in CAN communication circuit.
trouble
Action of • Blinks warning lamp and sounds alarm buzzer.
controller • Limits operations of engine and transmission.
Problem that • System may not operate normally.
machine • Once machine is stopped, gear speed is limited to F1 and R1.
Related
information

(2) – STCN2 (female) (32) – TMCN2
Resis-
Disconnection in wiring har- (female) (32) – EGC2 (female) (46) – CA1 Max. 1 z
tance
ness (Disconnection in wiring (female) (A) – CT1 (female) (A) – SRV
1
or defective contact in con- (male) (3) – KOM1 (female) (8)
nector)
Resis-
tance
(female) (32) – EGC2 (female) (46) – CA1 Resis-
Min. 1 Mz
Possible causes (female) (A) – CT1 (female) (A) – SRV tance
and standard (male) (3) – KOM1 (female) (8) with chassis
value in normal ground
circuit)
state Wiring harness between S04 (female) (3),
(female) (22) – EGC2 (female) (47) – CA1 Resis-
Min. 1 Mz
(female) (B) – CT1 (female) (B) – SRV tance
(male) (10) – KOM1 (female) (7) with chas-
sis ground
(female) (32) – EGC2 (female) (46) – CA1
Voltage Max. 1 V
(female) (A) – CT1 (female) (A) – SRV
Hot short (Contact with 24V (male) (3) – KOM1 (female) (8) with chassis
3
circuit) in wiring harness ground
(female) (22) – EGC2 (female) (47) – CA1
Voltage Max. 1 V
(male) (10) – KOM1 (female) (7) with chas-
sis ground
32 D275A-5R

Possible causes ing without turning starting switch ON.
Defective CAN terminal
and standard 4
resistor CA1 (male), CT1 (male) Resistance
value in normal
Between (A) – (B) 100 – 140 z
state
If causes 1 – 4 are not detected, steering controller or transmission
Defective transmission con-
5 controller may be defective. (Since trouble is in system, trouble-
troller or steering controller
shooting cannot be carried out.)
D275A-5R 33
D275A-5R Bulldozer
© 2007 KOMATSU
All Rights Reserved
34 D275A-5R
SEN02761-00
D275A-5R

D275A-5R 35001 and up
codes, Part 4
Failure code [DAQ0KT] Transmission controller internal abnormality ............................................................ 3
Failure code [DAQ1KK] Transmission controller main source voltage reduction............................................ 4
Failure code [DAQ2KK] Transmission controller load voltage reduction ........................................................ 6
Failure code [DAQ5KK] Transmission controller sensor 5 V power source (1) power supply source voltage
reduction .................................................................................................................................................. 8
Failure code [DAQ6KK] Transmission controller sensor 24 V power supply source voltage reduction ........ 10
Failure code [DAQ7KK] Transmission controller sensor 5 V power supply source (2) power source voltage
reduction .................................................................................................................................................11
Failure code [DAQ9KQ] Transmission controller type collation (Type select signal inconsistency).............. 12
Failure code [DAQRKR] Transmission controller CAN defective communication (Abnormality in objective
component system) ............................................................................................................................... 14
Failure code [DAQSKR] Transmission controller S-NET defective communication (Abnormality in objective
component system) ............................................................................................................................... 16
Failure code [DB2RKR] Engine controller CAN defective communication ................................................... 18
D275A-5R 1
Failure code [DB30KT] Steering controller abnormality in controller............................................................. 20

Failure code [DB31KK] Steering controller main power supply source voltage reduction ............................ 22
Failure code [DB32KK] Load power source of steering controller power source voltage drop ..................... 24
Failure code [DB35KK] Steering controller sensor 5 V power source (1) power source voltage drop .......... 26
Failure code [DB36KK] Steering controller sensor 24 V power supply source voltage reduction ................. 28
Failure code [DB37KK] Steering controller sensor 5 V power source (2) power source voltage drop .......... 30
Failure code [DB39KQ] Steering controller type collation (Type select signal inconsistency)....................... 32
Failure code [DB3RKR] Steering controller CAN defective communication (Abnormality in objective compo-
nent system) .......................................................................................................................................... 34
Failure code [DB3SKR] Steering controller S-NET defective communication (Abnormality in objective com-
ponent system) ...................................................................................................................................... 36
Failure code [DD12KA] Shift up switch disconnection .................................................................................. 38
Failure code [DD12KB] Shift up switch short circuit...................................................................................... 40
Failure code [DD13KA] Shift down switch disconnection.............................................................................. 42
Failure code [DD13KB] Shift down switch short circuit ................................................................................. 44
Failure code [DD14KA] Parking brake lever switch disconnection ............................................................... 46
Failure code [DD14KB] Parking brake lever switch short circuit ................................................................... 48
Failure code [DDB9L4] Reverse switch disagreement.................................................................................. 50
Failure code [DDK3L4] Forward switch disagreement.................................................................................. 51
Failure code [DDK5KA] Gearshift switch disconnection ............................................................................... 52
Failure code [DDK5KB] Gearshift switch short circuit ................................................................................... 53
Failure code [DDN7KA] Blade pitch switch disconnection ............................................................................ 54
Failure code [DDN7KB] Blade pitch switch short circuit................................................................................ 56
Failure code [DDN9KA] Blade tilt switch disconnection ................................................................................ 58
Failure code [DDN9KB] Blade tilt switch short circuit.................................................................................... 60
Failure code [DDNBLD] Ripper lift raise oil pressure switch is kept ON for long time .................................. 62
Failure code [DDNCLD] Ripper lift lower oil pressure switch is kept ON for long time ................................. 63
Failure code [DDNDLD] Ripper lift tilt-in oil pressure switch is kept ON for long time .................................. 64
Failure code [DDQ2KA] Parking brake lever switch disconnection............................................................... 66
Failure code [DDQ2KB] Parking brake lever switch short circuit .................................................................. 68
Failure code [DDQ2L4] Parking brake lever switch disagreement................................................................ 70
Failure code [DDT5KA] Neutral switch disconnection................................................................................... 71
Failure code [DDT5KB] Neutral switch short circuit ...................................................................................... 72
Failure code [DDT5KQ] Lever specification selection (Model selection signal disagreement) ..................... 73
Failure code [DGS1KX] Hydraulic oil temperature sensor input signal is out of normal range ..................... 74
2 D275A-5R
Failure code [DAQ0KT] Transmission controller internal abnormality 1

Action code Failure code Transmission controller internal abnormality
Trouble
E01 DAQ0KT (Transmission controller system)
Contents of
• Information of ROM (nonvolatile storage) of transmission controller is not normal.
trouble
Action of
• Sets default internal adjustment value.
controller
Problem that
appears on • Gear shift feeling of transmission may become worse.
machine
Related
information

and standard
value in normal Defective transmission con-
1 Troubleshooting cannot be carried out since it is internal defect.
state troller
D275A-5R 3
Failure code [DAQ1KK] Transmission controller main source voltage

reduction 1
Action code Failure code Transmission controller main source voltage reduction
Trouble
CALL E04 DAQ1KK (Transmission controller system)
Contents of
• Source voltage of transmission controller is below 17 V.
trouble
• Machine monitor may not display normally.
Problem that
• Relays and solenoids cannot operate, not allowing system operate normally.
appears on
machine
• Once machine is stopped, it cannot travel any more.
• Charge level (voltage) of battery can be checked in real-time monitoring mode.
Related
(Code 03200: Battery voltage)
information

Defective circuit breaker If circuit breaker (30 A) is tripped, circuit probably has short circuit
1
(CB30) (30A) with chassis ground.
If fuse FS12-2 is tripped, circuit probably has short circuit with
2 Defective fuse FS12-2
chassis ground.
Disconnection in wiring har- Wiring harness between TMCN3 (female) Resis-
ness Max. 1 z
(1), (11) – FS12-2 tance
defective contact in connec- Wiring harness between FS11 – CB105 – Resis-
Max. 1 z
tor) battery relay terminal BRB tance
Possible causes Wiring harness between TMCN3 (female) Resis-
Max. 1 z
and standard (21), (31), (32), (33) – chassis ground tance
TMCN3 (female) (1), (11) – FS12-2 with Min. 1 Mz
chassis ground
Resis-
FS11 – CB105 – battery relay terminal BRB Min. 1 Mz
tance
with chassis ground
5 TMCN3 Voltage
troller
Between (1), (11) – (21), (31),
20 – 30 V
(32), (33)
4 D275A-5R
D275A-5R 5
Failure code [DAQ2KK] Transmission controller load voltage reduction1

Action code Failure code Transmission controller load voltage reduction
Trouble
Contents of
• Source voltage of transmission controller is below 17 V.
trouble
Problem that
appears on
machine
Related
information

1
(CB3) (20 A) with chassis ground.
2
(CB105) (105 A) with chassis ground.
ness Max. 1 z
(2), (12), (22) – CB3 (2) tance
defective contact in connec- Wiring harness between CB3 (1) – CB105 – Resis-
Max. 1 z
tor) battery relay terminal BRC tance
Max. 1 z
TMCN3 (female) (2), (12), (22) – CB3 (2) Min. 1 Mz
with chassis ground
Short circuit of wiring harness between CB3
Resis-
(1) – CB105 – battery relay terminal BRC Min. 1 Mz
tance
with chassis ground
5 TMCN3 Voltage
troller
Between (2), (12), (22) – (21),
20 – 30 V
(31), (32), (33)
6 D275A-5R
D275A-5R 7
Failure code [DAQ5KK] Transmission controller sensor 5 V power

source (1) power supply source voltage reduction 1
Action code Failure code Transmission controller sensor 5 V power soruce (1) power supply
Trouble source voltage reduction
Contents of • Voltage of 5V power source (1) circuit of transmission controller sensor is below 4.5V or above 5.5V.
trouble • Abnormal current flowed in 5V power source circuit of transmission controller sensor.
Action of
• Stops output to 5V power source circuit if abnormal voltage flows
controller
machine • Once machine is stopped, travel is limited to F1 an R1.
Related
information

Defective forward-reverse TL2 (male) Resistance
1 potentiometer (Internal short
circuit) Between (4) – (1) 3.2 kz ± 20%
Sensor Between (4) –
Min. 1 Mz
chassis ground
Short circuit with chassis ing without turning starting switch ON.
Possible causes
2 ground in wiring harness Short circuit of wiring harness between
and standard Resis-
(Contact with ground circuit) TMCN1 (female) (22) – TL2 (female) (4) Min. 1 Mz
value in normal tance
state with chassis ground
Hot short circuit in wiring har- and carry out troubleshooting.
3 ness (Contact with 24V cir- Short circuit of wiring harness between
cuit) TMCN1 (female) (22) – TL2 (female) (4) Voltage Max. 1 V
with chassis ground
Defective transmission con- and carry out troubleshooting.
4
troller TMCN1 Voltage
Between (22) – (21) 4.5 – 5.5 V
8 D275A-5R
D275A-5R 9

supply source voltage reduction 1
Action code Failure code Transmission controller sensor 24 V power supply source voltage
Trouble
E01 DAQ6KK reduction (Transmission controller system)
Contents of • Voltage of 24 V power supply circuit of transmission controller sensor is below 12 V or above 30 V.
trouble • Abnormal current flowed in 24 V power supply circuit of transmission controller sensor.
Action of
• Stops output to 24 V power supply circuit if abnormal voltage flows
controller
Problem that
appears on • None in particular
machine
Related • Method of reproducing failure code: Turn starting switch ON. Since this power supply is not used,
information no wiring is made.

and standard and carry out troubleshooting.
value in normal Defective transmission con-
1
state troller TMCN1 Voltage
(16) – (21) 20 – 30 V
10 D275A-5R

supply source (2) power source voltage reduction 1
Action code Failure code Transmission controller sensor 5 V power supply source (2) power
Trouble
CALL E03 DAQ7KK source voltage reduction (Transmission controller system)
• Voltage of 5 V power source (2) circuit of transmission controller sensor is below 4.5 V or above 5.5
Contents of
V.
trouble
• Abnormal current flowed in 5 V power source circuit of transmission controller sensor.
Action of
• Stops output of 5 V power source (2) circuit if abnormal voltage has flowed.
controller
Problem that
appears on • System may not operate normally.
machine
Related
• Method of reproducing failure code: turn ON the starting switch.
information

If service code lights up steadily (reset display) when
Defective work equipment oil
right connector is disconnected, the defect is internal. HHP
1 pressure sensor
a Disconnect connector with starting switch OFF and connector
(Internal short circuit)
turn the switch ON to diagnose.
a Prepare with starting switch OFF and diagnose with starting
switch still OFF.
Defective harness grounding
2
(Contact with ground circuit) Between ground and wiring harness Resis-
Possible causes between TMCN3 (female) (34) – HHP Min. 1 Mz
tance
and standard (female) (B)
value in normal a Prepare with starting switch OFF and diagnose with starting
state switch ON.
Hot short of wiring harness
3 Between ground and wiring harness
(Contact with 24 V circuit)
between TMCN3 (female) (34) – HHP Voltage Max. 1 V
(female) (B)
switch ON.
4 TMCN3, TMCN1 Voltage
troller
Between TMCN3 (34) –
4.5 – 5.5 V
TMCN1 (21)
D275A-5R 11
Failure code [DAQ9KQ] Transmission controller type collation (Type

select signal inconsistency) 1
Action code Failure code Transmission controller type collation (Type select signal inconsis-
Trouble
CALL E04 DAQ9KQ tency) (Transmission controller system)
Contents of • Internal spec. setting of transmission controller is inconsistent with spec. set signal.
trouble (Transmission controller may not recognize normally)
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 failure code lights on (reset display) after carrying out
1 adjustment mode.
troller adjustment
• Adjustment code: 0003: Transmission controller spec.
Disconnection in wiring har- a Prepare with starting switch OFF, carry out troubleshooting
Possible causes ness without turning starting switch ON.
and standard 2 (Disconnection in wiring or
value in normal defective contact in connec- Short circuit of wiring harness between Resis-
Max. 1 z
state tor) TMCN3 (female) (10) with chassis ground tance

3
Between (10) – chassis ground Max. 1 V
12 D275A-5R
D275A-5R 13
Failure code [DAQRKR] Transmission controller CAN defective

communication (Abnormality in objective component system) 1
Action code Failure code Transmission controller CAN defective communication (Abnormal-
Trouble ity in objective component system)
CALL E03 DAQRKR (Transmission controller system)
Contents of
• Steering controller cannot recognize transmission controller in CAN communication circuit.
trouble
machine • Once machine is stopped, travel is limited to F1 and R1.
Related
information

ness tance
Resis-
tance
Min. 1 Mz
Min. 1 Mz
chassis ground
Voltage Max. 1 V
3
Voltage Max. 1 V
chassis ground
14 D275A-5R

4
state
Defective transmission con- If no problem is found in causes 1 to 4, it is suspected that trans-
5 troller, defective steering mission controller, steering controller is defective. (Troubleshooting
controller cannot be carried out since it is internal defect.)
D275A-5R 15
Failure code [DAQSKR] Transmission controller S-NET defective

Action code Failure code Transmission controller S-NET defective communication (Abnor-
Trouble mality in objective component system)
E01 DAQSKR (Transmission controller system)
Contents of
• Transmission controller cannot recognize S-NET.
trouble
Action of
controller
Problem that
• Machine may not acquire switch signal of machine monitor, not allowing normal operation of sys-
appears on
tem.
machine
Related
information

ness ing without turning starting switch ON.
defective contact in connec- Wiring harness between TMCN2 (female) Resis-
Max. 1 z
tor) (21) – S01 (female) (8) tance

(Contact with ground circuit) TMCN2 (female) (21) – S01 (female) (8) Resis-
Min. 1 Mz
tance
with chassis ground
Possible causes
and standard
value in normal Hot short in wiring harness
state 3 Short circuit of wiring harness between
TMCN2 (female) (21) – S01 (female) (8) Voltage Max. 1 V
with chassis ground
Defective machine monitor and carry out troubleshooting.
4
(Switch module) S01 Voltage
Between (8) – chassis ground 6–9V
5
Between (21) – (31) 6–9V
16 D275A-5R
D275A-5R 17
Failure code [DB2RKR] Engine controller CAN defective communication1

Action code Failure code Engine controller CAN defective communication
Trouble
CALL E03 DB2RKR (Steering controller system)
Contents of
• Steering controller cannot recognize engine controller in CAN communication circuit.
trouble
Related
information

ness tance
Resis-
tance
Min. 1 Mz
Min. 1 Mz
chassis ground
Voltage Max. 1 V
3
Voltage Max. 1 V
chassis ground
18 D275A-5R

4
state
If causes 1 – 4 are not detected, engine controller or steering con-
Defective engine controller
5 troller may be defective. (Since trouble is in system, troubleshoot-
or steering controller
ing cannot be carried out.)
D275A-5R 19
Failure code [DB30KT] Steering controller abnormality in controller 1

Action code Failure code Steering controller abnormality in controller
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
value in normal 1 Defective steering controller Troubleshooting cannot be carried out since it is internal defect.
state
20 D275A-5R
D275A-5R 21
Failure code [DB31KK] Steering controller main power supply source

voltage reduction 1
Action code Failure code Steering controller main power supply source voltage reduction
Trouble
CALL E04 DB31KK (Steering controller system)
Contents of
• Source voltage of steering controller is below 17V.
trouble
Problem that
appears on
machine
Related
information

Defective circuit breaker If circuit breaker is tripped, circuit probably has short circuit with
1
(CB30) chassis ground.
If fuse FS12-2 is tripped, circuit probably has short circuit with
2 Defective fuse FS12-2
chassis ground.
Disconnection in wiring har- Wiring harness between STCN3 (female) Resis-
Max. 1 z
ness (Disconnection in wiring (1), (11) – FS12-2 tance
3
or defective contact in con- Wiring harness between FS11 – battery Resis-
nector) Max. 1 z
relay terminal BRB tance
Possible causes Wiring harness between STCN3 (female) Resis-
Max. 1 z
STCN3 (female) (1), (11) – FS12-2 with Min. 1 Mz
chassis ground
Resis-
FS11 – battery relay terminal BRB with Min. 1 Mz
tance
chassis ground
a Prepare with starting switch OFF, turn starting switch ON and
carry out troubleshooting.
5 Defective steering controller STCN3 Voltage
Between (1), (11) – (21), (31),
20 – 30 V
(32), (33)
22 D275A-5R
D275A-5R 23
Failure code [DB32KK] Load power source of steering controller power

source voltage drop 1
Action code Failure code Load power source of steering controller power source voltage
Trouble
CALL E04 DB32KK drop (Steering controller system)
Contents of
• Power source voltage of load (relay, solenoid, etc.) on steering controller is below 17V.
trouble
Action of • Flashes warning lamp and turns on alarm buzzer.
Problem that • Relay and solenoid may not be driven and therefore system may not operate properly.
machine • Once machine is stopped, it can not travel any more.
• Battery charge state (voltage) can be checked in real-time monitoring mode.
Related
information

If circuit breaker CB1 is blown, it is highly possible that a defective
1 Defective circuit breaker CB1
grounding, etc. has occurred in the circuit.
Defective circuit breaker When the circuit breaker is cut off, it is highly possible that a defec-
2
CB105 tive harness grounding has occurred in the circuit.
switch still OFF.
Max. 1 z
ness (2), (12), (22) – CB1(1) tance
3
(Disconnection or defective Wiring harness between CB1(2) – battery Resis-
contact of connectors) Max. 1 z
relay BRC terminal tance
Possible causes Wiring harness between STCN3 (female) Resis-
Max. 1 z
and standard (21), (31), (32), (33) and ground tance
state switch still OFF.
Between ground and wiring harness
Resis-
Defective harness grounding between STCN3 (female) (2), (12), (22) – Min. 1 Mz
4 tance
(Contact with ground circuit) CB1(1)
Between ground and wiring harness
Resis-
between CB1(2) – battery relay BRC termi- Min. 1 Mz
tance
nal
switch ON.
Between (2), (12), (22) – (21),
20 – 30 V
(31), (32), (33)
24 D275A-5R
D275A-5R 25

power source voltage drop 1
Action code Failure code Steering controller sensor 5 V power source (1) power source volt-
Trouble
CALL E03 DB35KK age drop (Steering controller system)
• Voltage of 5 V power source circuit of steering controller sensor is less than 4.5 V or more than 5.5
Contents of
V.
trouble
• Abnormal current flowed in 5 V power source circuit of steering controller sensor.
• Flashes warning lamp and turns on alarm buzzer.
Action of
• Stops output of 5 V power source circuit if abnormal voltage has flowed.
controller
Related
information

BRK (male) Resistance
Defective brake potentiome-
1 Between (C) – (A) 5 kz ± 20%
ter (Internal short circuit)
Between (C) and ground Min. 1 Mz
DIAL (male) Resistance
Defective fuel dial potentiom-
2 Between (1) – (3) 5 kz ± 15%
eter (Internal short circuit)
Between (1) and ground Min. 1 Mz
TL2 (male) Resistance
Defective steering potenti-
3 Between (5) – (8) 3.2 kz ± 20 %
ometer (Internal short circuit)
Possible causes
and standard a Prepare with starting switch OFF and diagnose with starting
value in normal switch still OFF.
state 4
(Contact with ground circuit) Between ground and wiring harnesses Resis-
between STCN1 (female) (22) – DIAL Min. 1 Mz
tance
(female) (1) – BRK (female) (C)
switch ON.
5 Between ground and wiring harnesses
between STCN1 (female) (22) – DIAL Voltage Max. 1 V
(female) (1) – BRK (female) (C)
switch ON.
STCN1 Voltage
Between (22) – (21) 4.5 – 5.5 V
26 D275A-5R
D275A-5R 27
Failure code [DB36KK] Steering controller sensor 24 V power supply

source voltage reduction 1
Action code Failure code Steering controller sensor 24 V power supply source voltage
Trouble
CALL E03 DB36KK reduction (Steering controller system)
Contents of • Voltage of 24V power supply circuit of steering controller sensor is below 12 V or above 30 V.
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

It is internal defect if failure code lights on (reset dis-
play) when disconnecting right connector.
Defective blade pitch angle PT1
1 a Disconnect connector with starting switch OFF, then
sensor (Internal short circuit) connector
turn starting switch ON and carry out troubleshoot-
ing.
and standard Short circuit with chassis ing without turning starting switch ON.
value in normal 2 ground in wiring harness Short circuit of wiring harness between
state (Contact with ground circuit) STCN1 (female) (16) – PT1 (female) (C) Resis-
Min. 1 Mz
tance
with chassis ground
STCN1 Voltage
Between (16) – (21) 20 – 30 V
28 D275A-5R
D275A-5R 29

power source voltage drop 1
Action code Failure code Steering controller sensor 5 V power source (2) power source volt-
Trouble
CALL E03 DB37KK age drop (Steering controller system)
• Voltage of 5 V power source (2) circuit of steering controller sensor is less than 4.5 V or more than
Contents of
5.5 V.
trouble
• Abnormal current flowed in 5 V power source circuit of steering controller sensor.
controller • Stops output of 5 V power source (2) circuit if abnormal voltage has flowed.
Related
information

If service code lights up steadily (reset display) when
Defective acceleration sen- right connector is disconnected, the defect is internal. SSA
1
sor (Internal short circuit) a Disconnect connector with starting switch OFF and connector
turn the switch ON to diagnose.
switch still OFF.
2
(Contact with ground circuit) Between ground and wiring harness Resis-
Possible causes between STCN3 (female) (34) – SSA Min. 1 Mz
tance
and standard (female) (1)
state switch ON.
3 Between ground and wiring harness
(Contact with 24 V circuit) Resis-
between STCN3 (female) (34) – SSA Min. 1 Mz
tance
(female) (1)
switch ON.
4 Defective steering controller STCN3, STCN1 Voltage
Between STCN3 (34) –
4.5 – 5.5 V
STCN1 (21)
30 D275A-5R
D275A-5R 31
Failure code [DB39KQ] Steering controller type collation (Type select

signal inconsistency) 1
Action code Failure code Steering controller type collation (Type select signal inconsistency)
Trouble
CALL E04 DB39KQ (Steering controller system)
Contents of • Internal spec. setting of steering controller is inconsistent with spec. set signal.
trouble (Steering controller may not recognizes normally)
Action of
• Stops all outputs of steering controller.
controller
Problem that • Machine does not operate at all.
Related
information

It is normal if failure code lights on (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- a Prepare with starting switch OFF, then carry out troubleshoot-
and standard ness (Disconnection in wiring ing without turning starting switch ON.
2
value in normal or defective contact in con- Wiring harness between STCN3 (female) Resis-
nector) Max. 1 z
state (20) – chassis ground tance
Prepare with starting switch OFF, turn starting switch ON and carry
STCN3 Voltage
Between (20) – chassis ground Max. 1V
32 D275A-5R
D275A-5R 33
Failure code [DB3RKR] Steering controller CAN defective

Action code Failure code Steering controller CAN defective communication (Abnormality in
Trouble objective component system)
CALL E03 DB3RKR (Transmission controller system)
Contents of
• Transmission controller cannot recognize steering controller with CAN communication circuit.
trouble
Related
information

ness tance
Resis-
tance
Min. 1 Mz
Min. 1 Mz
chassis ground
Voltage Max. 1 V
3
Voltage Max. 1 V
chassis ground
34 D275A-5R

4
state
Defective transmission con- If no problem is found in causes 1 to 4, it is suspected that trans-
5 troller or defective steering mission controller, or steering controller either is defective. (Trou-
controller bleshooting cannot be carried out since it is internal defect.)
D275A-5R 35
Failure code [DB3SKR] Steering controller S-NET defective

Action code Failure code Steering controller S-NET defective communication (Abnormality in
Trouble objective component system)
E01 DB3SKR (Steering controller system)
Contents of
• Transmission controller cannot recognize S-NET.
trouble
Action of
controller
Problem that
• Machine may not acquire switch signal of machine monitor, not allowing normal operation of sys-
appears on
tem.
machine
Related
information

ness (Disconnection in wiring ing without turning starting switch ON.
1
or defective contact in con- Wiring harness between STCN2 (female) Resis-
nector) Max. 1 z
(21) – S01 (female) (8) tance
(Contact with ground circuit) STCN2 (female) (21) – S01 (female) (8) with Resis-
Min. 1 Mz
tance
chassis ground
Possible causes a Prepare with starting switch OFF, turn starting switch ON and
and standard Hot short circuit in wiring har- carry out troubleshooting.
value in normal 3 ness (Contact with 24V cir- Short circuit of wiring harness between
state cuit) STCN2 (female) (21) – S01 (female) (8) with Voltage Max. 1 V
chassis ground
Defective machine monitor carry out troubleshooting.
4
Between (8) – chassis ground 6–9V
STCN2 Voltage
Between (21) – (31) 6–9V
36 D275A-5R
D275A-5R 37
Failure code [DD12KA] Shift up switch disconnection 1

Action code Failure code Shift up switch disconnection
Trouble
E02 DD12KA (Transmission controller system)
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 real-time monitoring mode.
information (Code 40905: Transmission controller input signal 1)
• Method of reproducing failure code: Turn starting switch ON (+ Operate shift up switch).

Shift up switch
SFTU (male)
Defective shift up switch OFF (Release) ON (Press)
1
(Internal disconnection) Resistance between
Max. 1 z Min. 1 Mz
(2) – (3)
Resistance between
Min. 1 Mz Max. 1 z
(1) – (2)
Max. 1 z
ness (Disconnection in wiring (6) – SFTU (female) (3) tance
2
or defective contact in con- Wiring harness between TMCN2 (female) Resis-
nector) Max. 1 z
(37) – SFTU (female) (1) tance

Max. 1 z
and standard (4), – SFTU (female) (2) tance
value in normal a Prepare with starting switch OFF, turn starting switch ON and
state carry out troubleshooting.
TMCN1 (female) (6) – SFTU (female) (3) Voltage Max. 1 V
3 ness (Contact with 24V cir-
with chassis ground
cuit)
TMCN2 (female) (37) – SFTU (female) (1) Voltage Max. 1 V
with chassis ground
Shift up switch
TMCN1, TMCN2
OFF (Release) ON (Press)
Defective transmission con- Voltage between
4
troller TMCN1 (6) – Max. 1V 5 – 11V
TMCN1 (4)
Voltage between
TMCN2 (37) – 5 – 11V Max. 1V
TMCN1 (4)
38 D275A-5R
D275A-5R 39
Failure code [DD12KB] Shift up switch short circuit 1

Action code Failure code Shift up switch short circuit
Trouble
E02 DD12KB (Transmission controller system)
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 real-time monitoring mode.

Shift up switch
SFTU (male)
Defective shift up switch OFF (Release) ON (Press)
1
Max. 1 z Min. 1 Mz
(2) – (3)
Resistance between
Min. 1 Mz Max. 1 z
(1) – (2)
Possible causes Short circuit of wiring harness between

and standard TMCN1 (female) (6) – SFTU (female) (3) Min. 1 Mz
value in normal with chassis ground
state Short circuit of wiring harness between
Resis-
TMCN2 (female) (37) – SFTU (female) (1) Min. 1 Mz
tance
with chassis ground
Shift up switch
TMCN1, TMCN2
3
TMCN1 (4)
Voltage between
TMCN2 (37) – 5 – 11V Max. 1V
TMCN1 (4)
40 D275A-5R
D275A-5R 41
Failure code [DD13KA] Shift down switch disconnection 1

Action code Failure code Shift down switch disconnection
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 real-time monitoring mode.
• Method of reproducing failure code: Turn starting switch ON (+ Operate shift down switch).

Shift down switch
SFTD (female)
Defective shift down switch OFF (Release) ON (Press)
1
Max. 1 z Min. 1 Mz
(2) – (3)
Resistance between
Min. 1 Mz Max. 1 z
(1) – (2)
Max. 1 z
ness (Disconnection in wiring (19) – SFTD (male) (3) tance
2
nector) Max. 1 z
(29) – SFTD (male) (1) tance

Max. 1 z
and standard (4) – SFTD (male) (2) tance
TMCN3 (female) (19) – SFTD (male) (3) Voltage Max. 1 V
with chassis ground
cuit)
TMCN3 (female) (29) – SFTD (male) (1) Voltage Max. 1 V
with chassis ground
Shift down switch
TMCN1, TMCN3
4
TMCN1 (4)
Voltage between
TMCN3 (29) – 5 – 11V Max. 1V
TMCN1 (4)
42 D275A-5R
D275A-5R 43
Failure code [DD13KB] Shift down switch short circuit 1

Action code Failure code Shift down switch short circuit
Trouble
E02 DD13KB (Transmission controller system)
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 real-time monitoring mode.

Shift down switch
SFTD (female)
Defective shift down switch OFF (Release) ON (Press)
1
Max. 1 z Min. 1 Mz
(2) – (3)
Resistance between
Min. 1 Mz Max. 1 z
(1) – (2)

and standard TMCN3 (female) (19) – SFTD (male) (3) Min. 1 Mz
Resis-
TMCN3 (female) (29) – SFTD (male) (1) Min. 1 Mz
tance
with chassis ground
Shift down switch
TMCN1, TMCN3
3
TMCN1 (4)
Voltage between
TMCN3 (29) – 5 – 11V Max. 1V
TMCN1 (4)
44 D275A-5R
D275A-5R 45
Failure code [DD14KA] Parking brake lever switch disconnection 1

Action code Failure code Parking brake lever switch disconnection
Trouble
CALL E03 DD14KA (Transmission controller system)
Contents of • Signals of two systems of parking brake lever switch circuit were turned OFF (OPEN) at the same
trouble time.
Action of
• Recognizes parking brake lever is in Free position.
controller
Problem that
appears on
• Once machine is stopped, travel is limited to F1 and R1.
machine
a Signals of parking brake switch are commonly used by transmission controller and steering con-
troller. Depending on where problem occurs, related codes may be displayed at the same time.
(Related code: DDQ2KA, DDQ2L4).
Related
• NC of 2 system signals of switch is for detection of operation and NO is for detection or error.
information
• Input state (ON/OFF) from parking brake switch can be checked in real-time monitoring mode.
(Code 40905: Transmission controller input signal 1)
When failure code [DD14KA] occurred alone

1 Max. 1 z
or defective contact in con- (18) – branched point of circuit tance
nector) Wiring harness between TMCN1 (female) Resis-
(12) – branched point of circuit tance
and standard
value in normal
state
Parking brake lever
TMCN1
Defective transmission con- Free position Lock position
2
troller Between (18) –
Max. 1V 5 – 11V
chassis ground
Between (12) –
5 – 11V Max. 1V
chassis ground
When failure codes [DD14KA] and [DDQ2KA] occurred at the same time
Parking brake lever switch Parking brake lever

1 NSW (male)
(Internal disconnection) Free position Lock position
Between (A) – (B) Max. 1 z Min. 1 Mz
Possible causes
and standard Between (A) – (C) Min. 1 Mz Max. 1 z
Disconnection in wiring har- Wiring harness between NSW (female) (B) Resis-
Max. 1 z
ness (Disconnection in wiring – branched point of circuit tance
2
or defective contact in con- Wiring harness between NSW (female) (C) Resis-
nector) Max. 1 z
– branched point of circuit tance
Wiring harness between NSW (female) (A) Resis-
Max. 1 z
– chassis ground tance
46 D275A-5R
When failure codes [DD14KA] and [DDQ2KA] occurred at the same time
Possible causes
and standard Short circuit of wiring harness between
value in normal NSW (female) (B) – TMCN1 (female) (18) – Voltage Max. 1V
state STCN2 (female) (5) with chassis ground
cuit)
NSW (female) (C) – TMCN1 (female) (12) – Voltage Max. 1V
STCN2 (female) (15) with chassis ground
D275A-5R 47
Failure code [DD14KB] Parking brake lever switch short circuit 1

Action code Failure code Parking brake lever switch short circuit
Trouble
CALL E03 DD14KB (Transmission controller system)
Contents of • Signals of two systems of parking brake lever switch circuit were turned ON (CLOSE) at the same
trouble time.
Action of
controller
Problem that
appears on
machine
(Related code: DDQ2KB, DDQ2L4).
Related
• NC of 2 system signals of switch is for detection of operation and NO is for detection or error.
information


1 NSW (male)
Between (A) – (C) Min. 1 Mz Max. 1 z
ing without turning starting switch OFF.
Possible causes Wiring harness between NSW (female) (B)

and standard – TMCN1 (female) (18) – STCN2 (female) Min. 1 Mz
value in normal (5) with chassis ground
state Wiring harness between NSW (female) (C)
Resis-
– TMCN1 (female) (12) – STCN2 (female) Min. 1 Mz
tance
(15) with chassis ground
Parking brake lever
TMCN1
Defective transmission con- Free position Lock position
3
troller Between (18) –
Max. 1V 5 – 11V
chassis ground
Between (12) –
5 – 11V Max. 1V
chassis ground
48 D275A-5R
D275A-5R 49
Failure code [DDB9L4] Reverse switch disagreement 1

Action code Failure code Reverse switch disagreement
Trouble
CALL E03 DDB9L4 (Transmission controller system)
Contents of
• Signals of 2 reverse switch circuit systems of optional type travel lever disagree with each other.
trouble
• Blinks warning lamp and sounds alarm buzzer.
Action of
• Assumes that switch is not pressed.
controller
• Limits operations of engine, transmission and brake.
Problem that
appears on
• Once machine is stopped, gear speed is limited to F1.
machine
• Input state (ON/OFF) from reverse switch can be checked in real-time monitoring mode.
Related
information
• Method of reproducing failure code: Turn starting switch ON (+ Operate reverse switch).

Possible causes
and standard Wrong selection of travel lever
value in normal type Check travel lever type in adjust- Select PCCS standard type
state (Failure code DDT5KQ is display ment mode ID: 0004. lever.
simultaneously)
50 D275A-5R
Failure code [DDK3L4] Forward switch disagreement 1

Action code Failure code Forward switch disagreement
Trouble
CALL E03 DDK3L4 (Transmission controller system)
Contents of
• Signals of 2 forward switch circuit systems of optional type travel lever disagree with each other.
trouble
Action of
• Assumes that switch is not pressed.
controller
Problem that
appears on
• Once machine is stopped, gear speed is limited to F1.
machine
• Input state (ON/OFF) from forward switch can be checked in real-time monitoring mode.
Related
information
• Method of reproducing failure code: Turn starting switch ON (+ Operate forward switch).

Possible causes
simultaneously)
D275A-5R 51
Failure code [DDK5KA] Gearshift switch disconnection 1

Action code Failure code Gearshift switch disconnection
Trouble
E02 DDK5KA (Transmission controller system)
Contents of • Signals of 2 gearshift switch circuit systems of optional type travel lever are turned OFF (OPEN)
trouble simultaneously.
controller • Assumes that switch is not pressed.
Problem that • Gear cannot be shifted up or down (1st i
o 2nd).
machine • Once machine is stopped, gear speed is limited to 1st.
• Input state (ON/OFF) from gearshift switch can be checked in real-time monitoring mode.
Related
information
• Method of reproducing failure code: Turn starting switch ON (+ Operate gearshift switch).

Possible causes
simultaneously)
52 D275A-5R
Failure code [DDK5KB] Gearshift switch short circuit 1

Action code Failure code Gearshift switch short circuit
Trouble
E02 DDK5KB (Transmission controller system)
Contents of • Signals of 2 gearshift switch circuit systems of optional type travel lever are turned ON (CLOSE)
Problem that • Gear cannot be shifted up or down (1st i
o 2nd).
machine • Once machine is stopped, gear speed is limited to 1st.
• Input state (ON/OFF) from gearshift switch can be checked in real-time monitoring mode.
Related
information
• Method of reproducing failure code: Turn starting switch ON (+ Operate gearshift switch).

Possible causes
simultaneously)
D275A-5R 53
Failure code [DDN7KA] Blade pitch switch disconnection 1

Action code Failure code Blade pitch switch disconnection
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 real-time monitoring mode.
information (Code 70300: Blade lever knob switch input signal 1)
• Method of reproducing failure code: Turn starting switch ON (and operate blade pitch switch).

Blade pitch switch
WNBL (female)
Defective blade pitch switch OFF (Release) ON (Press)
1
Max. 1 z Min. 1 Mz
(2) – (3)
Resistance between
Min. 1 Mz Max. 1 z
(1) – (2)
Max. 1 z
ness (Disconnection in wiring (15) – WNBL (male) (3) tance
2
nector) Max. 1 z
(5) – WNBL (male) (1) tance

Max. 1 z
and standard (10) – WNBL (male) (2) tance
TMCN2 (female) (15) – WNBL (male) (3) Voltage Max. 1 V
with chassis ground
cuit)
TMCN2 (female) (5) – WNBL (male) (1) with Voltage Max. 1 V
chassis ground
Blade pitch switch
TMCN1, TMCN2
4
TMCN1 (10)
Voltage between
TMCN2 (5) – 5 – 11V Max. 1V
TMCN1 (10)
54 D275A-5R
D275A-5R 55
Failure code [DDN7KB] Blade pitch switch short circuit 1

Action code Failure code Blade pitch switch short circuit
Trouble
E02 DDN7KB (Transmission controller system)
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 real-time monitoring mode.
information (Code 70300: Blade lever knob switch input)
• Method of reproducing failure code: Turn starting switch ON and operate blade pitch switch.

Blade pitch switch
WNBL (female)
Defective blade pitch switch OFF (Release) ON (Press)
1
Max. 1 z Min. 1 Mz
(2) – (3)
Resistance between
Min. 1 Mz Max. 1 z
(1) – (2)

and standard TMCN2 (female) (15) – WNBL (male) (3) Min. 1 Mz
Resis-
TMCN2 (female) (5) – WNBL (male) (1) with Min. 1 Mz
tance
chassis ground
Blade pitch switch
TMCN1, TMCN2
3
TMCN1 (10)
Voltage between
TMCN2 (5) – 5 – 11V Max. 1V
TMCN1 (10)
56 D275A-5R
D275A-5R 57
Failure code [DDN9KA] Blade tilt switch disconnection 1

Action code Failure code Blade tilt switch disconnection
Trouble
E01 DDN9KA (Transmission controller system)
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 real-time monitoring mode.
information (Code 70300: Blade lever knob switch input signal)
• Method of reproducing failure code: Turn starting switch ON (and operate blade tilt switch).

Blade tilt switch
WNBU (male)
Defective blade tilt switch SINGLE DUAL
1
Max. 1 z Min. 1 Mz
(2) – (3)
Resistance between
Min. 1 Mz Max. 1 z
(1) – (2)
Max. 1 z
ness (Disconnection in wiring (35) – WNBU (female) (3) tance
2
nector) Max. 1 z
(25) – WNBU (female) (1) tance

Max. 1 z
and standard (10) – WNBU (female) (2) tance
TMCN2 (female) (35) – WNBU (female) (3) Voltage Max. 1 V
with chassis ground
cuit)
TMCN2 (female) (25) – WNBU (female) (1) Voltage Max. 1 V
with chassis ground
Blade tilt switch
TMCN1, TMCN2
SINGLE DUAL
4
TMCN1 (10)
Voltage between
TMCN2 (25) – 5 – 11V Max. 1V
TMCN1 (10)
58 D275A-5R
D275A-5R 59
Failure code [DDN9KB] Blade tilt switch short circuit 1

Action code Failure code Blade tilt switch short circuit
Trouble
E01 DDN9KB (Transmission controller system)
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 real-time monitoring mode.
information (Code 70300: Blade lever knob switch input state)
• Method of reproducing failure code: Turn starting switch ON (and operate blade tilt switch).

Blade tilt switch
WNBU (male)
Defective blade tilt switch SINGLE DUAL
1
Max. 1 z Min. 1 Mz
(2) – (3)
Resistance between
Min. 1 Mz Max. 1 z
(1) – (2)

and standard TMCN2 (female) (35) – WNBU (female) (3) Min. 1 Mz
Resis-
TMCN2 (female) (25) – WNBU (female) (1) Min. 1 Mz
tance
with chassis ground
Blade tilt switch
TMCN1, TMCN2
SINGLE DUAL
3
TMCN1 (10)
Voltage between
TMCN2 (25) – 5 – 11V Max. 1V
TMCN1 (10)
60 D275A-5R
D275A-5R 61
Failure code [DDNBLD] Ripper lift raise oil pressure switch is kept ON
for long time 1
Action code Failure code Ripper lift raise oil pressure switch is kept ON for long time
Trouble
— DDNBLD (Transmission controller system)
Contents of
• The signal of the ripper lift raise oil pressure switch circuit is kept turned ON for 60 seconds.
trouble
Action of
• Recognizes that the oil pressure switch is turned OFF.
controller
Problem that
• The shoe slip control (SSC) function does not operate normally.
appears on
• Ripper raise operation speed decreases.
machine
• The input state (ON/OFF) from the ripper lift raise oil pressure switch can be checked in the real-
Related time monitoring mode. (Code 70305: Steering controller input signal 3)
information • Method of reproducing failure code: Turn the starting switch ON (Error is reproduced after 60 sec-
onds).

Wrong operation of lever If the failure code lamp still lights up (resetting is still urged) after
1 (When electrical system is the resetting operation is performed, it is suspected that the lever
normal) was operated to cause an error.
Defective ripper lift raise oil
2 pressure switch RPU (male) Ripper lever Resistance
(Internal short circuit) Neutral Min. 1 Mz
Possible causes Between (1) and (2)
Raise Max. 1 z
and standard
state Short circuit with chassis ing without turning starting switch ON.
3 ground in wiring harness Between wiring harness between TMCN2
(Contact with ground circuit) (female) (13) and RPU (female) (1) and Resis-
Min. 1 Mz
tance
chassis ground
Defective transmission con- TMCN2, TMCN1 Ripper lever Voltage
4
troller
Between TMCN2 Neutral 5 – 11 V
(13) and TMCN1 (10) Raise Max. 1 V
62 D275A-5R
Failure code [DDNCLD] Ripper lift lower oil pressure switch is kept ON
for long time 1
Action code Failure code Ripper lift lower oil pressure switch is kept ON for long time
Trouble
— DDNCLD (Transmission controller system)
Contents of
• The signal of the ripper lift lower oil pressure switch circuit is kept turned ON for 60 seconds.
trouble
Action of
controller
Problem that
• The shoe slip control (SSC) function does not operate normally.
appears on
• Ripper raise operation speed decreases.
machine
• The input state (ON/OFF) from the ripper lift lower oil pressure switch can be checked in the real-
Related time monitoring mode. (Code 70305: Steering controller input signal 3)
onds).

Wrong operation of lever If the service code lamp still lights up (resetting is still urged) after
Defective ripper lift lower oil
2 pressure switch RPD(male) Ripper lever Resistance
(Internal short circuit) Neutral Min. 1 Mz
Lower Max. 1 z
and standard
(Contact with ground circuit) (female) (3) and RPD (female) (1) and chas- Resis- Min. 1 Mz
tance
sis ground
Defective transmission con- TMCN1, TMCN2 Ripper lever Voltage
4
troller
Between TMCN2 (3) Neutral 5 – 11 V
and TMCN1 (10) Lower Max. 1 V
D275A-5R 63
Failure code [DDNDLD] Ripper lift tilt-in oil pressure switch is kept ON
for long time 1
Action code Failure code Ripper lift tilt-in oil pressure switch is kept ON for long time
Trouble
— DDNDLD (Transmission controller system)
Contents of
• The signal of the ripper tilt in oil pressure switch circuit is kept turned ON for 60 seconds.
trouble
Action of
controller
Problem that
appears on • The shoe slip control (SSC) function does not operate normally.
machine
• The input state (ON/OFF) from the ripper tilt in oil pressure switch can be checked in the real-time
Related monitoring mode. (Code 70305: Ripper lever oil pressure switch input signal)
onds).

Wrong operation of lever If the service code lamp still lights up (resetting is still urged) after
Defective ripper tilt in oil
2 pressure switch (Internal RT (male) Ripper lever Resistance
short circuit) Neutral Min. 1 Mz
Tilt in Max. 1 z
and standard
(Contact with ground circuit) (female) (2) and RT (female) (1) and chas- Resis-
Min. 1 Mz
tance
sis ground
Defective transmission TMCN1, TMCN2 Ripper lever Voltage
4
controller
Between TMCN2 (2) Neutral 5 – 11 V
and TMCN1 (10) Tilt in Max. 1 V
64 D275A-5R
D275A-5R 65
Failure code [DDQ2KA] Parking brake lever switch disconnection 1

Action code Failure code Parking brake lever switch disconnection
Trouble
CALL E03 DDQ2KA (Transmission controller system)
Contents of • Signals of two systems of parking brake lever switch circuit were turned OFF (OPEN) at the same
trouble time.
Action of
controller
Problem that
appears on
machine
(Related code: DD14KA, DDQ2L4).
Related
information
(Code 40907: Blade lever knob switch input signal)
• Method of reproducing failure code: Turn starting switch ON and operate parking brake lever.
When failurecode [DDQ2KA] occurred alone

1 Max. 1 z
or defective contact in con- (5) – branched point of circuit M tance
nector) Wiring harness between STCN2 (female) Resis-
(15) – branched point of circuit N tance
and standard
value in normal
state
Parking brake lever
STCN2
Free position Lock position
Between (5) –
Max. 1V 5 – 11V
chassis ground
Between (15) –
5 – 11V Max. 1V
chassis ground
When failure codes [DDQ2KA] and [DD14KA] occurred at the same time

1 NSW
Possible causes
and standard Between (A) – (C) Min. 1 Mz Max. 1 z
Disconnection in wiring har- Wiring harness between NSW (female) (B) Resis-
Max. 1 z
ness (Disconnection in wiring – branched point of circuit M tance
2
or defective contact in con- Wiring harness between NSW (female) (C) Resis-
nector) Max. 1 z
– branched point of circuit N tance
Wiring harness between NSW (female) (A) Resis-
Max. 1 z
– chassis ground tance
66 D275A-5R
When failure codes [DDQ2KA] and [DD14KA] occurred at the same time
Possible causes
NSW (female) (B) – TMCN1 (female) (18) – Voltage Max. 1V
and standard Hot short circuit in wiring har- STCN2 (female) (5) with chassis ground
value in normal 3 ness (Contact with 24V cir-
state cuit) Short circuit of wiring harness between
NSW (female) (C) – TMCN1 (female) (12) – Voltage Max. 1V
Voltage Max. 1V
NSW (female) (4) with chassis ground
D275A-5R 67
Failure code [DDQ2KB] Parking brake lever switch short circuit 1

Action code Failure code Parking brake lever switch short circuit
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
a Since parking brake switch signal is used by both transmission controller and steering controller,
related codes may be displayed simultaneously, depending on troubled part. (Related codes:
DD14KB, DDQ2L4)
Related
information
(Code 40907: Blade control lever knob switch input signal)

Defective parking brake lever Parking brake lever

1 NSW
switch (Internal short circuit) At FREE At LOCK
Between (A) – (C) Min. 1 Mz Max. 1 z

and standard NSW (female) (B) – TMCN1 (female) (18) – Min. 1 Mz
value in normal STCN2 (female) (5) with chassis ground
Resis-
NSW (female) (C) – TMCN1 (female) (12) – Min. 1 Mz
tance
Parking brake lever
STCN2
At FREE At LOCK
Between (5) –
Max. 1 V 5 – 11 V
chassis ground
Between (15) –
5 – 11 V Max. 1 V
chassis ground
68 D275A-5R
D275A-5R 69
Failure code [DDQ2L4] Parking brake lever switch disagreement 1

Action code Failure code Parking brake lever switch disagreement
Trouble
CALL E03 DDQ2L4 (Steering controller system)
Contents of • Switch input signal of steering controller disagrees with communication signal from transmission
trouble controller.
Problem that
appears on
machine
a Since parking brake switch signal is used by both transmission controller and steering controller
and information is exchanged by CAN communication, related codes may be displayed simulta-
neously, depending on troubled part. (Related codes: DAFRKR, DB2RKR, DB3RKR, DAQRKR,
Related
DD14KA, DD14KB, DDQ2KA, DDN4LD, DDN5LD)
information
(Code 40907: Blade lever knob switch input signal)

See if failure codes [DAFRKR], [DB2RKR], [DB3RKR], and
Defective CAN communica-
Possible causes 1 [DAQRKR] are displayed. If they are displayed, carry out trouble-
tion signal system
and standard shooting for them first.
value in normal See if failure codes [DD14KA], [DD14KB], [DDQ2KA], and
state Defective parking brake lever
2 [DDQ2KB] are displayed. If they are displayed, carry out trouble-
switch signal system
shooting for them first.
3 Defective steering controller Since trouble is in system, troubleshooting cannot be carried out.
70 D275A-5R
Failure code [DDT5KA] Neutral switch disconnection 1

Action code Failure code Neutral switch disconnection
Trouble
CALL E04 DDT5KA (Transmission controller system)
Contents of • Signals of 2 neutral switch circuit systems of optional type travel lever are turned OFF (OPEN)
Problem that
appears on
• Once machine is stopped, it cannot travel at all.
machine
• Input state (ON/OFF) from neutral switch can be checked in real-time monitoring mode.
Related
information
• Method of reproducing failure code: Turn starting switch ON (+ operate neutral switch).

Possible causes
simultaneously)
D275A-5R 71
Failure code [DDT5KB] Neutral switch short circuit 1

Action code Failure code Neutral switch short circuit
Trouble
CALL E04 DDT5KB (Transmission controller system)
Contents of • Signals of 2 neutral switch circuit systems of optional type travel lever are turned ON (CLOSE)
Problem that
appears on
machine
Related
• Method of reproducing failure code: Turn starting switch ON (+ operate neutral switch).
information

Possible causes
simultaneously)
72 D275A-5R
Failure code [DDT5KQ] Lever specification selection (Model selection

signal disagreement) 1
Action code Failure code Lever specification selection (Model selection signal disagree-
Trouble ment)
CALL E04 DDT5KQ (Transmission controller system)
Contents of
• Specification of standard PCCS lever is not selected.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Possible causes Wrong selection of travel Check travel lever type in adjust- Select PCCS standard type
1
and standard lever type ment mode ID: 0004. lever.
value in normal If cause 1 is not detected, transmission controller may be defec-
state Defective transmission con-
2 tive. (Since trouble is in system, troubleshooting cannot be carried
troller
out.)
D275A-5R 73
Failure code [DGS1KX] Hydraulic oil temperature sensor input signal is

out of normal range 1
Action code Failure code Hydraulic oil temperature sensor input signal is out of normal range
Trouble
— DGS1KX (Transmission controller system)
Contents of
• Hydraulic oil temperature sensor signal is out of normal range.
trouble
Action of
• Recognizes that hydraulic oil temperature is maximum.
controller
Problem that
appears on • Hydraulic oil temperature gauge of machine monitor may not display normally.
machine
• Hydraulic oil temperature (temperature) can be checked in real-time monitoring mode.
Related
(Code 04401: Hydraulic oil temperature)
information
• Method of reproducing failure code: Turn starting switch ON or start engine.

Defective hydraulic oil tem-
1 perature sensor (Internal dis- 452 (male) Resistance
connection or short circuit) Between (1) – (2) 3.5 – 90 kz
Between (1) – chassis ground Min. 1 Mz
2 Max. 1 z
or defective contact in con- (14) – 452 (female) (1) tance
and standard (21) – 452 (female) (2) tance
(Contact with ground circuit) TMCN1 (female) (14) – 452 (female) (1) Resis-
Min. 1 Mz
tance
with chassis ground
Short circuit with power carry out troubleshooting.
4 source in wiring harness Short circuit of wiring harness between
(Contact with 24V circuit) TMCN1 (female) (14) – 452 (female) (1) Voltage Max. 1 V
with chassis ground
If causes 1 – 4 are not detected, tranmission controller may be
troller
carried out.)
74 D275A-5R
D275A-5R 75
D275A-5R Bulldozer
© 2007 KOMATSU
All Rights Reserved
76 D275A-5R
SEN02762-00
D275A-5R

D275A-5R 35001 and up
codes, Part 5
Failure code [DGT1KA] Power train oil temp sensor disconnection................................................................ 4
Failure code [DGT1KX] Power train oil temp sensor out of input signal range ............................................... 6
Failure code [DH21KB] Work equipment pump oil pressure sensor short circuit ........................................... 8
Failure code [DH22KA] Work equipment pump oil pressure sensor disconnection...................................... 10
Failure code [DH22KB] Work equipment pump oil pressure sensor short circuit ......................................... 12
Failure code [DK10KA] Fuel control dial disconnection ................................................................................ 14
Failure code [DK10KB] Fuel control dial short circuit.................................................................................... 16
Failure code [DK30KA] Steering potentiometer (1) disconnection................................................................ 18
Failure code [DK30KB] Steering potentiometer (1) short circuit ................................................................... 20
Failure code [DK30KX] Steering potentiometer (1) out of input signal range ............................................... 22
Failure code [DK30KZ] Steering potentiometer (1) disconnection or short circuit ........................................ 23
Failure code [DK30L8] Steering potentiometer (1) analog signals do not agree .......................................... 24
Failure code [DK31KA] Steering potentiometer (2) disconnection................................................................ 26
Failure code [DK31KB] Steering potentiometer (2) short circuit ................................................................... 28
D275A-5R 1
Failure code [DK40KA] Brake potentiometer disconnection ......................................................................... 30

Failure code [DK40KB] Brake potentiometer short circuit............................................................................. 32
Failure code [DK55KX] Directional potentiometer out of input signal range ................................................. 34
Failure code [DK55KZ] Directional potentiometer disconnection or short circuit .......................................... 35
Failure code [DK55L8] Directional potentiometer analog signals do not agree ............................................ 36
Failure code [DK56KA] F-R potentiometer (1) disconnection ....................................................................... 38
Failure code [DK56KB] F-R potentiometer (1) short circuit........................................................................... 40
Failure code [DK57KA] F-R potentiometer (2) disconnection ....................................................................... 42
Failure code [DK57KB] F-R potentiometer (2) short circuit........................................................................... 44
Failure code [DK60KA] Acceleration sensor disconnection .......................................................................... 46
Failure code [DK60KB] Acceleration sensor short circuit.............................................................................. 48
Failure code [DKH1KA] Pitch angle sensor disconnection ........................................................................... 50
Failure code [DKH1KB] Pitch angle sensor short circuit ............................................................................... 52
Failure code [DKH1KX] Pitch angle sensor out of input signal range ........................................................... 54
Failure code [DLT3KA] Transmission out-speed sensor disconnection ........................................................ 56
Failure code [DLT3KB] Transmission out-speed sensor abnormal ............................................................... 58
Failure code [DV00KB] Caution buzzer short circuit ..................................................................................... 59
Failure code [DW59KA] Blade dual selector solenoid disconnection............................................................ 60
Failure code [DW59KB] Blade dual selector solenoid short circuit ............................................................... 62
Failure code [DW59KY] Blade dual selector solenoid hot short.................................................................... 64
Failure code [DW5AKA] Blade pitch selector solenoid disconnection .......................................................... 65
Failure code [DW5AKB] Blade pitch selector solenoid short circuit .............................................................. 66
Failure code [DW5AKY] Blade pitch selection solenoid hot short circuit ...................................................... 68
2 D275A-5R
D275A-5R 3
Failure code [DGT1KA] Power train oil temp sensor disconnection 1

Action code Failure code Power train oil temp sensor disconnection
Trouble
E01 DGT1KA (Transmission system)
Contents of
• Signal of torque converter oil temperature sensor is below specified value.
trouble
Action of
• Limits operations of fan.
controller
Problem that • Power train oil temperature gauge of machine monitor does not indicate normally.
appears on • Fan speed is limited to medium (half).
machine • Gear shift shock of transmission may increase.
• Power train oil temperature can be checked with real-time monitoring mode.
Related
(Code: 30100 Power train oil temperature)
information

Defective power train oil tem- ing without turning starting switch ON.
perature sensor (Internal 453 (male) Resistance
1
short circuit or disconnec-
tion) Between (1) – (2) 3.5 – 90 kz (10°C – 100°C)
ness (Disconnection in wiring Wiring harness between S04 (female) (12) – Resis-
2 Max. 1 z
or defective contact in con- 453 (female) (1) tance
Possible causes
nector) Wiring harness between S03 (female) (3), Resis-
value in normal (4) – 453 (female) (2) tance
circuit) Wiring harness between S04 (female) (12) – Resis-
Min. 1 Mz
453 (female) (1) and chassis ground tance
Hot short (Short circuit with and carry out troubleshooting.
4
24V circuit) in wiring harness Wiring harness between S04 (female) (12) –
Voltage Max. 1 V
453 (female) (1) and chassis ground
If causes 1 – 4 are not detected, machine monitor may be defec-
5 Defective machine monitor tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
4 D275A-5R
D275A-5R 5
Failure code [DGT1KX] Power train oil temp sensor out of input signal
range 1
Action code Failure code Power train oil temp sensor out of input signal range
Trouble
E01 DGT1KX (Machine monitor system)
Contents of
• Power train oil temperature sensor signal is out of normal range.
trouble
Action of
• Limits operations of fan.
controller
Problem that • Power train oil temperature gauge of machine monitor does not indicate normally.
appears on • Fan speed is limited to medium (half).
machine • Gear shift shock of transmission may increase.
• Power train oil temperature can be checked with real-time monitoring mode.
Related
(Code: 30100 Power train oil temperature)
information

Defective Power train oil
temperature sensor (Internal Resistance
1 453 (male)
short circuit or disconnec- (Oil temperature: At 10 – 100°C)
tion) Between (1) – (2) 35 – 90 kz
ness (Disconnection in wiring Wiring harness between S04 (female) (12) – Resis-
2 Max. 1 z
Possible causes or defective contact in con- 453 (female) (1) tance
and standard nector) Wiring harness between S03 (female) (3), Resis-
(4) – 453 (female) (2) tance
state
circuit) Wiring harness between S04 (female) (12) – Resis-
Min. 1 Mz
453 (female) (1) and chassis ground tance
Hot short (Short circuit with and carry out troubleshooting.
4
24V circuit) in wiring harness Wiring harness between S04 (female) (12) –
Voltage Max. 1 V
453 (female) (1) and chassis ground
If causes 1 – 4 are not detected, machine monitor may be defec-
out.)
6 D275A-5R
D275A-5R 7
Failure code [DH21KB] Work equipment pump oil pressure sensor short
circuit 1
Action code Failure code Work equipment pump oil pressure sensor short circuit
Trouble
E01 DH21KB (Steering controller system)
Contents of
• Work equipment pump oil pressure sensor signal voltage is out of specified range.
trouble
Action of
Reference: Detection information in transmission controller is sent through CAN to steering controller
controller
and detected.
Problem that
• Work equipment oil pressure cannot be monitored.
appears on
• Power may become insufficient during steering operation.
machine
• Input (Voltage) from work equipment pump oil pressure sensor can be checked in real-time monitor-
Related ing mode. (Code 70701: Voltage of work equipment pump oil pressure sensor)
information • Method of reproducing failure code: Turn starting switch ON.
• DH22KA, DH22KB and DAQRKR are displayed this code at the same time.

and standard
value in normal If DH22KA, DH22KB and/or DAQRKR are displayed, carry out troubleshooting for them.
state
8 D275A-5R
D275A-5R 9
Failure code [DH22KA] Work equipment pump oil pressure sensor

disconnection 1
Action code Failure code Work equipment pump oil pressure sensor disconnection
Trouble
— DH22KA (Transmision controller system)
Contents of
• Signal voltage of work equipment pump oil pressure sensor circuit is below specified value.
trouble
Action of
controller
Problem that
appears on • Work equipment pump oil pressure cannot be monitored.
machine
Related ing mode. (Code 70701: Voltage of work equipment pump oil sensor)
• DH21KB is displayed as well as this code.

Defective 5 V power source See if failure code [DAQ7KK] is displayed. If it is displayed, carry
1
system out troubleshooting for it first.
Defective work equipment carry out troubleshooting.
2 pump oil pressure sensor
HHP Voltage
(Internal trouble)
Between (C) – (A) 0.5 – 6.0 V
Max. 1 z
ness (Disconnection in wiring (34) – HHP (female) (B) tance
Possible causes 3
and standard nector) Max. 1 z
(9) – HHP (female) (C) tance
value in normal
state Wiring harness between TMCN1 (female) Resis-
Max. 1 z
(21) – HHP (female) (A) tance
TMCN1 (female) (9) – HHP (female) (C) Min. 1 Mz
with chassis ground
Resis-
TMCN3 (female) (34) – HHP (female) (B) Min. 1 Mz
tance
with chassis ground
If causes 1 – 4 are not detected, transmission controller may be
troller
carried out.)
10 D275A-5R
D275A-5R 11
Failure code [DH22KB] Work equipment pump oil pressure sensor short
circuit 1
Action code Failure code Work equipment pump oil pressure sensor short circuit
Trouble
— DH22KB (Transmision controller system)
Contents of
• Signal voltage of work equipment pump oil pressure sensor circuit is above specified value.
trouble
Action of
controller
Problem that
appears on • Work equipment pump oil pressure cannot be monitored.
machine
Related ing mode. (Code 70701: Voltage of work equipment pump oil pressure sensor)
• DH21KB is displayed as well as this code.

Defective 5 V power source See if failure code [DAQ7KK] is displayed. If it is displayed, carry
1
Defective work equipment carry out troubleshooting.
2 pump oil pressure sensor
HHP Voltage
(Internal trouble)
Between (C) – (A) 0.5 – 6.0 V
Possible causes carry out troubleshooting.
and standard Short circuit of wiring harness between
value in normal TMCN1 (female) (9) – HHP (female) (C) Voltage Max. 1 V
state Short circuit with power with chassis ground
3 source in wiring harness Short circuit of wiring harness between
(Contact with 24V circuit) TMCN3 (female) (34) – HHP (female) (B) Voltage Max. 1 V
with chassis ground
TMCN1 (female) (21) – HHP (female) (A) Voltage Max. 1 V
with chassis ground
troller
carried out.)
12 D275A-5R
D275A-5R 13
Failure code [DK10KA] Fuel control dial disconnection 1

Action code Failure code Fuel control dial disconnection
Trouble
CALL E03 DK10KA (Steering controller system)
Contents of
• Input voltage from fuel control dial is below specified value
trouble
Action of
controller
• Continues control with signal of decelerator pedal potentiometer.
Problem that
appears on
machine
• Input voltage of fuel control dial can be checked in real-time monitoring mode.
Related
(Code: 03000: Fuel control dial input voltage)
information

Defective 5V power source If failure code [DB35KK] is displayed, carry out troubleshooting for
1
system it first.
Defective fuel control dial DIAL (male) Resistance
2 (Internal disconnection or
(1) – (3) 4.0 – 6.0 kz
short circuit)
(1) – (2) 0.5 – 4.5 kz
(3) – (2) 0.5 – 4.5 kz
Max. 1 z
Possible causes ness (Disconnection in wiring (22) – DIAL (female) (1) tance
3
(21) – DIAL (female) (3) tance
state
Max. 1 z
circuit)
Min. 1 Mz
Between STCN1 (22) – (21) 4.6 – 5.4 V
Between STCN1 (8) – (21) 0.5 – 4.5 V
14 D275A-5R
D275A-5R 15
Failure code [DK10KB] Fuel control dial short circuit 1

Action code Failure code Fuel control dial short circuit
Trouble
CALL E03 DK10KB (Steering controller system)
Contents of
• Input voltage from fuel control dial is above specified value.
trouble
Action of
controller
• Continues control with signal of decelerator pedal potentiometer.
Problem that
appears on
machine
• Input voltage of fuel control dial can be checked in real-time monitoring mode.
Related
(Code: 03000: Fuel control dial input voltage)
information

Defective 5V power source If failure code [DB35KK] is displayed, carry out troubleshooting for
1
system it first.
Defective fuel control dial DIAL (male) Resistance
2 (Internal disconnection or
(1) – (3) 4.0 – 6.0 kz
short circuit)
(1) – (2) 0.5 – 4.5 kz
(3) – (2) 0.5 – 4.5 kz
3
Possible causes or defective contact in con- Wiring harness between STCN1 (female) Resis-
nector) Max. 1 z
and standard (22) – DIAL (female) (1) tance
value in normal a Prepare with starting switch OFF, then turn starting switch ON
state and carry out troubleshooting.
Wiring harness between STCN1 (female)
Voltage Min. 1 V
Hot short (Short circuit with (22) – DIAL (female) (1) with chassis ground
4
24V circuit) in wiring harness Wiring harness between STCN1 (female)
Voltage Min. 1 V
(8) – DIAL (female) (2) with chassis ground
Voltage Min. 1 V
(21) – DIAL (female) (3) with chassis ground
Between STCN1 (22) – (21) 4.6 – 5.4 V
Between STCN1 (8) – (21) 0.5 – 4.5 V
16 D275A-5R
D275A-5R 17
Failure code [DK30KA] Steering potentiometer (1) disconnection 1

Action code Failure code Steering potentiometer (1) disconnection
Trouble
Contents of
• Signal voltage of steering potentiometer 1 system (L) is below specified value.
trouble
• Continues control with signal of steering potentiometer 2 system (R).
Action of
controller
Problem that
appears on
machine
• State of steering potentiometer 1 (L) signal can be checked with real-time monitoring mode. (Code:
Related 50300 Steering lever potentio 1 voltage)
information • Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (in steering
direction).

Defective sensor 5V power If failure code [DB35KK] is also displayed, carry out troubleshoot-
1
supply system ing for it first.
Between (5) – (8) 3.2 kz ± 20%
2 ometer 1 (Internal discon-
nection) 6–1z
Between (5) – (7)
(Right – Left steering)
1–6z
Between (7) – (8)
and standard Disconnection in wiring har-
value in normal ness (Disconnection in wiring Wiring harness between STCN1 (female) Resis-
3 Max. 1 z
state or defective contact in con- (22) – TL2 (female) (5) tance
Max. 1 z
(2) – TL2 (female) (7) tance
(2) – TL2 (female) (7) with chassis ground tance
circuit)
Min. 1 Mz
STCN1 Voltage
Between (2) – (21) 0.5 – 4.5 V
18 D275A-5R
D275A-5R 19
Failure code [DK30KB] Steering potentiometer (1) short circuit 1

Action code Failure code Steering potentiometer 1 short circuit
Trouble
Contents of
• Signal voltage of steering potentiometer 1 system (L) is higher than specified value.
trouble
• Continues control with signal of steering potentiometer 2 system (R).
Action of
controller
Problem that
appears on
machine
• State of steering potentiometer 1 (L) signal can be checked with real-time monitoring mode. (Code:
direction).

1
Between (5) – (8) 3.2 kz ± 20%
2 ometer 1 (Internal short cir-
cuit) 1 – 6 kz
Between (5) – (7)
Possible causes
6 – 1 kz
and standard Between (7) – (8)
value in normal
Hot short (Short circuit with Wiring harness between STCN1 (female)
3 Voltage Max. 1 V
24V circuit) in wiring harness (2) – TL2 (female) (7) with chassis ground
Voltage Max. 1 V
(22) – TL2 (female) (5) with chassis ground
STCN1 Voltage
Between (2) – (21) 0.5 – 4.5 V
20 D275A-5R
D275A-5R 21
Failure code [DK30KX] Steering potentiometer (1) out of input signal

range 1
Action code Failure code Steering potentiometer (1) out of input signal range
Trouble
CALL E04 DK30KX (Steering controller system)
Contents of • In steering potentiometer 1 and 2 systems, either of failure codes [DK30KA] and [DK30KB] and
trouble either of failure codes [DK31KA] and [DK31KB] occurred simultaneously.
Action of • Limits operation of engine and transmission.
controller • Flashes caution lamp and turns on caution buzzer.
Problem that
appears on
machine
• State of steering potentiometer signal can be checked with real-time monitoring mode.
(Code: 50300 Steering lever potentio 1 voltage)
Related
information
• Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (in steering
direction).

and standard
value in normal Carry out troubleshooting for failure codes [DK30KA], [DK30KB], [DK31KA], and [DK31KB].
state
22 D275A-5R
Failure code [DK30KZ] Steering potentiometer (1) disconnection or

short circuit 1
Action code Failure code Steering potentiometer (1) disconnection or short circuit
Trouble
CALL E04 DK30KZ (Steering controller system)
• In steering potentiometer 1 and 2 systems, when starting switch is turned ON, only either side is
Contents of
abnormal and then either of failure codes [DK30KA] and [DK30KB] and either of failure codes
trouble
[DK31KA] and [DK31KB] occurred simultaneously.
Problem that
appears on
machine
Related
information
direction).

and standard
state
D275A-5R 23
Failure code [DK30L8] Steering potentiometer (1) analog signals do not

agree 1
Action code Failure code Steering potentiometer (1) analog signals do not agree
Trouble
CALL E03 DK30L8 (Steering controller system)
Contents of
• Total of signal voltages of steering potentiometer 1 and 2 systems is above specified range.
trouble
• Continues control with signal of normal one of PCCS lever steering potentiometer 1 and 2 systems.
Action of
controller
Problem that
appears on
machine
Related
information
direction).

and standard
state
24 D275A-5R
D275A-5R 25
Failure code [DK31KA] Steering potentiometer (2) disconnection 1

Action code Failure code Steering potentiometer (2) disconnection
Trouble
Contents of
• Signal voltage of steering potentiometer 2 system (R) is below specified value.
trouble
• Continues control with signal of steering potentiometer 1 system (L).
Action of
controller
Problem that
appears on
machine
• State of steering potentiometer 2 (R) signal can be checked with real-time monitoring mode.
Related (Code: 50301 Steering lever potentio 2 voltage)
direction).

1
Between (5) – (8) 3.2 kz ± 20%
2 ometer 2 (Internal discon-
nection) 6–1z
Between (5) – (6)
1–6z
Between (6) – (8)
and standard Disconnection in wiring har-
3 Max. 1 z
state or defective contact in con- (22) – TL2 (female) (5) tance
Max. 1 z
circuit)
Min. 1 Mz
STCN1 Voltage
Between (19) – (21) 0.5 – 4.5 V
26 D275A-5R
D275A-5R 27
Failure code [DK31KB] Steering potentiometer (2) short circuit 1

Action code Failure code Steering potentiometer (2) short circuit
Trouble
Contents of
• Signal voltage of steering potentiometer 2 system (R) is above specified value.
trouble
• Continues control with signal of steering potentiometer 1 system (L).
Action of
controller
Problem that
appears on
machine
• State of steering potentiometer 2 (R) signal can be checked with real-time monitoring mode. (Code:
direction).

1
Between (5) – (8) 3.2 kz ± 20%
2 ometer 2 (Internal short cir-
cuit) 6–1z
Between (5) – (6)
Possible causes
1–6z
and standard Between (6) – (8)
value in normal
3 Voltage Max. 1 V
24V circuit) in wiring harness (19) – TL2 (female) (6) with chassis ground
Voltage Max. 1 V
STCN1 Voltage
Between (19) – (21) 0.5 – 4.5 V
28 D275A-5R
D275A-5R 29
Failure code [DK40KA] Brake potentiometer disconnection 1

Action code Failure code Brake potentiometer disconnection
Trouble
Contents of
• Signal voltage of brake pedal potentiometer is below specified value
trouble
Action of
• Does not control brake with brake potentiometer signal (Pedal can be operated).
controller
• Limits operations of engine and transmission.
Problem that • Brake control performance of brake pedal lowers.
• State of brake pedal potentiometer signal can be checked with real-time monitoring mode.
Related
(Code: 50400 Brake pedal potentio voltage)
information
• Method of reproducing failure code: Turn starting switch ON + Operate brake pedal.

1
Defective brake pedal poten- BRK (male) Resistance
2 tiometer (Internal disconnec-
Between (A) – (C) 4.0 – 6.0 kz
tion)
Between (A) – (B) 1.5 – 4.5 kz (Free – fullstroke)
Between (B) – (C) 4.5 – 1.5 kz (Free – fullstroke)
Max. 1 z
Possible causes ness (Disconnection in wiring (21) – BRK (female) (A) tance
and standard 3
(3) – BRK (female) (B) tance
state
Max. 1 z
(22) – BRK (female) (C) tance
Ground fault in wiring har- Wiring harness between STCN1 (female) Resis-
Min. 1 Mz
4 ness (Contact with ground (3) – BRK (female) (B) and chassis ground tance
circuit) Wiring harness between STCN1 (female)
Resis-
(22) – BRK (female) (C) or circuit branch Min. 1 Mz
tance
end and chassis ground
STCN1 Voltage
Between (3) – (21) 1.5 – 4.5 V
30 D275A-5R
D275A-5R 31
Failure code [DK40KB] Brake potentiometer short circuit 1

Action code Failure code Brake potentiometer short circuit
Trouble
Contents of
• Signal voltage of brake pedal potentiometer is above specified value.
trouble
Action of
• Does not control brake with brake potentiometer signal (Pedal can be operated).
controller
• Limits operations of engine and transmission.
Problem that • Brake control performance of brake pedal lowers.
• State of brake pedal potentiometer signal can be checked with real-time monitoring mode.
Related
(Code: 50400 Brake pedal potentio voltage)
information
• Method of reproducing failure code: Turn starting switch ON + Operate brake pedal.

1
Defective brake pedal poten- BRK (male) Resistance
2 tiometer (Internal short cir-
Between (A) – (C) 4.0 – 6.0 kz
cuit)
Between (A) – (B) 1.5 – 4.5 kz (Free – fullstroke)
Between (B) – (C) 4.5 – 1.5 kz (Free – fullstroke)
and standard Wiring harness between STCN1 (female)
value in normal Hot short (Short circuit with Voltage Max. 1 V
3 (3) – BRK (female) (B) and chassis ground
state 24V circuit) in wiring harness
(22) – BRK (female) (C) or circuit branch Voltage Max. 1 V
end and chassis ground
4
nector) Max. 1 z
(21) – BRK (female) (A) tance
STCN1 Voltage
Between (3) – (21) 1.5 – 4.5 V
32 D275A-5R
D275A-5R 33
Failure code [DK55KX] Directional potentiometer out of input signal

range 1
Action code Failure code Directional potentiometer out of input signal range
Trouble
CALL E04 DK55KX (Transmission controller system)
Contents of • In F-R potentiometer 1 and 2 systems, either of failure codes [DK56KA] and [DK56KB] and either
trouble of failure codes [DK57KA] and [DK57KB] occurred simultaneously.
Problem that
appears on
machine
• State of F-R potentiometer signal can be checked with real-time monitoring mode.
(Code: 50200 F-R lever potentio 1 voltage)
Related
information
• Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (in F-R direc-
tion).

and standard
state
34 D275A-5R
Failure code [DK55KZ] Directional potentiometer disconnection or short

circuit 1
Action code Failure code Directional potentiometer disconnection or short circuit
Trouble
CALL E04 DK55KZ (Transmission controller system)
• In F-R potentiometer 1 and 2 systems, when starting switch is turned ON, only either side is abnor-
Contents of
mal and then either of failure codes [DK56KA] and [DK56KB] and either of failure codes [DK57KA]
trouble
and [DK57KB] occurred simultaneously.
Problem that
appears on
machine
Related
information
tion).

and standard
state
D275A-5R 35
Failure code [DK55L8] Directional potentiometer analog signals do not

agree 1
Action code Failure code Directional potentiometer analog signals do not agree
Trouble
CALL E03 DK55L8 (Transmission controller system)
Contents of
• Total of signal voltages of directional potentiometer 1 and 2 systems is above specified range.
trouble
Action of • Continues control with signal of normal one of F-R potentiometer 1 and 2 systems.
Problem that
appears on
machine
Related
information
tion).

and standard
state
36 D275A-5R
D275A-5R 37
Failure code [DK56KA] F-R potentiometer (1) disconnection 1

Action code Failure code F-R potentiometer (1) disconnection
Trouble
CALL E03 DK56KA (Transmission controller system)
Contents of
• Signal voltage of F-R potentiometer 1 system (R) is below specified value.
trouble
• Continues control with signal of F-R potentiometer 2 system (F).
Action of
controller
Problem that
appears on
machine
• State of F-R potentiometer 1 (R) signal can be checked with real-time monitoring mode.
Related (Code: 50200 F-R lever potentio 1 voltage)
information • Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (in F-R direc-
tion).

Defective sensor 5V power If failure code [DAQ5KK] is also displayed, carry out troubleshoot-
1
Defective F-R potentiometer TL2 (male) Resistance

2
1 (Internal disconnection) Between (4) – (1) 3.2 kz ± 20%
Between (4) – (3) 6 – 1 kz (F-R)
Between (3) – (1) 1 – 6 kz (F-R)
Possible causes
and standard ness (Disconnection in wiring Wiring harness between TMCN1 (female) Resis-
3 Max. 1 z
value in normal or defective contact in con- (22) – TL2 (female) (4) tance
state nector) Wiring harness between TMCN1 (female) Resis-
Max. 1 z
Wiring harness between TMCN1 (female) Resis-
circuit)
Min. 1 Mz
5
Between (2) – (21) 0.5 – 4.5 V
38 D275A-5R
D275A-5R 39
Failure code [DK56KB] F-R potentiometer (1) short circuit 1

Action code Failure code F-R potentiometer (1) short circuit
Trouble
CALL E03 DK56KB (Transmission controller system)
Contents of
• Signal voltage of directional potentiometer 1 system (R) is above specified value.
trouble
• Continues control with signal of F-R potentiometer 2 system.
Action of
controller
Problem that
appears on
machine
tion).

1

2
1 (Internal short circuit) Between (4) – (1) 3.2 kz ± 20%
Between (4) – (3) 6 – 1 kz (F-R)
Between (3) – (1) 1 – 6 kz (F-R)
Possible causes
and standard Wiring harness between TMCN1 (female)
Voltage Max. 1 V
value in normal Hot short (Short circuit with (2) – TL2 (female) (3) with chassis ground
3
state 24V circuit) in wiring harness Wiring harness between TMCN1 (female)
Voltage Max. 1 V
Wiring harness between TMCN1 (female)
Voltage Max. 1 V
4
nector) Max. 1 z
5
Between (2) – (21) 0.5 – 4.5 V
40 D275A-5R
D275A-5R 41
Failure code [DK57KA] F-R potentiometer (2) disconnection 1

Action code Failure code F-R potentiometer (2) disconnection
Trouble
CALL E03 DK57KA (Transmission controller system)
Contents of
• Signal voltage of F-R potentiometer 2 system (F) is below specified value.
trouble
• Continues control with signal of F-R potentiometer 1 system (R).
Action of
controller
Problem that
appears on
machine
tion).

1

2
2 (Internal disconnection) Between (4) – (1) 3.2 kz ± 20%
Between (4) – (2) 1 – 6 kz (F-R)
Between (2) – (1) 6 – 1 kz (F-R)
Possible causes
and standard ness (Disconnection in wiring Wiring harness between TMCN1 (female) Resis-
3 Max. 1 z
value in normal or defective contact in con- (22) – TL2 (female) (4) tance
state nector) Wiring harness between TMCN1 (female) Resis-
Max. 1 z
circuit)
Min. 1 Mz
5
Between (19) – (21) 0.5 – 4.5 V
42 D275A-5R
D275A-5R 43
Failure code [DK57KB] F-R potentiometer (2) short circuit 1

Action code Failure code F-R potentiometer (2) short circuit
Trouble
CALL E03 DK57KB (Transmission controller system)
Contents of
• Signal voltage of F-R potentiometer 2 system (F) is above specified value.
trouble
• Continues control with signal of F-R potentiometer 1 system (R).
Action of
controller
Problem that
appears on
machine
• State of F-R potentiometer 2 (F) signal can be checked with real-time monitoring mode.
tion).

1

2
2 (Internal short circuit) Between (4) – (1) 3.2 kz ± 20%
Between (4) – (2) 1 – 6 kz (F-R)
Between (2) – (1) 6 – 1 kz (F-R)
Possible causes
and standard Wiring harness between TMCN1 (female)
Voltage Max. 1 V
value in normal Hot short (Short circuit with (19) – TL2 (female) (2) with chassis ground
3
state 24V circuit) in wiring harness Wiring harness between TMCN1 (female)
Voltage Max. 1 V
Voltage Max. 1 V
4
nector) Max. 1 z
5
Between (19) – (21) 0.5 – 4.5 V
44 D275A-5R
D275A-5R 45
Failure code [DK60KA] Acceleration sensor disconnection 1

Action code Failure code Acceleration sensor disconnection
Trouble
E01 DK60KA (Steering controller system)
Contents of
• Signal voltage of acceleration sensor is below specified value.
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 real-time monitoring mode.
Related
(Code 60200: Voltage of acceleration sensor)
information

Defective 5V power source See if failure code [DB37KK] is displayed. If it is displayed, carry
1
Defective acceleration sen- and carry out troubleshooting.
2
sor (Internal trouble) SSA Voltage
Between (2) – (3) 0.75 – 4.25 V
Possible causes 3 Max. 1 z
or defective contact in con- (34) – SSA (female) (1) tance
and standard nector) Wiring harness between STCN1 (female) Resis-
(1) – SSA (female) (2) tance
state
STCN1 (female) (1) – SSA (female) (2) with Min. 1 Mz
chassis ground
Resis-
STCN3 (female) (34) – SSA (female) (1) Min. 1 Mz
tance
with chassis ground
If causes 1 – 4 are not detected, steering controller may be defec-
5 Defective steering controller tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
46 D275A-5R
D275A-5R 47
Failure code [DK60KB] Acceleration sensor short circuit 1

Action code Failure code Acceleration sensor short circuit
Trouble
E01 DK60KB (Steering controller system)
Contents of
• Signal voltage of acceleration sensor is below specified value
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 real-time monitoring mode.
Related
(Code 60200: Voltage of acceleration sensor)
information

Defective 5V power source See if failure code [DB37KK] is displayed. If it is displayed, carry
1
Defective acceleration sen- and carry out troubleshooting.
2
sor (Internal trouble) SSA Voltage
Between (2) – (3) 0.75 – 4.25 V
Possible causes STCN1 (female) (1) – SSA (female) (2) with Voltage Max. 1 V
and standard Short circuit with power chassis ground
value in normal 3 source in wiring harness Short circuit of wiring harness between
state (Contact with 24V circuit) STCN1 (female) (21) – SSA (female) (3) Voltage Max. 1 V
with chassis ground
STCN3 (female) (34) – SSA (female) (1) Voltage Max. 1 V
with chassis ground
4
nector) Max. 1 z
(21) – SSA (female) (3) tance
out.)
48 D275A-5R
D275A-5R 49
Failure code [DKH1KA] Pitch angle sensor disconnection 1

Action code Failure code Pitch angle sensor disconnection
Trouble
CALL E03 DKH1KA (Steering controller system)
Contents of
• Signal voltage of pitch angle sensor is below specified value.
trouble
• Cannot sense pitch angle of machine.
Action of
controller
Problem that • Gearshift shock is made on slope or steering shock is made on level ground.
• State of pitch angle sensor signal can be checked with real-time monitoring mode.
Related
(Code: 60100 voltage of pitch angle sensor)
information

1
PT1 Voltage
Defective pitch angle sensor Between (C) – (A) Power supply 20 – 30 V
2
(Internal trouble) Between (B) – (A) Signal 0.15 – 4.85 V
value in normal
state 3 Max. 1 z
or defective contact in con- (13) – PT1 (female) (B) tance
Max. 1 z
(16) – PT1 (female) (C) tance
(13) – PT1 (female) (B) with chassis ground tance
circuit)
Min. 1 Mz
(16) – PT1 (female) (C) with chassis ground tance
out.)
50 D275A-5R
D275A-5R 51
Failure code [DKH1KB] Pitch angle sensor short circuit 1

Action code Failure code Pitch angle sensor short circuit
Trouble
CALL E03 DKH1KB (Steering controller system)
Contents of
• Signal voltage of pitch angle sensor is above specified value
trouble
• Cannot sense pitch angle of machine.
Action of
controller
Problem that • Gearshift shock is made on slope or steering shock is made on level ground.
• State of pitch angle sensor signal can be checked with real-time monitoring mode.
Related
(Code: 60100 Pitch angle sensor voltage)
information

1
PT1 Voltage
Defective pitch angle sensor Between (C) – (A) Power supply 20 – 30 V
2
(Internal trouble) Between (B) – (A) Signal 0.15 – 4.85 V
Possible causes troller, too, for another cause of trouble, and then judge.
and standard a Prepare with starting switch OFF, then turn starting switch ON
value in normal and carry out troubleshooting.
state
3 Voltage Max. 1 V
24V circuit) in wiring harness (13) – PT1 (female) (B) with chassis ground
Voltage Max. 1 V
(21) – PT1 (female) (A) with chassis ground
4
nector) Max. 1 z
(21) – PT1 (female) (A) tance
out.)
52 D275A-5R
D275A-5R 53
Failure code [DKH1KX] Pitch angle sensor out of input signal range 1
Action code Failure code Pitch angle sensor out of input signal range
Trouble
E01 DKH1KX (Transmission controller system)
Contents of • Either of pitch angle sensor errors [DKH1KA] and [DKH1KB] occurred or steering controller CAN
trouble communication failure code [DB3RKR] occurred.
Action of
• Cannot recognize pitch angle.
controller
Problem that
appears on • Gear speed is not changed automatically.
machine
• Input voltage from pitch angle sensor can be checked in real-time monitoring mode.
Related
(Code: 60100: Pitch angle sensor voltage)
information

and standard
value in normal Carry out troubleshooting for disconnection in pitch angle sensor [DKH1KA] and short circuit
state [DKH1KB] and steering controller CAN communication error [DB3RKR].
54 D275A-5R
D275A-5R 55
Failure code [DLT3KA] Transmission out-speed sensor disconnection 1

Action code Failure code Transmission out-speed sensor disconnection
Trouble
E01 DLT3KA (Transmission controller system)
Contents of
• No signal is input from transmission bevel speed sensor.
trouble
Action of
• Recognizes that transmission bevel speed is 0 rpm.
controller
• Transmission bevel speed cannot be monitored.
Problem that
• Traction force cannot be calculated.
appears on
• Auto shift down function does not work normally.
machine
• Gear shift shock is large.
• Transmission bevel speed can be checked with real-time monitoring mode.
Related (Code: 31400 Transmission output speed)
information • Method of reproducing failure code: Turn starting switch ON + Drive machine (actually or with no
load).

Defective transmission bevel
1 speed sensor (Internal dis- TM1 (male) Resistance
connection or short circuit) Between (1) – (2) 500 – 1,000 z
2 Max. 1 z
or defective contact in con- (30) – TM1 (female) (1) tance
Max. 1 z
(39) – TM1 (female) (2) tance
Possible causes
and standard a Prepare with starting switch OFF, then carry out troubleshoot-
value in normal ing without turning starting switch ON.
state Ground fault in wiring har-
(30) – TM1 (female) (1) with chassis ground tance
circuit)
Min. 1 Mz
Hot short (Short circuit with Wiring harness between TMCN2 (female)
4 Voltage Max. 1 V
24V circuit) in wiring harness (30) – TM1 (female) (1) with chassis ground
Voltage Max. 1 V
(39) – TM1 (female) (2) with chassis ground
troller
carried out.)
56 D275A-5R
D275A-5R 57
Failure code [DLT3KB] Transmission out-speed sensor abnormal 1

Action code Failure code Transmission out-speed sensor abnormal
Trouble
E01 DLT3KB (Transmission controller system)
Contents of
• While machine is traveling, signal from transmission bevel speed sensor does not change.
trouble
Action of
• Recognizes that transmission bevel speed is 0 rpm.
controller
• Transmission bevel speed cannot be monitored.
Problem that
• Traction force cannot be calculated.
appears on
• Auto shift down function does not work normally.
machine
• Gear shift shock is large.
• Transmission bevel speed can be checked with real-time monitoring mode.
Related (Code: 31400 Transmission output speed)
information • Method of reproducing failure code: Turn starting switch ON + Drive machine (actually or with no
load).

Defective installation of
Carry out Testing and adjusting, "Adjusting transmission speed
1 transmission output speed
sensor".
sensor
Defective transmission bevel
2 speed sensor (Internal dis- TM1 (male) Resistance
Possible causes connection or short circuit) Between (1) – (2) 500 – 1,000 z
and standard Between (1) – chassis ground Min. 1 Mz
value in normal
state
circuit)
Min. 1 Mz
troller
carried out.)
58 D275A-5R
Failure code [DV00KB] Caution buzzer short circuit 1

Action code Failure code Caution buzzer short circuit
Trouble
– DV00KB (Machine monitor system)
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 failure code: Turn starting switch ON (When it is turned ON, buzzer sounds
information for 1 second).

Defective caution buzzer ing without turning starting switch ON.
1
(Internal short circuit) 217 (male) Resistance
Between (1) – (2) 200 z
Possible causes
Hot short (Short circuit with
state 2
24V circuit) in wiring harness Short circuit of wiring harness between 217
(female) (1) – S03 (female) (18) with chas- Voltage Max. 1 V
sis ground
If causes 1 and 2 are not detected, machine monitor may be defec-
out.)
D275A-5R 59
Failure code [DW59KA] Blade dual selector solenoid disconnection 1

Action code Failure code Blade dual selector solenoid disconnection
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 real-time monitoring mode.
Related
(Code 70600: Blade dual solenoid drive current)
information
• Method of reproducing failure code: Turn starting switch ON and perform blade dual tilt operation.

Defective blade dual selector ing without turning starting switch ON.
1 solenoid (Internal short cir-
PA (male) Resistance
cuit)
Between (1) – (2) 10 – 40 z
value in normal
state 2 Max. 1 z
or defective contact in con- (27) – PA (female) (1) tance
Max. 1 z
(23) – PA (female) (2) tance
If causes 1 and 2 are not detected, transmission controller may be
troller
carried out.)
60 D275A-5R
D275A-5R 61
Failure code [DW59KB] Blade dual selector solenoid short circuit 1

Action code Failure code Blade dual selector solenoid short circuit
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 real-time monitoring mode.
Related
information
• Method of reproducing failure code: Turn starting switch ON and perform blade dual tilt operation.

Defective blade dual selector
1 solenoid (Internal short cir- PA (male) Resistance
cuit) Between (1) – (2) 10 – 40 z
Possible causes Short circuit with chassis ing without turning starting switch ON.
and standard 2 ground in wiring harness Short circuit of wiring harness between
(Contact with ground circuit) TMCN3 (female) (27) – PA (female) (1) with Resis-
tance
state chassis ground
3 ness (with another wiring Wiring harness between TMCN3 (female)
harness) Resis-
(23) – PA (female) (2), TMCN3 (female) (29) Min. 1 Mz
tance
– PA (female) (1)
If causes 1 – 3 is not detected, transmission controller may be
troller
carried out.)
62 D275A-5R
D275A-5R 63
Failure code [DW59KY] Blade dual selector solenoid hot short 1

Action code Failure code Blade dual selector solenoid hot short
Trouble
E01 DW59KY (Transmission controller system)
Contents of
• Some current keeps flowing to blade dual selection solenoid circuit.
trouble
Action of
• Stops outputting signal to blade dual selection solenoid circuit.
controller
Problem that
appears on • Blade dual tilt mechanism keeps operation.
machine
• Output (Current) to blade dual selection solenoid can be checked in real-time monitoring mode.
Related
information
• Method of reproducing failure code: Turn starting switch ON + (Perform blade pitch).

Defective blade dual selec- ing without turning starting switch ON.
1 tion solenoid (Internal short
PPA (male) Resistance
circuit)
Possible causes Between (1) – (2) 10 – 40 z
Hot short (Contact with 24V
state 2
circuit) in wiring harness Wiring harness between TMCN3 (female)
Voltage Max. 1 V
(27) – PA (female) (1)
troller
carried out.)
64 D275A-5R
Failure code [DW5AKA] Blade pitch selector solenoid disconnection 1

Action code Failure code Blade pitch selector solenoid disconnection
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 real-time monitoring mode.
Related
(Code 31625: Blade pitch solenoid drive current)
information
• Method of reproducing failure code: Turn starting switch ON and perform blade pitch operation.

Defective blade pitch selec- ing without turning starting switch ON.
1 tor solenoid (Internal short
PB (male) Resistance
circuit)
Between (1) – (2) 10 – 40 z
value in normal
state 2 Max. 1 z
or defective contact in con- (37) – PB (female) (1) tance
Max. 1 z
(23) – PB (female) (2) tance
troller
carried out.)
D275A-5R 65
Failure code [DW5AKB] Blade pitch selector solenoid short circuit 1

Action code Failure code Blade pitch selector solenoid short circuit
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 real-time monitoring mode.
Related
information
• Method of reproducing failure code: Turn starting switch ON and perform blade pitch operation.

Defective blade pitch selec-
1 tor solenoid (Internal short PB (male) Resistance
circuit) Between (1) – (2) 10 – 40 z
Possible causes Short circuit with chassis ing without turning starting switch ON.
and standard 2 ground in wiring harness Short circuit of wiring harness between
(Contact with ground circuit) TMCN3 (female) (37) – PB (female) (1) with Resis-
tance
state chassis ground
3 ness (with another wiring Wiring harness between TMCN3 (female)
harness) Resis-
(23) – PB (female) (1), TMCN3 (female) (37) Min. 1 Mz
tance
- PB (female) (2)
troller
carried out.)
66 D275A-5R
D275A-5R 67
Failure code [DW5AKY] Blade pitch selection solenoid hot short

circuit 1
Action code Failure code Blade pitch selection solenoid hot short circuit
Trouble
E02 DW5AKY (Transmission controller system)
Contents of
• Some current keeps flowing to blade pitch selection solenoid circuit.
trouble
controller • Stops outputting signal to blade pitch selection solenoid circuit.
Problem that
appears on • Blade pitch selector solenoid keeps operation.
machine
• Output state (Current) to blade pitch selection solenoid can be checked in real-time monitoring
Related
mode. (Code 31625: Blade pitch solenoid drive current)
information
• Method of reproducing failure code: Turn starting switch ON + (Perform blade pitch)

Defective blade pitch selec- ing without turning starting switch ON.
1 tion solenoid (Internal short
PTH (male) Resistance
circuit)
state 2
circuit) in wiring harness Wiring harness between TMCN3 (female)
Voltage Max. 1 V
(37) – PB (female) (1)
troller
carried out.)
68 D275A-5R
D275A-5R 69
D275A-5R Bulldozer
© 2007 KOMATSU
All Rights Reserved
70 D275A-5R
SEN02763-01
D275A-5R

D275A-5R 35001 and up
codes, Part 6
Failure code [DW7BKA] Fan rev EPC disconnection ..................................................................................... 3
Failure code [DW7BKB] Fan rev EPC short circuit ......................................................................................... 4
Failure code [DW7BKY] Fan reverse solenoid hot short circuit ...................................................................... 5
Failure code [DWN3KA] Sudden stop prevention solenoid disconnection ..................................................... 6
Failure code [DWN3KB] Sudden stop prevention solenoid short circuit ......................................................... 8
Failure code [DWN3KY] Sudden stop prevention solenoid hot short circuit ................................................. 10
Failure code [DWN5KA] Fan pump solenoid disconnection ......................................................................... 12
Failure code [DWN5KB] Fan pump solenoid short circuit............................................................................. 14
Failure code [DWN5KY] Fan pump solenoid hot short circuit....................................................................... 16
Failure code [DXH4KA] 1st clutch ECMV disconnection .............................................................................. 18
Failure code [DXH4KB] 1st clutch ECMV short circuit.................................................................................. 20
Failure code [DXH4KY] 1st clutch ECMV hot short circuit............................................................................ 22
Failure code [DXH5KA] 2nd clutch ECMV disconnection ............................................................................. 24
Failure code [DXH5KB] 2nd clutch ECMV short circuit................................................................................. 26
D275A-5R 1
Failure code [DXH5KY] 2nd clutch ECMV hot short circuit........................................................................... 28

Failure code [DXH6KA] 3rd clutch ECMV disconnection .............................................................................. 30
Failure code [DXH6KB] 3rd clutch ECMV short circuit.................................................................................. 32
Failure code [DXH6KY] 3rd clutch ECMV hot short circuit............................................................................ 34
Failure code [DXH7KA] Reverse clutch ECMV disconnection...................................................................... 36
Failure code [DXH7KB] Reverse clutch ECMV short circuit ......................................................................... 38
Failure code [DXH7KY] R clutch ECMV hot short circuit .............................................................................. 40
Failure code [DXH8KA] Forward clutch ECMV disconnection ...................................................................... 42
Failure code [DXH8KB] Forward clutch ECMV short circuit.......................................................................... 44
Failure code [DXH8KY] F clutch ECMV hot short circuit............................................................................... 46
Failure code [DXH9KA] Right steering clutch ECMV disconnection ............................................................. 48
Failure code [DXH9KB] Right steering clutch ECMV short circuit................................................................. 50
Failure code [DXH9KY] Right steering clutch ECMV hot short ..................................................................... 52
Failure code [DXHAKA] Left steering clutch ECMV disconnection ............................................................... 54
Failure code [DXHAKB] Left steering clutch ECMV short circuit................................................................... 56
Failure code [DXHAKY] Left steering clutch ECMV hot short ....................................................................... 58
Failure code [DXHBKA] Right brake ECMV disconnection........................................................................... 60
Failure code [DXHBKB] Right brake ECMV short circuit .............................................................................. 62
Failure code [DXHBKY] Right brake ECMV hot short circuit ........................................................................ 64
Failure code [DXHCKA] Left brake ECMV disconnection ............................................................................. 66
Failure code [DXHCKB] Left brake ECMV short circuit................................................................................. 68
Failure code [DXHCKY] Left brake ECMV hot short circuit........................................................................... 70
2 D275A-5R
Failure code [DW7BKA] Fan rev EPC disconnection 1

Action code Failure code Fan rev EPC disconnection
Trouble
E01 DW7BKA (Steering controller system)
Contents of
• When signal is output to fan reverse solenoid circuit, no current flows.
trouble
Action of
• Turns signal to fan reverse solenoid circuit OFF.
controller
Problem that
appears on • Fan reverse function cannot be used.
machine
• Output state (ON/OFF) to fan reverse solenoid can be checked in real-time monitoring mode.
Related
(Code 40914: Steering controller output signal 1)
information
• Method of reproducing failure code: Turn starting switch ON + Select fan reverse mode.

Defective fan reverse sole- ing without turning starting switch ON.
1
noid (Internal disconnection) FAR (male) Resistance
Between (1) – (2) 34 – 44 z
value in normal
state 2 Max. 1 z
or defective contact in con- (17) – FAR (female) (1) tance
Max. 1 z
(13) – FAR (female) (2) tance
out.)
D275A-5R 3
Failure code [DW7BKB] Fan rev EPC short circuit 1

Action code Failure code Fan rev EPC short circuit
Trouble
E01 DW7BKB (Steering controller system)
Contents of
• When signal was output to fan reverse solenoid circuit, abnormal current flowed.
trouble
Action of
• Turns signal to fan reverse solenoid circuit OFF.
controller
Problem that
appears on • Fan reverse function cannot be used.
machine
Related
information
• Method of reproducing failure code: Turn starting switch ON + Select fan reverse mode.

Defective fan reverse sole- FAR (male) Resistance
1
noid (Internal short circuit)
Between (1) – (2) 34 – 44 z
Possible causes Ground fault in wiring har- ing without turning starting switch ON.
and standard 2 ness (Contact with ground
circuit) Wiring harness between STCN3 (female) Resis-
(17) – FAR (female) (1) and chassis ground tance
state
3 ness (with another wiring Wiring harness between STCN3 (female)
harness) Resis-
(17) – FAR (female) (1) and between Min. 1 Mz
tance
STCN3 (female) (13) – FAR (female) (2)
out.)
4 D275A-5R
Failure code [DW7BKY] Fan reverse solenoid hot short circuit 1

Action code Failure code Fan reverse solenoid hot short circuit
Trouble
E02 DW7BKY (Steering controller system)
Contents of
• Some current keeps flowing to fan reverse solenoid circuit.
trouble
controller • Stops outputting signal to fan reverse solenoid circuit.
Problem that
appears on • Fan keeps running in reverse.
machine
Related
information
• Method of reproducing failure code: Turn starting switch ON (+ Perform fan reverse operation).

Defective fan reverse sole- ing without turning starting switch ON.
1
noid (Internal short circuit) FAR (male) Resistance
state 2
circuit) in wiring harness Wiring harness between STC3 (female) (17)
Voltage Max. 1 V
– FAR (female) (1)
troller
carried out.)
D275A-5R 5
Failure code [DWN3KA] Sudden stop prevention solenoid

disconnection 1
Action code Failure code Sudden stop prevention solenoid disconnection
Trouble
CALL E04 DWN3KA (Steering controller system)
Contents of
• When signal is output to sudden stop prevention solenoid circuit, any current does not flow.
trouble
Problem that
appears on
machine
• Output (Current) to sudden stop prevention solenoid can be checked in real-time monitoring mode.
Related
(Code 31628: Sudden stop prevention solenoid drive current)
information

Defective sudden stop pre- ing without turning starting switch ON.
1 vention solenoid (Internal
ST8 (male) Resistance
disconnection)
Between (1) – (2) 5 – 25 z
and standard Disconnection in wiring har- ing without turning starting switch ON.
state 2 Max. 1 z
or defective contact in con- (7) – ST8 (female) (1) tance
Max. 1 z
(23) – ST8 (female) (2) tance
If causes 1, 2 are not detected, steering controller may be defec-
out.)
6 D275A-5R
D275A-5R 7
Failure code [DWN3KB] Sudden stop prevention solenoid short circuit1

Action code Failure code Sudden stop prevention solenoid short circuit
Trouble
CALL E04 DWN3KB (Steering controller system)
Contents of
• When signal was output to sudden stop prevention solenoid circuit, abnormal current flowed.
trouble
Problem that
appears on
machine
• Output (Current) to sudden stop prevention solenoid can be checked in real-time monitoring mode.
Related
information

Defective sudden stop pre-
1 vention solenoid (Internal ST8 (male) Resistance
short circuit) Between (1) – (2) 5 – 25 z
Possible causes 2 ground in wiring harness Short circuit of wiring harness between
and standard (Contact with ground circuit) STCN3 (female) (7) – ST8 (female) (1) with Resis-
Min. 1 Mz
chassis ground
state
Short circuit in wiring har-
3 ness (with another wiring Short circuit in wiring harness between
harness) STCN3 (female) (7) – ST8 (female) (1) with Resis-
Min. 1 Mz
wiring harness between STCN3 (female) tance
(23) – ST8 (female) (2)
out.)
8 D275A-5R
D275A-5R 9
Failure code [DWN3KY] Sudden stop prevention solenoid hot short

circuit 1
Action code Failure code Sudden stop prevention solenoid hot short circuit
Trouble
CALL E04 DWN3KY (Steering controller system)
Contents of
• Some current keeps flowing in sudden stop prevention solenoid circuit.
trouble
Problem that • Sudden stop prevention valve does not operate in emergency.
machine • Once machine is stopped, it cannot travel at all.
• Output to sudden stop prevent solenoid can be checked with real-time monitoring mode.
Related
information

Defective sudden stop pre-
1 vent solenoid (Internal short ST8 (male) Resistance
Possible causes
state Hot short (Short circuit with Wiring harness between STCN3 (female)
2 Voltage Max. 1 V
24V circuit) in wiring harness (7) – ST8 (female) (1) with chassis ground
Voltage Max. 1 V
(23) – ST8 (female) (2) with chassis ground
out.)
10 D275A-5R
D275A-5R 11
Failure code [DWN5KA] Fan pump solenoid disconnection 1

Action code Failure code Fan pump solenoid disconnection
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 pump output is kept at its maximum.
machine
• Output (Current) to fan pump solenoid can be checked in real-time monitoring mode.
Related
(Code 31623, 31624: Cooling fan solenoid command current, output current)
information

Defective fan pump solenoid ing without turning starting switch ON.
1
(Internal disconnection) FAC (male) Resistance
Between (1) – (2) 15 – 25 z
value in normal
state 2 Max. 1 z
or defective contact in con- (17) – FAC (female) (1) tance
Max. 1 z
(23) – FAC (female) (2) tance
If causes 1, 2 are not detected, transmission controller may be
troller
carried out.)
12 D275A-5R
D275A-5R 13
Failure code [DWN5KB] Fan pump solenoid short circuit 1

Action code Failure code Fan pump solenoid short circuit
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 pump output is kept at its maximum.
machine
Related
information
• Method of reproducing service code: Turn starting switch ON.

Defective fan pump solenoid FAC (male) Resistance
1
Between (1) – (2) 15 – 25 z
and standard (Contact with ground circuit) TMCN3 (female) (17) – FAC (female) (1) Resis-
Min. 1 Mz
with chassis ground
state
harness) TMCN3 (female) (17) – FAC (female) (1) Resis-
Min. 1 Mz
with wiring harness between TMCN3 tance
(female) (23) – FAC (female) (2)
If causes 1 - 3 are not detected, transmission controller may be
troller
carried out.)
14 D275A-5R
D275A-5R 15
Failure code [DWN5KY] Fan pump solenoid hot short circuit 1

Action code Failure code Fan pump solenoid hot short circuit
Trouble
E02 DWN5KY (Transmission controller system)
Contents of
• Some current keeps flowing to fan pump solenoid circuit.
trouble
controller • Stops outputting signal to fan pump solenoid circuit.
Problem that
• Fan pump output is kept at its maximum.
appears on
• Fan speed does not increase.
machine
Related
information

Defective fan pump solenoid FAC (male) Resistance
1
(Internal disconnection)
Between (1) – (2) 15 – 25 z
Between (1) ground Min. Mz
Possible causes
state Hot short (Contact with 24V Wiring harness between TMCN3 (female)
2 Voltage Max. 1 V
circuit) in wiring harness (17) – FAC (female) (1) with chassis ground
Voltage Max. 1 V
(23) – FAC (female) (2) with chassis ground
troller
carried out.)
16 D275A-5R
D275A-5R 17
Failure code [DXH4KA] 1st clutch ECMV disconnection 1

Action code Failure code 1st clutch ECMV disconnection
Trouble
CALL E03 DXH4KA (Transmission controller system)
Contents of
• When signal is output to 1st clutch ECMV solenoid circuit, any current does not flow.
trouble
Action of
• Stops outputting to transmission 1st clutch ECMV solenoid circuit.
controller
Problem that
appears on
machine
• Output (Current) to 1st clutch ECMV solenoid can be checked in real-time monitoring mode.
Related
(Code 31602, 31612: Output current of 1st clutch ECMV)
information
• Method of reproducing failure code: Start engine and drive machine in F1 or R1.

Defective 1st clutch ECMV ing without turning starting switch ON.
S1T (male) Resistance
cuit)
Between (1) – (2) 5 – 15 z
value in normal
state 2 Max. 1 z
or defective contact in con- (15) – S1T (female) (1) tance
Max. 1 z
(3) – S1T (female) (2) tance
troller
carried out.)
18 D275A-5R
D275A-5R 19
Failure code [DXH4KB] 1st clutch ECMV short circuit 1

Action code Failure code 1st clutch ECMV short circuit
Trouble
CALL E03 DXH4KB (Transmission controller system)
Contents of
• When signal was output to transmission 1st clutch ECMV solenoid circuit, abnormal current flowed.
trouble
Action of
• Stops outputting to transmission 1st clutch ECMV solenoid circuit.
controller
Problem that
appears on
machine
• Output (Current) to 1st clutch ECMV solenoid can be checked in real-time monitoring mode.
Related
information

Defective 1st clutch ECMV
1 solenoid (Internal short cir- S1T (male) Resistance
cuit) Between (1) – (2) 5 – 15 z
and standard (Contact with ground circuit) TMCN3 (female) (15) – S1T (female) (1) Resis-
Min. 1 Mz
with chassis ground
state
harness) TMCN3 (female) (15) – S1T (female) (1) Resis-
Min. 1 Mz
(female) (3) – S1T (female) (2)
troller
carried out.)
20 D275A-5R
D275A-5R 21
Failure code [DXH4KY] 1st clutch ECMV hot short circuit 1

Action code Failure code 1st clutch ECMV hot short circuit
Trouble
CALL E03 DXH4KY (Transmission controller system)
Contents of
• Some current keeps flowing in transmission 1st clutch ECMV solenoid circuit.
trouble
Action of
• Turns signal to transmission 1st clutch ECMV solenoid circuit OFF.
controller
Problem that
appears on
machine
• Output to 1st clutch ECMV solenoid can be checked with real-time monitoring mode.
Related
information
• Method of reproducing failure code: Start engine + Set gear to F2 or R2.

Defective 1st clutch ECMV
cuit) Between (1) – (2) 5 – 15 z
Possible causes
state Hot short (Short circuit with Wiring harness between TMCN3 (female)
2 Voltage Max. 1 V
24V circuit) in wiring harness (15) – S1T (female) (1) with chassis ground
Voltage Max. 1 V
(3) – S1T (female) (2) with chassis ground
troller
carried out.)
22 D275A-5R
D275A-5R 23
Failure code [DXH5KA] 2nd clutch ECMV disconnection 1

Action code Failure code 2nd clutch ECMV disconnection
Trouble
Contents of
• When signal is output to 2nd clutch ECMV solenoid circuit, any current does not flow.
trouble
Action of
• Stops outputting to transmission 2nd clutch ECMV solenoid circuit.
controller
Problem that
appears on
machine
• Output (Current) to 2nd clutch ECMV solenoid can be checked in real-time monitoring mode.
Related
(Code 31603, 31613: Output current of 2nd clutch ECMV)
information

Defective 2nd clutch ECMV ing without turning starting switch ON.
cuit)
Between (1) – (2) 5 – 15 z
value in normal
state 2 Max. 1 z
Max. 1 z
troller
carried out.)
24 D275A-5R
D275A-5R 25
Failure code [DXH5KB] 2nd clutch ECMV short circuit 1

Action code Failure code 2nd clutch ECMV short circuit
Trouble
Contents of
• When signal was output to transmission 2nd clutch ECMV solenoid circuit, abnormal current flowed.
trouble
Action of
• Stops outputting to transmission 2nd clutch ECMV solenoid circuit.
controller
Problem that
appears on
machine
• Output (Current) to 2nd clutch ECMV solenoid can be checked in real-time monitoring mode.
Related
information

Defective 2nd clutch ECMV
cuit) Between (1) – (2) 5 – 15 z
and standard (Contact with ground circuit) TMCN3 (female) (36) – S2T (female) (1) Resis-
Min. 1 Mz
with chassis ground
state
harness) TMCN3 (female) (36) – S2T (female) (1) Resis-
Min. 1 Mz
(female) (13) – S2T (female) (2)
troller
carried out.)
26 D275A-5R
D275A-5R 27
Failure code [DXH5KY] 2nd clutch ECMV hot short circuit 1

Action code Failure code 2nd clutch ECMV hot short circuit
Trouble
Contents of
• Some current keeps flowing in transmission 2nd clutch ECMV solenoid circuit.
trouble
Action of
• Turns signal to transmission 2nd clutch ECMV solenoid circuit OFF.
controller
Problem that
appears on
machine
• Output to 2nd clutch ECMV solenoid can be checked with real-time monitoring mode.
Related
information

Defective 2nd clutch ECMV
cuit) Between (1) – (2) 5 – 15 z
Possible causes
and standard Between (1) – chassis ground Min. 1 Mz
value in normal a Prepare with starting switch OFF, then turn starting switch ON
state Hot short (Short circuit with and carry out troubleshooting.
2
24V circuit) in wiring harness Wiring harness between TMCN3 (female)
Voltage Max. 1 V
(36) – S2T (female) (1) and chassis ground
troller
carried out.)
28 D275A-5R
D275A-5R 29
Failure code [DXH6KA] 3rd clutch ECMV disconnection 1

Action code Failure code 3rd clutch ECMV disconnection
Trouble
Contents of
• When signal is output to 3rd clutch ECMV solenoid circuit, any current does not flow.
trouble
Action of
• Stops outputting to transmission 3rd clutch ECMV solenoid circuit.
controller
Problem that
appears on
machine
• Output (Current) to 3rd clutch ECMV solenoid can be checked in real-time monitoring mode.
Related
(Code 31604, 31614: Output current of 3rd clutch ECMV)
information

Defective 3rd clutch ECMV ing without turning starting switch ON.
cuit)
Between (1) – (2) 5 – 15 z
value in normal
state 2 Max. 1 z
Max. 1 z
troller
carried out.)
30 D275A-5R
D275A-5R 31
Failure code [DXH6KB] 3rd clutch ECMV short circuit 1

Action code Failure code 3rd clutch ECMV short circuit
Trouble
Contents of
• When signal was output to transmission 3rd clutch ECMV solenoid circuit, abnormal current flowed.
trouble
Action of
• Stops outputting to transmission 3rd clutch ECMV solenoid circuit.
controller
Problem that
appears on
machine
• Output (Current) to 3rd clutch ECMV solenoid can be checked in real-time monitoring mode.
Related
information

Defective 3rd clutch ECMV
cuit) Between (1) – (2) 5 – 15 z
and standard (Contact with ground circuit) TMCN3 (female) (5) – S3T (female) (1) with Resis-
Min. 1 Mz
chassis ground
state
harness) TMCN3 (female) (5) – S3T (female) (1) with Resis-
Min. 1 Mz
wiring harness between TMCN3 (female) tance
(3) – S3T (female) (2)
troller
carried out.)
32 D275A-5R
D275A-5R 33
Failure code [DXH6KY] 3rd clutch ECMV hot short circuit 1

Action code Failure code 3rd clutch ECMV hot short circuit
Trouble
E03 DXH6KY (Transmission controller system)
Contents of
• Some current keeps flowing in transmission 3rd solenoid circuit.
trouble
Action of
• Turns signal to transmission 3rd clutch ECMV solenoid circuit OFF.
controller
Problem that
appears on
machine
• Output to 3rd clutch ECMV solenoid can be checked with real-time monitoring mode.
Related
information

Defective 3rd clutch ECMV
cuit) Between (1) – (2) 5 – 15 z
Possible causes
2 Voltage Max. 1 V
24V circuit) in wiring harness (5) – S3T (female) (1) with chassis ground
Voltage Max. 1 V
(3) – S3T (female) (2) with chassis ground
troller
carried out.)
34 D275A-5R
D275A-5R 35
Failure code [DXH7KA] Reverse clutch ECMV disconnection 1

Action code Failure code Reverse clutch ECMV disconnection
Trouble
Contents of
• When signal is output to reverse clutch ECMV solenoid circuit, any current does not flow.
trouble
Action of
• Stops outputting to transmission reverse clutch ECMV solenoid circuit.
controller
Problem that
appears on
• Once machine is stopped, travel is limited to F1.
machine
• Output (Current) to reverse clutch ECMV solenoid can be checked in real-time monitoring mode.
Related
(Code 31606, 31616: Output current of reverse clutch ECMV)
information
• Method of reproducing failure code: Start engine and drive machine in reverse.

Defective reverse clutch ing without turning starting switch ON.
1 ECMV solenoid (Internal
SRT (male) Resistance
short circuit)
Between (1) – (2) 5 – 15 z
value in normal
state 2 Max. 1 z
or defective contact in con- (25) – SRT (female) (1) tance
Max. 1 z
(13) – SRT (female) (2) tance
troller
carried out.)
36 D275A-5R
D275A-5R 37
Failure code [DXH7KB] Reverse clutch ECMV short circuit 1

Action code Failure code Reverse clutch ECMV short circuit
Trouble
Contents of • When signal was output to transmission reverse clutch ECMV solenoid circuit, abnormal current
trouble flowed.
Action of
• Stops outputting to transmission reverse clutch ECMV solenoid circuit.
controller
Problem that
appears on
machine
• Output (Current) to reverse clutch ECMV solenoid can be checked in real-time monitoring mode.
Related
(Code 31606, 31616: Output current of reverse clutch ECMV)
information

Defective reverse clutch
1 ECMV solenoid (Internal SRT (male) Resistance
and standard (Contact with ground circuit) TMCN3 (female) (25) – SRT (female) (1) Resis-
Min. 1 Mz
with chassis ground
state
harness) TMCN3 (female) (25) – SRT (female) (1) Resis-
Min. 1 Mz
(female) (13) – SRT (female) (2)
troller
carried out.)
38 D275A-5R
D275A-5R 39
Failure code [DXH7KY] R clutch ECMV hot short circuit 1

Action code Failure code R clutch ECMV hot short circuit
Trouble
Contents of
• Some current keeps flowing in transmission R clutch ECMV solenoid circuit.
trouble
Action of
• Turns signal to transmission R clutch ECMV solenoid circuit OFF.
controller
Problem that
appears on
• Once machine is stopped, travel is limited to R1.
machine
• Output to R clutch ECMV solenoid can be checked with real-time monitoring mode.
Related
(Code 31606, 31616: Output current of reverse clutch ECMV))
information
• Method of reproducing failure code: Start engine and drive machine forward.

Defective R clutch ECMV
1 solenoid (Internal short cir- SRT (male) Resistance
cuit) Between (1) – (2) 5 – 15 z
Possible causes
2 Voltage Max. 1 V
24V circuit) in wiring harness (25) – SRT (female) (1) with chassis ground
Voltage Max. 1 V
(13) – SRT (female) (2) with chassis ground
troller
carried out.)
40 D275A-5R
D275A-5R 41
Failure code [DXH8KA] Forward clutch ECMV disconnection 1

Action code Failure code Forward clutch ECMV disconnection
Trouble
Contents of
• When signal is output to forward clutch ECMV solenoid circuit, any current does not flow.
trouble
Action of
• Stops outputting to transmission forward clutch ECMV solenoid circuit.
controller
Problem that
appears on
machine
• Output (Current) to forward clutch ECMV solenoid can be checked in real-time monitoring mode.
Related
(Code 31608, 31622: Output current of forward clutch ECMV)
information

Defective forward clutch ing without turning starting switch ON.
1 ECMV solenoid (Internal
SFT (male) Resistance
short circuit)
Between (1) – (2) 5 – 15 z
value in normal
state 2 Max. 1 z
or defective contact in con- (35) – SFT (female) (1) tance
Max. 1 z
(13) – SFT (female) (2) tance
troller
carried out.)
42 D275A-5R
D275A-5R 43
Failure code [DXH8KB] Forward clutch ECMV short circuit 1

Action code Failure code Forward clutch ECMV short circuit
Trouble
Contents of • When signal was output to transmission forward clutch ECMV solenoid circuit, abnormal current
trouble flowed.
Action of
• Stops outputting to transmission forward clutch ECMV solenoid circuit.
controller
Problem that
appears on
machine
• Output (Current) to forward clutch ECMV solenoid can be checked in real-time monitoring mode.
Related
information

Defective forward clutch
1 ECMV solenoid (Internal SFT (male) Resistance
and standard (Contact with ground circuit) TMCN3 (female) (35) – SFT (female) (1) Resis-
Min. 1 Mz
with chassis ground
state
harness) TMCN3 (female) (35) – SFT (female) (1) Resis-
Min. 1 Mz
(female) (13) – SFT (female) (2)
troller
carried out.)
44 D275A-5R
D275A-5R 45
Failure code [DXH8KY] F clutch ECMV hot short circuit 1

Action code Failure code F clutch ECMV hot short circuit
Trouble
Contents of
• Some current keeps flowing in transmission F clutch ECMV solenoid circuit.
trouble
Action of
• Turns signal to transmission F clutch ECMV solenoid circuit OFF.
controller
Problem that
appears on
machine
• Output to F clutch ECMV solenoid can be checked with real-time monitoring mode.
Related
information

Defective F clutch ECMV
1 solenoid (Internal short cir- SFT (male) Resistance
cuit) Between (1) – (2) 5 – 15 z
Possible causes
2 Voltage Max. 1 V
24V circuit) in wiring harness (35) – SFT (female) (1) with chassis ground
Voltage Max. 1 V
(3) – SFT (female) (2) with chassis ground
troller
carried out.)
46 D275A-5R
D275A-5R 47
Failure code [DXH9KA] Right steering clutch ECMV disconnection 1

Action code Failure code Right steering clutch ECMV disconnection
Trouble
CALL E03 DXH9KA (Steering controller system)
Contents of
• When signal is output to right steering clutch solenoid circuit, current does not flow.
trouble
Action of
• Stops outputting to right steering clutch solenoid circuit.
controller
Problem that • Machine cannot be steered to right.
• Outputting to right steering clutch solenoid (Current) can be checked in real-time moniitoring mode.
Related (Code 90601, 90603: Right steering clutch ECMV (E-POCV) command current, output current)
information • Method of reproducing failure code:
Turn starting switch ON + Release parking brake lever, + Operate PCCS lever (to steer to right).

a Prepare with starting switch OFF, then carry out troubleshooting
Defective right steering without turning starting switch ON.
1 clutch solenoid
SRC (male) Resistance
Between (1) – (2) 5 – 15 z
Possible causes a Prepare with starting switch OFF, then carry out troubleshooting
and standard without turning starting switch ON.
Disconnection in wiring
value in normal
harness (Disconnection in Wiring harness between STCN3 (female) Resis-
state 2 Max. 1 z
wiring or defective contact in (35) – SRC (female) (1) tance
connector) Wiring harness between STCN3 (female) (3) Resis-
Max. 1 z
– SRC7 (female) (2) tance
If causes 1 and 2 are not detected, steering controller may be defec-
out.)
48 D275A-5R
D275A-5R 49
Failure code [DXH9KB] Right steering clutch ECMV short circuit 1

Action code Failure code Right steering clutch ECMV short circuit
Trouble
CALL E03 DXH9KB (Steering controller system)
Contents of
• When signal was output to right steering clutch solenoid circuit, abnormal current flowed.
trouble
Action of
controller
Problem that • Machine cannot be steered to right.

without turning starting switch ON.
1 clutch solenoid SRC (male) Resistance
(Internal short circuit) Between (1) – (2) 5 – 15 z
Short circuit with chassis without turning starting switch ON.
and standard (Contact with ground circuit) STCN3 (female) (35) – SRC (female) (1) Resis-
Min. 1 Mz
with chassis ground
state
Short circuit in wiring
3 harness (with another wiring Short circuit of wiring harness between
harness) STCN3 (female) (35) – SRC (female) (1) Resis-
Min. 1 Mz
with wiring harness between STCN3 tance
(female) (3) – SRC (female) (2)
out.)
50 D275A-5R
D275A-5R 51
Failure code [DXH9KY] Right steering clutch ECMV hot short 1

Action code Failure code Right steering clutch ECMV hot short
Trouble
CALL E04 DXH9KY (Steering controller system)
Contents of
• Some current always flows into right steering clutch solenoid circuit.
trouble
Action of
controller
Problem that • Machine cannot be steered to right. (R clutch cannot be disengaged.)

1 clutch solenoid SRC (male) Resistance
value in normal Short circuit of wiring harness between
state Hot short in wiring harness STCN3 (female) (35) – SRC (female) (1) Voltage Max. 1 V
2
(Contact with 24 V circuit) with chassis ground
STCN3 (female) (3) – SRC (female) (2) with Voltage Max. 1 V
chassis ground
out.)
52 D275A-5R
D275A-5R 53
Failure code [DXHAKA] Left steering clutch ECMV disconnection 1

Action code Failure code Left steering clutch ECMV disconnection
Trouble
CALL E03 DXHAKA (Steering controller system)
Contents of
• When signal is output to left steering clutch solenoid circuit, current does not flow.
trouble
Action of
• Stops outputting to left steering clutch solenoid circuit.
controller
Problem that • Machine cannot be steered to left.
• Outputting to left steering clutch solenoid (Current) can be checked in real-time moniitoring mode.
Related (Code 90600, 90602: Left steering clutch ECMV (E-POCV) command current, output current)
Turn starting switch ON + Release parking brake lever, + Operate PCCS lever (to steer to left).

Defective left steering clutch without turning starting switch ON.
1 solenoid
SLC (male) Resistance
Between (1) – (2) 5 – 15 z
Possible causes a Prepare with starting switch OFF, then carry out troubleshooting
and standard without turning starting switch ON.
value in normal
harness (Disconnection in Wiring harness between STCN3 (female) Resis-
state 2 Max. 1 z
wiring or defective contact in (25) – SLC (female) (1) tance
connector) Wiring harness between STCN3 (female) (3) Resis-
Max. 1 z
– SLC (female) (2) tance
out.)
54 D275A-5R
D275A-5R 55
Failure code [DXHAKB] Left steering clutch ECMV short circuit 1

Action code Failure code Left steering clutch ECMV short circuit
Trouble
CALL E03 DXHAKB (Steering controller system)
Contents of
• When signal was output to left steering clutch solenoid circuit, abnormal current flowed.
trouble
Action of
controller
Problem that • Machine cannot be steered to left.
information • Method of reproducing error code:

1 solenoid SLC (male) Resistance
Short circuit with chassis without turning starting switch ON.
and standard (Contact with ground circuit) STCN3 (female) (25) – SLC (female) (1) with Resis-
Min. 1 Mz
chassis ground
state
Short circuit in wiring
3 harness (with another wiring Short circuit of wiring harness between
harness) STCN3 (female) (25) – SLC (female) (1) with Resis-
Min. 1 Mz
wiring harness between STCN3 (female) (3) tance
– SLC (female) (2)
out.)
56 D275A-5R
D275A-5R 57
Failure code [DXHAKY] Left steering clutch ECMV hot short 1

Action code Failure code Left steering clutch ECMV hot short
Trouble
CALL E04 DXHAKY (Steering controller system)
Contents of
• Some current always flows into left steering clutch solenoid circuit, current does not flow.
trouble
Action of
controller
Problem that • Machine cannot be steered to left. (L clutch cannot be disengaged.)

1 solenoid SLC (male) Resistance
value in normal Short circuit of wiring harness between
state Hot short in wiring harness STCN3 (female) (25) – SLC (female) (1) with Voltage Max. 1 V
2
STCN3 (female) (3) – SLC (female) (2) with Voltage Max. 1 V
chassis ground
out.)
58 D275A-5R
D275A-5R 59
Failure code [DXHBKA] Right brake ECMV disconnection 1

Action code Failure code Right brake ECMV disconnection
Trouble
CALL E04 DXHBKA (Steering controller system)
Contents of
• When signal is output to right steering brake ECMV solenoid circuit, any current does not flow.
trouble
Action of • Stops outputting to right steering brake ECMV solenoid circuit.
controller • Limits operation of engine, transmission and brake.
• Operates sudden stop prevention valve.
Problem that • Right brake keeps operating.
• Output (Current) to right steering brake ECMV solenoid can be checked in real-time monitoring
Related
mode. (Code 31620, 31618: Output current of right steering brake ECMV)
information
• Method of reproducing failure code: Turn starting switch ON and release parking brake lever.

Defective right steering ing without turning starting switch ON.
1 brake ECMV solenoid (Inter-
SRB (male) Resistance
nal short circuit)
Between (1) – (2) 5 – 15 z
value in normal
state 2 Max. 1 z
or defective contact in con- (15) – SRB (female) (1) tance
Max. 1 z
(13) – SRB (female) (2) tance
out.)
60 D275A-5R
D275A-5R 61
Failure code [DXHBKB] Right brake ECMV short circuit 1

Action code Failure code Right brake ECMV short circuit
Trouble
CALL E04 DXHBKB (Steering controller system)
Contents of
• When signal was output to right steering brake ECMV solenoid circuit, abnormal current flowed.
trouble
Action of • Stops outputting to right steering brake ECMV solenoid circuit.
• Output (Current) to right steering brake ECMV solenoid can be checked in real-time monitoring
Related
mode. (Code 31620, 31618: Output current of right steering brake ECMV)
information
• Method of reproducing failure code: Start engine and release parking brake lever.

1 brake ECMV (Internal short SRB (male) Resistance
and standard (Contact with ground circuit) STCN3 (female) (15) – SRB (female) (1) Resis-
Min. 1 Mz
with chassis ground
state
harness) STCN3 (female) (15) – SRB (female) (1) Resis-
Min. 1 Mz
with wiring harness between STCN3 tance
(female) (13) – SRB (female) (2)
If causes 1 - 3 are not detected, steering controller may be defec-
out.)
62 D275A-5R
D275A-5R 63
Failure code [DXHBKY] Right brake ECMV hot short circuit 1

Action code Failure code Right brake ECMV hot short circuit
Trouble
CALL E04 DXHBKY (Steering controller system)
Contents of
• Some current keeps flowing in right brake ECMV solenoid circuit.
trouble
Action of • Turns signal to steering right steering brake ECMV solenoid circuit OFF.
• Output to right steering brake ECMV solenoid can be checked with real-time monitoring mode.
Related
(Code 31620, 31618: Output current of right steering brake ECMV)
information
• Method of reproducing failure code: Turn starting switch ON + Operate parking brake lever (Lock).

Defective right steering-
1 brake ECMV solenoid (Inter- SRB (male) Resistance
nal short circuit) Between (1) – (2) 5 – 15 z
Possible causes
2 Voltage Max. 1 V
24V circuit) in wiring harness (15) – SRB (female) (1) with chassis ground
Voltage Max. 1 V
(13) – SRB (female) (2) with chassis ground
out.)
64 D275A-5R
D275A-5R 65
Failure code [DXHCKA] Left brake ECMV disconnection 1

Action code Failure code Left brake ECMV disconnection
Trouble
CALL E04 DXHCKA (Steering controller system)
Contents of
• When signal is output to left steering brake ECMV solenoid circuit, any current does not flow.
trouble
Action of • Stops outputting to left steering brake brake ECMV solenoid circuit.
controller • Limits operation of engine, transmission and brake.
Problem that • Left brake keeps operating.
• Output (Current) to left steering brake ECMV solenoid can be checked in real-time monitoring
Related
mode. (Code 31621, 31619: Output current of left steering brake ECMV)
information
• Method of reproducing failure code: Turn starting switch ON and release parking brake lever.

Defective steering case left ing without turning starting switch ON.
1 brake ECMV solenoid (Inter-
SLB (male) Resistance
nal short circuit)
Between (1) – (2) 5 – 15 z
value in normal
state 2 Max. 1 z
or defective contact in con- (5) – SLB (female) (1) tance
Max. 1 z
(13) – SLB (female) (2) tance
3 Defective steering controller defective. (Since trouble is in system, troubleshooting cannot be
carried out.)
66 D275A-5R
D275A-5R 67
Failure code [DXHCKB] Left brake ECMV short circuit 1

Action code Failure code Left brake ECMV short circuit
Trouble
CALL E04 DXHCKB (Steering controller system)
Contents of
• When signal was output to left steering brake ECMV solenoid circuit, abnormal current flowed.
trouble
Action of • Stops outputting to left steering brake ECMV solenoid circuit.
Problem that • Left brake keeps operating.
• Output (Current) to left steering brake ECMV solenoid can be checked in real-time monitoring
Related
mode. (Code 31621, 31619: Output current of left steering brake ECMV)
information
• Method of reproducing failure code: Start engine and release parking brake lever.

Defective left steering brake
1 ECMV solenoid (Internal SLB (male) Resistance
and standard (Contact with ground circuit) STCN3 (female) (5) – SLB (female) (1) with Resis-
Min. 1 Mz
chassis ground
state
harness) STCN3 (female) (5) – SLB (female) (1) with Resis-
Min. 1 Mz
wiring harness between STCN3 (female) tance
(13) – SLB (female) (2)
If causes 1 - 3 are not detected, steering controller may be defec-
out.)
68 D275A-5R
D275A-5R 69
Failure code [DXHCKY] Left brake ECMV hot short circuit 1

Action code Failure code Left brake ECMV hot short circuit
Trouble
CALL E04 DXHCKY (Steering controller system)
Contents of
• Some current keeps flowing in left steering brake ECMV solenoid circuit.
trouble
Action of • Turns signal to left steering brake ECMV solenoid circuit OFF.
controller • Limits operation of engine and transmission, brake.
Problem that • Left brake does not operate.
• Output to left steering brake ECMV solenoid can be checked with real-time monitoring mode.
Related
(Code 31621, 31619: Output current of left steering brake ECMV)
information
• Method of reproducing failure code: Turn starting switch ON + Operate parking brake lever (Lock).

Defective left steering brake
1 ECMV solenoid (Internal SLB (male) Resistance
Possible causes
2 Voltage Max. 1 V
24V circuit) in wiring harness (5) – SLB (female) (1) with chassis ground
Voltage Max. 1 V
(13) – SLB (female) (2) with chassis ground
out.)
70 D275A-5R
D275A-5R 71
D275A-5R Bulldozer
© 2008 KOMATSU
All Rights Reserved
72 D275A-5R
SEN02764-01
D275A-5R

D275A-5R 35001 and up
Troubleshooting of electrical system
(E-mode)
Information in troubleshooting table................................................................................................................ 3
E-1 The engine does not start......................................................................................................................... 4
E-2 The preheater does not operate (Manual preheating function) ................................................................ 7
E-3 The ripper pin puller cylinder does not operate ...................................................................................... 10
E-4 The machine monitor does not come on at all when the starting switch is turned ON ........................... 12
E-5 When the starting switch is turned ON, the machine monitor completely remains lighted
and does not go out ............................................................................................................................... 14
E-6 When the starting switch is turned ON, the basic check items flash ...................................................... 15
E-7 While the engine is operating, any caution item flashes ........................................................................ 16
E-8 While the engine is operating, the emergency warning item flashes ..................................................... 19
E-9 While the preheater is operating, the preheating pilot lamp does not come on ..................................... 24
E-10 At the selecting time of dual tilt, the dual/single tilt selector lamp does not come on
(Dual tilt-mounted machine)................................................................................................................... 26
E-11 The engine coolant temperature gauge does not indicate normally ..................................................... 27
D275A-5R 1
E-12 Indication of the power train (torque converter) temperature gauge is abnormal................................. 28
E-13 The hydraulic oil temperature gauge does not indicate normally ......................................................... 30
E-14 Indication of the fuel gauge is abnormal............................................................................................... 31
E-15 Indications of gear speed and engine speed are abnormal.................................................................. 32
E-16 Indication of the shift mode service meter is abnormal ........................................................................ 32
E-17 The switch module cannot be operated................................................................................................ 33
E-18 The warning lamp does not flash or does not go out............................................................................ 34
E-19 The alarm buzzer does not sound or does not stop ............................................................................. 35
E-20 Auto shift down is not possible or is not released................................................................................. 36
E-21 The alarm buzzer cannot be cancelled................................................................................................. 37
E-22 The operator mode cannot be operated ............................................................................................... 38
E-23 The service mode cannot be operated ................................................................................................. 40
E-24 The back-up alarm does not sound ...................................................................................................... 42
E-25 The night light, the headlamp, the working lamp and the rear lamp on the panel do not come on ...... 44
E-26 The air conditioner does not operate.................................................................................................... 50
E-27 KOMTRAX system does not operate normally..................................................................................... 56
E-28 Fan does not reverse............................................................................................................................ 58
E-29 Gear cannot be shifted ......................................................................................................................... 60
E-30 Electric priming pump does not operate or does not stop automatically .............................................. 62
2 D275A-5R
Information in troubleshooting table 1

a The following information is summarized in the troubleshooting table and the related electrical circuit dia-
gram. Before carrying out troubleshooting, understand that information fully.
Trouble Trouble which occurred in the machine

Related
Information related to detected trouble or troubleshooting
information
<Contents of description>
• Standard value in normal state to judge possible causes
• Remarks on judgment
1
<Troubles in wiring harness>
• Disconnection
Connector is connected defectively or wiring harness is
broken.
• Ground fault
Wiring harness which is not connected to chassis ground
circuit is in contact with chassis ground circuit.
• Hot short
Wiring harness which is not connected to power source (24
2 V) circuit is in contact with power source (24 V) circuit.
• Short circuit
Independent wiring harnesses are in contact with each
Possible causes other abnormally.
and standard Possible causes of trouble
value in normal (Given numbers are refer-
<Precautions for troubleshooting>
state ence numbers, which do
(1) Method of indicating connector No. and handling of T-
not indicate priority)
adapter
Insert or connect T-adapter as explained below for trouble-
shooting, unless otherwise specified.
3 • If connector No. has no marks of "male" and "female",
disconnect connector and insert T-adapters in both male
side and female side.
• If connector No. has marks of "male" and "female", dis-
connect connector and connect T-adapter to only male
side or female side.
(2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative (–) lead of tester as
explained below for troubleshooting, unless otherwise
specified.
4 • Connect positive (+) lead to pin No. or wiring harness
entered on front side.
• Connect negative (–) lead to pin No. or harness entered
on rear side.
This drawing is a part of the electric circuit diagram related to troubleshooting.

• Connector No.: Indicates (Model – Number of pins) and (Color).
• "Connector No. and pin No." from each branching/merging point: Shows the ends
of branch or source of merging within the parts of the same wiring harness.
• Arrow (io): Roughly shows the location on the machine.
D275A-5R 3
E-1 The engine does not start 1

Trouble • The engine does not start.
• Since engine start circuit has neutral safety function, engine cannot be started if parking brake lever
is not in lock position or travel lever is not in neutral.
Related
• If "the machine monitor does not come on" or "the battery relay does not cause operating sound"
information
when the starting switch is turned 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. 24 V Min. 1.26
a Prepare with the starting switch OFF, then carry out trouble-
shooting without turning the starting switch ON.
Defective starting switch Key SW terminal Switch position Resistance
2
Between terminal OFF Min. 1 Mz
250 and terminal 280 START Max. 1 z
a Prepare with the starting switch OFF, then start the engine and
Defective neutral safety relay
3 If the engine starts in accordance with the engine starting arrange-
ment after the neutral safety relay (NSF) is replaced with another
one while the starting switch is set to OFF, the relay is defective.
a Prepare with the starting switch OFF, then turn the starting
Defective alternator (Internal switch ON and carry out troubleshooting.
4
short-circuit) Alternator Voltage
Between Terminal R and ground Max. 1 V
Starting motor Voltage
Possible causes
and standard Electric power supply : between
20 – 30 V
value in normal Terminal ST/B and ground
state Detective starting motor Charge: between ST (2) and
5 Max. 1 V
(Internal defect) ground
Starting: between ST (1) and
20 – 30 V
ground
When the voltages of electric power supply, for charging and start-
ing are normal but the starting motor does not rotate, the starting
motor is defective.
Disconnection in wiring har- shooting without turning the starting switch ON.
ness (Disconnection in wiring Wiring harness between terminal 280 and Resis-
6 Max. 1 z
or defective contact in con- NFS (female) (3) tance
nector) Wiring harness between NSF (female) (5) Resis-
Max. 1 z
and ST (female) (1) tance
switch ON and carry out troubleshooting.
Hot short circuit of wiring har- Hot short circuit of wiring harness between
7 ness (Contact with 24V cir- alternator R terminal and ST (female) (2) –
cuit) TMCN1 (female) (15) – S04 (female) (9) – Voltage Max. 1 V
STCN1 (female) (15) – KOM1 (female) (28)
– RSD (female) (2) with ground
Defective diode If diode CN-RSD is shorted, starting motor R terminal voltage is 20
8
(Internal short circuit) – 30 V and the starting motor does not operate.
4 D275A-5R

a Prepare with starting switch OFF, then carry out trouble-
Possible causes shooting without turning starting switch ON.
and standard Ground fault in wiring har-
value in normal Wiring harness between NSF (female) (5) – Resis-
state circuit) ST (female) (1) and ground tance
Wiring harness between terminal 280 – NSF Resis-
Min. 1 Mz
(female) (3) and ground tance
D275A-5R 5
6 D275A-5R
E-2 The preheater does not operate (Manual preheating function) 1

Trouble • The preheater does not operate. (Manual preheating function)
a This troubleshooting describes the procedures to be followed when the manual preheating func-
tion 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 machine monitor does not come on" or "the battery relay does not cause operating sound"
when the starting switch is turned ON, the main electric power supply system supposed to be out of
order. So, inspect the main electric power supply system.

a Prepare with starting switch OFF, then keep starting switch
OFF and turn it to HEAT and carry out troubleshooting in each
case.
a Carry out troubleshooting only when manual heating is defec-
Defective starting switch
1 tive.
Key SW terminal Switch position Resistance
Between terminal OFF Min. 1 Mz
250 and terminal 255 HEAT Max. 1 z
2 Defective fuse (FS22-2) If fuse is broken, circuit probably has ground fault etc.
Defective circuit breaker If circuit breaker is turned OFF, circuit probably has ground fault
3
(CB105H) etc.
Prepare with starting switch OFF, then turn it to HEAT and carry out
troubleshooting in each case.
Defective preheater relay
4 Replace preheater relay with another one and turn starting switch
to HEAT. If preheater operates at this time, preheater relay (PHR)
is probably defective.
a Prepare with the starting switch OFF, then set the starting
switch to HEAT and carry out troubleshooting.
Possible causes Heater relay Voltage
and standard
Electric power supply : between
value in normal 20 – 30 V
Defective heater relay (Inter- Terminal HT/A (A) and ground
state 5
nal defect) Signal : between Terminal HT
20 – 30 V
(C) and ground
When the both voltages of electric power supply and signal are
normal and no operating sound is caused, the heater relay is
defective.
Defective electrical intake air shooting without turning the starting switch ON.
6
heater (Internal defect) Electrical intake air heater Continuity
Between terminals Continue
Wiring harness between FS22-2 output – Resis-
Max. 1 z
Disconnection in wiring har- PHR (female) (5) tance
ness (Disconnection in wiring Wiring harness between PHR (female) (3) Resis-
7 Max. 1 z
or defective contact in con- and terminal 255 or terminal heater relay HT tance
nector) Wiring harness between battery relay BRC Resis-
Max. 1 z
terminal or heater relay HVA terminal tance
Wiring harness between heater relay HT/B Resis-
Max. 1 z
terminal and electrical intake air heater tance
D275A-5R 7

Wiring harness between FS22-2 (outlet Resis-
Possible causes Ground fault in wiring har- Min. 1 Mz
side) – PHR (female) (5) and ground tance
and standard 8 ness (Contact with ground
value in normal circuit) Wiring harness between PHR (female) (3) – Resis-
Min. 1 Mz
state heater relay HT terminal and ground tance
Wiring harness between heater relay HT Resis-
Min. 1 Mz
terminal – HTD (female) (1) and ground tance
Defective diode HTD (Inter- If diode HTD is shorted, circuit has ground fault and heater does
9
nal short circuit) not operate probably.
8 D275A-5R
D275A-5R 9
E-3 The ripper pin puller cylinder does not operate 1

Trouble • The ripper pin puller cylinder does not operate.
Related
information

When the fuse is blown, a ground fault may have possibly occurred
1 Defective fuse (FS22-2)
to the circuit.
Defective pin puller switch
2 (Internal disconnection or 263 (male) Switch Resistance
short circuit) Pull Max. 1 z
Between (1) and (2)
Press Min. 1 Mz
Defective pin puller solenoid
3 (Internal disconnection or PPL (male) Resistance
short circuit) Between (1) and (2) 10 – 80 z
Possible causes Disconnection of wiring har- Wiring harness between FS22-2 outlet and Resis-
Max. 1 z
and standard ness (Disconnection in wiring 263 (female) (1) tance
value in normal 4
or defective contact in con- Wiring harness between 263 (female) (2) Resis-
state nector) Max. 1 z
and PPL (female) (1) tance
Wiring harness between PPL (female) (2) Resis-
Max. 1 z
and ground tance
Ground fault of wiring har- Between wiring harness between FS22-2 Resis-
Min. 1 Mz
5 ness (Contact with ground (outlet side) and 263 (female) and ground tance
circuit) Between wiring harness between 263
Resis-
(female) (2) and PPL (female) (1) and Min. 1 Mz
tance
ground
switch ON and carry out troubleshooting. (Push on the switch)
Hot short circuit of wiring har- Between wiring harness between 263
6 ness (Contact with 24V cir- (female) (2) and PPL (female) (1) and Voltage Max. 1 V
cuit) ground
Between wiring harness between PPL
Voltage Max. 1 V
(female) (2) and ground and ground
10 D275A-5R
D275A-5R 11
E-4 The machine monitor does not come on at all when the starting
switch is turned ON 1
Trouble • The machine monitor 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 3 sec.

Defective circuit breaker When the circuit breaker is cut off, the circuit may have possibly
1
(CB2, CB6) been short-circuited with ground.
shooting without turning the starting switch ON .
Wiring harness between S03 (female) (1), Resis-
Max. 1 z
(2) and CB2 outlet tance
Disconnection of wiring har- Wiring harness between S03 (female) (3), Resis-
Max. 1 z
ness (Disconnection in wiring (4) and ground tance
2
or defective contact in con- Wiring harness between S03 (female) (5), Resis-
nector) Max. 1 z
(6) and CB6 outlet tance
Wiring harness between S01 (female) (1) Resis-
Max. 1 z
and CB2 outlet tance
Max. 1 z
and ground tance
Possible causes
and standard
value in normal Ground fault of wiring har- Between wiring harness CB2 (outlet side)
Resis-
state 3 ness (Contact with ground and S03 (female) (2) and S01 (female) (1) Min. 1 Mz
tance
circuit) and ground
Between wiring harness CB6 (outlet side) Resis-
Min. 1 Mz
and S03 (female) (5) (6) and ground tance
S03 Voltage
Between (1), (2) and (3), (4) 20 – 30 V
Defective machine monitor S01 Voltage
4
(Gauge/lamp module) Between (1) and (2) 20 – 30 V
shooting without turning the starting switch ON and OFF.
S03 Voltage
Between (5) (6) and (3) (4) 20 – 30 V
If failure code [DAFRKR] of CAN communication error is dis-
5 CAN communication error
played, carry out troubleshooting for it.
12 D275A-5R
D275A-5R 13
E-5 When the starting switch is turned ON, the machine monitor
completely remains lighted and does not go out 1
• When the starting switch is turned ON, the machine monitor completely remains lighted and does
Trouble
not go 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 3 sec. and go out.

and standard
value in normal Defective machine monitor
1 This internal defect cannot be diagnosed.
state (Gauge/lamp module)
14 D275A-5R
E-6 When the starting switch is turned ON, the basic check items flash1
Trouble • The radiator coolant 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 coolant level was detected, inspect the radiator
1 Drop of radiator coolant level coolant levels. (The lamp flashes when the level is below the spec-
ified level.)
The radiator coolant level Radiator coolant
2 sensor is defective. WLV (male) Resistance
level
Normal level Max. 1 z
Between (1) and (2)
Possible causes Lower level Min. 1 Mz
and standard a Prepare with the starting switch OFF, then carry out trouble-
value in normal Disconnection of wiring har- shooting without turning the starting switch ON.
state ness (Disconnection in wiring Wiring harness between S03 (female) (11) Resis-
3 Max. 1 z
or defective contact in con- and WLV (female) (1) tance
nector) Wiring harness between WLV (female) (2) Resis-
Max. 1 z
and ground tance
Defective machine monitor Radiator coolant
4 S03 Voltage
(Gauge/lamp module) level
Between (11) and Normal level Max. 1 V
ground Lower level 20 – 30 V
D275A-5R 15
E-7 While the engine is operating, any caution item flashes 1

Trouble (1) • 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 – 30 V
and ground (half)
Disconnection of wiring har- a Prepare with the starting switch OFF, then carry out trouble-
ness (Disconnection in wiring shooting without turning the starting switch ON.
2
or defective contact in con- Wiring harness between S04 (female) (9) Resis-
nector) Max. 1 z
Possible causes and alternator R terminal tance
value in normal shooting without turning the starting switch ON.
state
Ground fault of wiring har- Between wiring harness between S04
3 ness (Contact with ground (female) (9) and alternator R terminal, or
circuit) Resis-
starting motor R terminal or STCN1 (female) Min. 1 Mz
tance
(5) or TMCN1 (female) (15) or KOM1
(female) (28) and ground
Defective machine monitor
4 S04 Engine speed Voltage
(Gauge/lamp module)
Between (9) and Min. medium speed
20 – 30 V
ground (half)
16 D275A-5R
D275A-5R 17
Trouble (2) • The air cleaner clogging caution lamp flashes. (If equipped spec.)
Related
• If abnormality is detected while the engine is running, the caution item lamp flashes.
information

1 Clogged air cleaner Clean or replace the air cleaner.
Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshoot-
harness (Disconnection in ing without turning starting switch ON.
2
wiring harness or defective Wiring harness between S03 (female) (13) Resis-
contact in connector) Max. 1 z
and AF1 (female) (1) tance
and standard Short circuit with chassis ing without turning starting switch ON.
value in normal 3 ground in wiring harness Between wiring harness between S03
state (Contact with ground circuit) (female) (13) and AF1 (female) (1) and chas- Resis-
Min. 1 Mz
tance
sis ground
Defective machine monitor S03 Air cleaner Voltage
4
(gauge, lamp module)
Between (13) and When normal Max. 1 V
chassis ground When clogged 20 – 30 V
18 D275A-5R
E-8 While the engine is operating, the emergency warning item flashes1
Trouble (1) • The engine oil pressure caution lamp flashes.

• If abnormality is detected while the engine is running, the emergency calculation item flashes and
Related
the caution buzzer sounds.
information
• Engine oil pressure is checked by engine controller.

Check the engine oil pressure, as the drop of engine oil pressure is
Reduction of engine oil pres-
1 detected.
Possible causes sure
Carry out the engine troubleshooting of "S-12 Oil pressure drops."
and standard
value in normal If no problem is found in cause 1, the engine oil pressure sensor cir-
state Defective engine hydraulic cuit can be suspected to be defective. So, carry out the trouble-
2
system shooting of "Failure codes [CA135] and [CA141] Abnormal engine
oil pressure sensor."
3 Defective machine monitor Since this is an internal defect, it cannot be diagnosed.
D275A-5R 19
Trouble (2) • The engine coolant temperature caution lamp flashes.

• When any abnormality is detected during engine operation, the relevant emergency warning item
will sound the alarm buzzer.
Related • The engine coolant temperature caution lamp flashes or goes out as it links with indication on the
information engine coolant temperature gauge.
• Failure code [B@BCNS] may be displayed, too.
• Engine coolant temperature is checked by engine controller.

As overheated engine coolant was detected, check the engine
Overheated engine coolant coolant temperature. (When the coolant temperature is over
1
temperature 102°C, the lamp flashes. When the coolant temperature is over
Possible causes 105°C, the lamp flashes and the buzzer sounds.)
and standard The engine coolant tempera- Check the indication on the engine coolant temperature gauge. If
value in normal ture sensor system is defec- the indication is abnormal, carry out the troubleshooting of "E-11
state 2
tive. (Engine controller The engine coolant temperature gauge does not indicate nor-
system) mally."
When Causes 1 and 2 are not applicable, the machine monitor is
3 supposed to be defective. (This is an internal defect, which cannot
(Gauge/lamp module)
be troubleshot.)
20 D275A-5R
Trouble (3) • The power train oil temperature caution lamp flashes.
Related
• The power train oil temperature caution lamp flashes or goes out as it links with indication on the
information
power train oil temperature gauge.
• Failure code [B@CENS] may be displayed, too.

As an overheated power train oil temperature was detected, check
Overheated oil temperature the power train oil temperature. (When the oil temperature is over
1
of power train 120°C, the lamp flashes. When the oil temperature is over 130°C,
Possible causes the lamp flashes and the buzzer sounds.)
and standard The power train oil tempera-
value in normal Check the indication on the power train oil temperature gauge. If
ture sensor system is defec-
state 2 the indication is abnormal, carry out the troubleshooting of "E-12
tive. (Machine monitor
Indication of the power train temperature gauge is abnormal."
system)
(Gauge/lamp module)
be troubleshot.)
D275A-5R 21
Trouble (4) • The hydraulic oil temperature caution lamp flashes.

Related
• The hydraulic oil temperature caution lamp flashes or goes out as it links with indication on the
information
hydraulic oil temperature gauge.
• Failure code [B@HANS] may be displayed, too.

As an overheated hydraulic oil temperature was detected, check
Overheated hydraulic oil the hydraulic oil temperature. (When the oil temperature is over
1
temperature 100°C, the lamp flashes. When the oil temperature is over 110°C,
Possible causes the lamp flashes and the buzzer sounds.)
and standard
value in normal The hydraulic oil temperature Check the indication on the engine coolant temperature gauge. If
state 2 sensor system is defective. the indication is abnormal, carry out the troubleshooting of "E-13
(Machine monitor system) The hydraulic oil temperature gauge does not indicate normally."
(Gauge/lamp module)
be troubleshot.)
22 D275A-5R
D275A-5R 23
E-9 While the preheater is operating, the preheating pilot lamp does not
come on 1
Trouble • While the preheater is operating, the preheating pilot lamp does not come on.
a This troubleshooting describes the procedures to be followed when the preheating lamp doe not
come on. (When the electrical intake air heater mounting section is not heated, carry out the trou-
Related
bleshooting of "The electrical intake air 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.

Disconnection of wiring har- a Prepare with the starting switch OFF, then carry out trouble-
ness (Disconnection in wiring shooting without turning the starting switch ON.
1
or defective contact in con- Wiring harness between S03 (female) (9) Resis-
nector) Max. 1 z
and heater relay HT terminal tance
Possible causes Ground fault of wiring har- shooting without turning the starting switch ON.
and standard 2 ness (Contact with ground Between wiring harness between S03
value in normal circuit) Resis-
(female) (9) and heater relay HT terminal Min. 1 Mz
state tance
and ground
Defective machine monitorl S03 Starting switch Voltage
3
(Gauge/lamp module)
Between (9) and ON Max. 1V
ground HEAT 20 – 30 V
24 D275A-5R
D275A-5R 25
E-10 At the selecting time of dual tilt, the dual/single tilt selector lamp
does not come on (Dual tilt-mounted machine) 1
• At the selecting time of dual tilt, the dual/single tilt selector lamp does not come on. (Dual tilt-
Trouble
mounted machine)
• Before troubleshooting the blade, make sure that the dual tilt can operate. (When the blade does
Related
not operate normally, the electrical system on the machine side or the hydraulic/mechanical system
information
is supposed to be out of order. So, troubleshoot the relevant system.)

and standard
1 This is an internal defect, which cannot be troubleshot.
26 D275A-5R
E-11 The engine coolant temperature gauge does not indicate normally1
Trouble • The engine coolant temperature gauge does not indicate normally.
• Information of the engine coolant temperature sensor is received from the engine controller by CAN
Related communication.
information • When any abnormality occurs in the engine coolant temperature sensor system, failure code
[CA144] or [CA145] may be displayed.

If failure code [CA144] or [CA145] is displayed, carry out trouble-
shooting for it.
a Diagnose with starting switch ON or with engine started.
Defective engine coolant
1 Caution lamp (d)
Possible causes temperature sensor system
OFF Flashing
and standard
value in normal White range (a)
Red range (c)
state Green range (b)
Engine controller CAN If failure code [DB2RKR] is displayed, carry out troubleshooting for
2
communication error it.
3 Defective engine controller This is an internal defect, which cannot be troubleshot.
(Gauge/lamp module)
Coolant temperature gauge and caution lamp

Serial No.: 35001 – 35004
D275A-5R 27
E-12 Indication of the power train (torque converter) temperature gauge

is abnormal 1
Trouble • Indication of the power train (torque converter) temperature gauge is abnormal.
Related • When any abnormality occurs in the power train oil pressure sensor system, failure code [DGT1KX]
information or [DGT1KA] may be displayed.

If failure code [DGT1KX] or [DGT1KA] is displayed, carry out trou-
bleshooting for it.
Defective power train oil
1 Caution lamp (d)
pressure sensor system
Possible causes OFF Flashing
and standard White range (a)
value in normal Red range (c)
Green range (b)
state
Defective machine monitor Torque converter oil
2 S04 (female) Resistance
(Gauge/lamp module) temperature
Between (12) and About 3.8 kz –
10 – 130°C
ground about 80 kz

Serial No.: 35001 – 35004
28 D275A-5R
D275A-5R 29
E-13 The hydraulic oil temperature gauge does not indicate normally 1
Trouble • The hydraulic oil temperature gauge does not indicate normally.
• Signals of the hydraulic oil temperature sensor are received from the transmission controller
Related through communication.
information • When any abnormality occurred in the hydraulic oil temperature sensor system, the failure code
[DGS1KX] is displayed sometimes.

If failure code [DGS1KX] is displayed, carry out troubleshooting for
it.
Defective hydraulic oil tem-
1 Caution lamp (d)
perature sensor system
Possible causes OFF Flashing
and standard White range (a)
value in normal Red range (c)
Green range (b)
state
Transmission controller If failure code [DAQRKR] is displayed, carry out troubleshooting
2
CAN communication error for it.
Defective transmission
controller
(Gauge/lamp module)

Serial No.: 35001 – 35004
30 D275A-5R
E-14 Indication of the fuel gauge is abnormal 1

Trouble • Indication of the fuel gauge is abnormal.
Related
information

Defective fuel level sensor.
1 (Internal disconnection or FLV (male) Remained fuel level Resistance
short circuit) Between (1) and (2) Full About 4 z
(ground) Empty About 85 z
Disconnection of wiring har- shooting without turning the starting switch ON.
ness (Disconnection in wiring Wiring harness between S04 (female) (10) Resis-
2 Max. 1 z
or defective contact in con- and FLV (female) (1) tance
nector) Wiring harness between FLV (female) (2) Resis-
Max. 1 z
and ground tance
Possible causes
value in normal Ground fault of wiring har- shooting without turning the starting switch ON.
state 3 ness (Contact with ground Between wiring harness between S04
circuit) Resis-
(female) (10) and FLV (female) (1) and Min. 1 Mz
tance
ground
Hot short circuit of wiring har- switch ON and carry out troubleshooting.
4 ness (Contact with 24V cir- Between wiring harness between S04
cuit) (female) (10) and FLV (female) (1) and Voltage Max. 1 V
ground
Defective machine monitor S04 (female) Remained fuel level Resistance
5
(Gauge/lamp module)
Between (10) and Full About 4 z
ground Empty About 85 z
D275A-5R 31
E-15 Indications of gear speed and engine speed are abnormal 1

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
information engine controller through communication.

Possible causes Defective machine monitor
and standard (Gauge/lamp module)
value in normal Engine controller or travel
state If failure code [DB2RKR] or [DAQRKR] is displayed, carry out trou-
2 controller CAN communica-
bleshooting for it.
tion error
E-16 Indication of the shift mode service meter is abnormal 1

Trouble (1) • During engine operation, the service meter does not advance.
Related
• The service meter measures time according to engine drive signals (alternator voltage).
information

Possible causes When the battery charge level caution lamp flashes during engine
and standard 1 Defective alternator system operation, carry out the troubleshooting of "While the engine is
value in normal operating, caution items flash."
state Defective machine monitor
(Gauge/lamp module)
Trouble (2) • Shift mode and service meter are not displayed at all.
Related
information

and standard
32 D275A-5R
E-17 The switch module cannot be operated 1

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

ness (Disconnection in wiring
1
Possible causes or defective contact in con- Wiring harness between S01 (female) (8) Resis-
and standard nector) and STCN2 (female) (21), or TMCN2 Max. 1 z
tance
value in normal (female) (21)
state a Prepare with the starting switch OFF, then start the engine and
Defective machine monitor carry out the troubleshooting.
2
Between (8) and ground 6–9V
D275A-5R 33
E-18 The warning lamp does not flash or does not go out 1
Trouble • The warning lamp does not flash or does not go out.
Related
information

and standard
34 D275A-5R
E-19 The alarm buzzer does not sound or does not stop 1
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
information failure codes are displayed.

Defective circuit breaker When the circuit breaker is cut off, a ground fault may have possi-
1
(CB2) bly occurred in the circuit.
Defective alarm buzzer
2 (Internal disconnection or 217 (male) Resistance
short circuit) Between (1) and (2) 200 z
Possible causes ness (Disconnection in wiring Wiring harness between S03 (female) (18) Resis-
3 Max. 1 z
and standard or defective contact in con- and 217 (female) (1) tance
value in normal nector) Wiring harness between 217 (female) (2) Resis-
state Max. 1 z
Ground fault of wiring har- shooting without turning the starting switch ON.
circuit) Between wiring harness related to CB2 (out- Resis-
Min. 1 Mz
let side) and ground tance
Defective machine monitor S03 Alarm buzzer Voltage
5
(Gauge/lamp module) At stop 20 – 30 V
Between (18) and
ground At operation
Max. 3 V
(sounding)
D275A-5R 35
E-20 Auto shift down is not possible or is not released 1

Trouble • Auto shift down is not possible or is not released.
Related
information

Defective auto shift down Auto shift down
1 switch (Internal disconnec- ASD (male) Resistance
switch
tion or short circuit)
OFF (0) Min. 1 Mz
Between (2) and (3)
ON (1) Max. 1 z
Possible causes ness (Disconnection in wiring Wiring harness between TMCN3 (female) Resis-
or defective contact in con- (39) and ASD (female) (3) tance
value in normal nector) Wiring harness between ASD (female) (2) Resis-
state Max. 1 z
and ground tance
Ground fault of wiring har- shooting without turning the starting switch ON.
3 ness (Contact with ground Between wiring harness between TMCN3
circuit) Resis-
(female) (39) and ASD (female) (3) and Min. 1 Mz
tance
ground
troller
Defective transmission con- If causes 1 – 4 are not detected, transmission control system may
5
trol system have another defect.
36 D275A-5R
E-21 The alarm buzzer cannot be cancelled 1

Trouble • The alarm buzzer cannot be cancelled.
Related
• Cancel signal is sent from steering controller to machine monitor through communication system.
information

BUZ (male) Buzzer cancel switch Resistance
Defective buzzer cancel
1 switch (Internal disconnec- OFF (0) Min. 1 Mz
Between (1) and (2)
tion or short circuit) U Max. 1 z
OFF (0) Min. 1 Mz
Between (1) and (3)
T Max. 1 z
Disconnection of wiring har- Wiring harness between STCN2 (female) Resis-
Max. 1 z
Possible causes ness (Disconnection in (36) and BUZ (female) (2) tance
2
and standard wiring or defective contact in Wiring harness between STCN2 (female) Resis-
connector) Max. 1 z
value in normal (26) and BUZ (female) (3) tance
state Wiring harness between BUZ (female) (1) Resis-
Max. 1 z
and ground tance
Between wiring harness between STCN2
Ground fault of wiring har- Resis-
(female) (36) and BUZ (female) (2) and Min. 1 Mz
ground
circuit)
Resis-
(female) (26) and BUZ (female) (3) and Min. 1 Mz
tance
ground
Machine monitor CAN com- If failure code [DAFRKR] is displayed, carry out troubleshooting for
4
munication error it.
5 Defective steering controller This is an internal defect, which cannot be troubleshot.
D275A-5R 37
E-22 The operator mode cannot be operated 1

Trouble • The operator mode cannot be operated.
Related
information

Since the buzzer cancel switch system is supposed to be out of
1 order, carry out the troubleshooting of "The alarm buzzer cannot be
switch system
cancelled."
CUR (male) Information switch Resistance
Defective information switch
2 (Internal short circuit or dis- OFF (0) Min. 1 Mz
Between (1) and (2)
connection) < Max. 1 z
OFF (0) Min. 1 Mz
Between (1) and (3)
> Max. 1 z
Possible causes shooting without turning the starting switch ON.
and standard
Disconnection of wiring har- Wiring harness between STCN2 (female) Resis-
ness (Disconnection in wiring (16) and CUR (female) (2) tance
state 3
nector) Max. 1 z
(6) and CUR (female) (3) tance
Wiring harness between CUR (female) (1) Resis-
Max. 1 z
and ground tance
(female) (16) and CUR (female) (2) and Min. 1 Mz
ground
circuit)
Resis-
(female) (6) and CUR (female) (3) and Min. 1 Mz
tance
ground
38 D275A-5R
D275A-5R 39
E-23 The service mode cannot be operated 1

Trouble • The service mode cannot be operated.
Related
information

Since the buzzer cancel switch system is supposed to be out of
1 order, carry out the troubleshooting of "The alarm buzzer cannot be
switch system
cancelled."
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
system
cancelled."
3
Defective service switch
4 (Internal short circuit or dis- S24 Service switch Resistance
connection) Between (2) and (3), OFF Min. 1 Mz
Between (5) and (6) ON Max. 1 z
Wiring harness between CB6 outlet and Resis-
Max. 1 z
Disconnection of wiring har- S24 (3) tance
Possible causes ness (Disconnection in wiring Resis-
5 Wiring harness between S24 (6) and ground Max. 1 z
and standard or defective contact in con- tance
value in normal nector) Wiring harness between S03 (female) (16) Resis-
Max. 1 z
state and S24 (2) tance
Max. 1 z
(6) and S24 (5) tance
Between wiring harness between CB6 (out- Resis-
Min. 1 Mz
let) – S24 (3) with ground tance
Ground fault of wiring har-
Between wiring harness between S24 (6) – Resis-
ground with ground tance
circuit)
Between wiring harness between S03 Resis-
Min. 1 Mz
(female) (16) – S24 (2) ground with ground tance
Between wiring harness between STCN1 Resis-
Min. 1 Mz
(female) (6) – S24 (5) ground with ground tance
Defective machine monitor S03 Service switch Voltage
7
(Gauge/lamp module)
Between (16) and OFF Max. 1 V
ground ON 20 – 30 V
40 D275A-5R
D275A-5R 41
E-24 The back-up alarm does not sound 1

Trouble • The back-up alarm does not sound.
• When a failure occurs on the primary side (coil side) of the back-up alarm relay, a relevant failure
Related
code is displayed, but in case of failure on the secondary side (contact side), no failure code is dis-
information
played.

When the fuse is blown, a ground fault may have probably
occurred in the circuit.
Defective back-up relay When the relay is replaced with another relay while the starting
2
(Internal disconnection) switch is set to OFF and the alarm sounds after the starting switch
is turned on and the machine is operated in reverse, the back-up
alarm relay (BKA) is defective.
Wiring harness between FS22-1 outlet and Resis-
Max. 1 z
Disconnection of wiring har- BKA (female) (1), (3) tance
Possible causes
ness (Disconnection in wiring Wiring harness between BKA (female) (5) Resis-
or defective contact in con- and BKAL (female) (1) tance
value in normal
nector) Wiring harness between BKAL (female) (2) Resis-
state Max. 1 z
and ground tance
Max. 1 z
(8) and BKA (female) (2) tance
Between wiring harness between FS22-1
(outlet side) and BKA (female) (1), (3) and Min. 1 Mz
ground
circuit)
Between wiring harness between BKA
Resis-
(female) (5) and BKAL (female) (1) and Min. 1 Mz
tance
ground
Defective back-up alarm When causes 1 to 4 are not applicable, the back-up alarm is sup-
5
(Internal defect) posed to be defective.
42 D275A-5R
D275A-5R 43
E-25 The night light, the headlamp, the working lamp and the rear lamp
on the panel do not come on 1
Trouble (1) • None of the night light, the headlamp and the working lamp on the panel comes on.
Related • Headlamp and working lamp are operated with 1 switch.
information • If headlamp switch is operated, panel lighting is changed for night.

If circuit breaker is turned OFF, circuit probably has ground fault
1 Defective circuit breaker CB5
etc.
Defective headlamp and
2 working lamp switch (Inter- FWL (male) Switch Resistance
national disconnection) OFF Min. 1 Mz
Between (2) and (3)
ON Max. 1 z
Wiring harness between FWL (female) (3) Resis-
Max. 1 z
Disconnection of wiring har-
Possible causes ness (Disconnection in wiring Wiring harness between FWL (female) (2)
3
and standard or defective contact in con- and LMFL (female) (1) and LMFR (female) Resis-
Max. 1 z
nector) (1) and LMW (female) (1) and S01 (female) tance
value in normal
(10) or S03 (female) (8)
state
Wiring harness between LMFL (female) (2)
Resis-
and LMFR (female) (2) or LMW (female) (2) Max. 1 z
tance
and ground
Wiring harness between FWL (female) (3) – Resis-
Min. 1 Mz
CB5 outlet and ground tance
Ground fault of wiring har- Wiring harness between FWL (female) (2) –
4 ness (Contact with ground LMFL (female) (1), LMFR (female) (1), LMW Resis-
circuit) Min. 1 Mz
(female) (1), S01 (female) (10) or S03 tance
Wiring harness between LMFL (female) (2),
Resis-
LMFR (female) (2), or LMW (female) (2) – Min. 1 Mz
tance
ground and ground
44 D275A-5R
Trouble (2) • Only the night light on the panel does not comes on. (Whole or part)
Related
• If headlamp switch is operated, panel lighting is changed for night.
information

Defective night lamp (S02) The night lamp is supposed to be defective. Check if the bulb is
1
(Blown) blown.
Max. 1 z
and FWL (female) (2) tance
Max. 1 z
Disconnection of wiring har- and ground tance
ness (Disconnection in wiring Wiring harness between S02 (female) (1) Resis-
2 Max. 1 z
or defective contact in con- and CB2 (outlet) tance
nector) Wiring harness between S02 (female) (2) Resis-
Max. 1 z
and ground tance
Max. 1 z
Wiring harness between S03 (female) (3), Resis-
(4) and ground tance
and standard
value in normal a Prepare with the starting switch OFF, then carry out trouble-
state shooting without turning the starting switch ON.
Ground fault of wiring har- Min. 1 Mz
circuit) Wiring harness between S02 (female) (1) Resis-
Min. 1 Mz
and CB2 (outlet) tance
Min. 1 Mz
Defective machine monitor Between S01 (10)
4
(Switch module) and (2)
Light switch ON 20 – 30 V
Between S02 (1) and
(2)
Defective machine monitor switch ON and carry out troubleshooting.
5
(Gauge/lamp module) Between S03 (8) and
Light switch ON 20 – 30 V
(3), (4)
D275A-5R 45
Trouble (3) • Only the headlamp does not comes on. (Both right and left, or one side only)
Related
information

The headlamp is supposed to be defective. Check if the bulb is
1 Defective headlamp (Blown)
blown.
2
Defective headlamp relay When the relay is replace with another relay while the starting
3
(Internal disconnection) switch is set to OFF and the headlamp comes on after the starting
switch is turned ON and the light switch is turned ON, the head-
lamp relay (LMFL, LMFR) are defective.
Max. 1 z
LMFL (female) (3) and LMFR (female) (3) tance
Disconnection of wiring har-
ness (Disconnection in wiring Resis-
Possible causes 4 – LHDL (female) (1) and LMFR (female) (5) Max. 1 z
or defective contact in con- tance
and standard – LHDR (female) (1)
nector)
value in normal Wiring harness between LMFL (female) (2) Resis-
state Max. 1 z
– ground tance
Wiring harness between LMFR (female) (2) Resis-
Max. 1 z
– ground tance
Between wiring harness between CB5 (out-
let side) and LMFL (female) (3) and LMFR Min. 1 Mz
circuit)
Resis-
– LHDL (female) (1) and LMFR (female) (5) Min. 1 Mz
tance
– LHDR (female) (1) and ground
Hot short (Contact with 24V Between wiring harness between LMFL
6 Voltage Max. 1 V
circuit) in wiring harness (female) (2) and ground and ground
Between wiring harness between LMFR
Voltage Max. 1 V
46 D275A-5R
Trouble (4) • 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.
Defective working lamp relay When the relay is replace with another relay while the starting
3
(Internal disconnection) switch is set to OFF and the headlamp comes on after the starting
switch is turned ON and the light switch is turned ON, the working
lamp relay (LMW) is defective.
Possible causes Disconnection of wiring har- Wiring harness between FS22-4 outlet and Resis-
Max. 1 z
and standard ness (Disconnection in wiring LMW (female) (3) tance
4
value in normal or defective contact in con- Wiring harness between LMW (female) (5) Resis-
state nector) Max. 1 z
and LMKL (female) (1) or 242 (female) (1) tance
Wiring harness between LMW (female) (2) Resis-
Max. 1 z
and ground tance
Min. 1 Mz
5 ness (Contact with ground (outlet side) LMW (female) (3) and ground tance
circuit) Between wiring harness between LMW
Resis-
(female) (5) and LMKL (female) (1) or 242 Min. 1 Mz
tance
Hot short (Contact with 24V shooting without turning the starting switch ON.
6
circuit) in wiring harness Between wiring harness between LMW
Voltage Max. 1 V
D275A-5R 47
Trouble (5) • 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 RWL (male) Switch Resistance
3
(International disconnection)
OFF Min. 1 Mz
Between (2) and (3)
ON Max. 1 z
Possible causes
value in normal Disconnection of wiring har- shooting without turning the starting switch ON.
state ness (Disconnection in wiring Wiring harness between RWL (female) (2) Resis-
4 Max. 1 z
or defective contact in con- and FS22-5 (outlet side) tance
nector) Wiring harness between RWL (female) (3) Resis-
Max. 1 z
and LRER (female) (1) or LREL (female) (1) tance
Min. 1 Mz
5 ness (Contact with ground (outlet side) - RWL (female) (2) and ground tance
circuit) Between wiring harness between RWL
Resis-
(female) (3) - LRER (female) (1) and LREL Min. 1 Mz
tance
48 D275A-5R
D275A-5R 49
E-26 The air conditioner does not operate 1

Trouble (1) • No air flow
Related
information

1
Defective blower main relay shooting without turning the starting switch ON.
2
(coil side) CN-R1 (male) Resistance
Between (1) and (2) 240 ± 40 z
Defective blower main relay switch ON and carry out troubleshooting.
3
(contact side) CN-R1 Voltage
Between (6C) and ground 20 – 30 V
Defective blower Hi relay shooting without turning the starting switch ON.
4
(coil side) CN-R2 (male) Resistance
Between (1) and (2) 240 ± 40 z
Defective blower Hi relay switch 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 shooting without turning the starting switch ON.
6
Possible causes (coil side) CN-R3 (male) Resistance
and standard Between (1) and (2) 240 ± 40 z
value in normal
state
Defective blower Mi relay switch 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)
Resis-
(0B), CN-AC1 (female) (0C), CN-R (female) Max. 1 z
tance
(0D) or CN-R2 (female) (0E) and ground
Wiring harness between CN-B(female) Resis-
Max. 1 z
Disconnection of wiring har- (10A) and CN-R1 (female) (10B) tance
ness (Disconnection in wiring Wiring harness between CN-B (female)
9 Resis-
or defective contact in con- (11A) and CN-R2 (female) (11B) or CN-R Max. 1 z
nector) tance
(female) (11C)
Wiring harness between CB4 outlet and
CN-AC1 (female) (13C), CN-R1 (female) Resis-
Max. 1 z
(13D), CN-R2 (female) (13E) or CN-R3 tance
(female) (13H)
Wiring harness between CN-R1 (female) Resis-
Max. 1 z
(14A) and CN-AC1 (female) (14B) tance
50 D275A-5R

ness (Disconnection in wiring Wiring harness between CN-R3 (female) Resis-
9 Max. 1 z
Possible causes or defective contact in con- (17A) and CN-AC1 (female) (17B) tance
and standard nector) Wiring harness between CN-R2 (female) Resis-
state
When Causes 1 to 9 are not applicable, the control panel is sup-
10 Defective control panel
posed to be defective.
When any cause cannot be specified, failure phenomenon may
11 Different failure phenomenon have been mistaken. Carry out the troubleshooting of "Cooling is
not possible."
D275A-5R 51
Trouble (2) • Cooling is not possible.

Related
information

1 Defective pressure switch CN-P Blower switch Voltage
Between (26A) and
ON 20 – 30 V
ground
Defective compressor clutch shooting without turning the starting switch ON.
2
relay (coil side) CN-R4 (male) Resistance
Between (1) and (2) 240 ± 40 z
Defective compressor clutch switch ON and carry out troubleshooting.
3
relay (contact side) CN-R4 Voltage
Between (9B) and ground 20 – 30 V
Defective condenser relay switch ON and carry out troubleshooting.
4
(contact side) CN-R5 Voltage
Between (7B) and ground 20 – 30 V
5 Defective thermistor
CN-AC1 (male) Resistance
Between (15B) and (16C) Max. 3,500 z
Possible causes a Prepare with the starting switch OFF, then carry out trouble-
and standard shooting without turning the starting switch ON.
value in normal Defective condenser blower
6
state resistor Condenser blower resistor Resistance
Between terminals 2.8 z ± 5 %
a 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.
a Start the engine and carry out the troubleshooting.
Defective compressor mag-
8 The compressor magnet clutch is supposed to be out of order, so
net clutch
inspect it directly.
a 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
Resis-
CN-R5 (female) (6B) or CN-R4 (female) Max. 1 z
tance
(6D)
Disconnection of wiring har- Wiring harness between CN-R5 (female) Resis-
ness (Disconnection in wiring (7B) and ARC (female) (2) Max. 1 z
10 tance
or defective contact in con-
nector) Wiring harness between CN-R4 (female) Resis-
Max. 1 z
(9B) and 351 (female) (1) tance
Max. 1 z
CN-R4 (female) (13I) tance
Wiring harness between CN-T (female) Resis-
Max. 1 z
52 D275A-5R

Disconnection of wiring har- Wiring harness between CN-P (female) Resis-
ness (Disconnection in wiring (19A) and CN-R4 (female) (19C) tance
and standard 10
or defective contact in con- Wiring harness between CN-P (female) Resis-
nector) (26A) and CN-AC1 (female) (26B) tance
state
Wiring harness between ARC (female) (1) Resis-
Max. 1 z
and ground tance
When causes 1 to 10 are not applicable, the control panel is sup-
11 Defective control panel
posed to be defective.
D275A-5R 53
54 D275A-5R
D275A-5R 55
E-27 KOMTRAX system does not operate normally 1

Trouble • KOMTRAX system does not operate properly.
• If KOMTRAX system administrator makes request for checking system on machine side for trouble,
Related
carry out the following troubleshooting.
information
• Even if KOMTRAX system has a trouble, it does not particularly appear on machine.

Defective specification Check the code 0021: KOMTRAX specification setting in adjust-
1
setting ment mode and set to "ACTIVE".
switch still OFF.
Defective electric power
2 KOM1 Signal Voltage
supply
Between (39) (40) – Constant power
20 – 30 V
(37) (38) source
a Diagnose with starting switch ON and with the engine started.
LED(1) Normal condition
LED-C1 ON
a Prepare with starting switch OFF and start the engine to diag-
nose.
3 ACC signal and alternator R
signal KOM1 Signal Voltage
Between (36) –
Starting switch ACC 20 – 30 V
(37) (38)
Between (28) –
Alternator R 20 – 30 V
(37) (38)
switch ON.
KOM1 Signal Voltage
Possible causes
and standard Between (27) –
Starting switch C Max. 1 V
value in normal Defective starting switch C (37) (38)
4
state signal a Prepare with starting switch OFF and start the engine to diag-
nose.
KOM1 Signal Voltage
Between (27) –
Starting switch C 20 – 30 V
(37) (38)
a Diagnose with starting switch ON.
LED-C4 ON
Defective CAN connecting
5 a Prepare with starting switch OFF and diagnose with starting
condition
switch still OFF.
KOM1 Signal Resistance
Between (7) – (8) CAN 40 – 80 z
6 Number of mails not yet sent LED(7) Normal condition
7 segments 0–9
Defective GPS positioning Dot ON
7
status
It may take more than 1 minute from turning on the starting switch
to the completion of positioning even in an outdoor place where
radio wave can reach.
56 D275A-5R
LED display section of KOMTRAX terminal KOM1 connector
CPU LED
1. LED-C1 (R signal and ACC signal status)
2. LED-C2 (starting output status)
3. LED-C3 (S-NET, C signal status)
4. LED-C4 (CAN status)
5. LED-C5 (download writing condition)
6. LED-C6 (download writing condition)
7-segment and dot for CPU
7. 7-segment (number of mails not yet sent)
8. Dot (GPS positioning in progress)
a CPU LED and 7-segment and dot for CPU can

be also checked by monitoring function of
machine monitor.
a See "Special functions of machine monitor

(EMMS)" of Testing and adjusting, Part 3 for
operation of monitoring functions.
D275A-5R 57
E-28 Fan does not reverse 1

Trouble • When fan is set in fan cleaning mode or fan reverse mode (if equipped), fan does not reverse.
Related • If any switch is operated during reverse prohibition period, orange lamp blinks.
information • Orange lamp lights up in cleaning mode and reverse mode.

Abnormality in fan reverse If failure code [DW7BKA], [DW7BKB] or [DW7BKY] is displayed,
1
solenoid carry out troubleshooting for it first.
Operation of fan cleaning
2 switch in reverse prohibition If switch is operated after engine is started, fan does not reverse
period and orange lamp blinks. At this time, orange lamp indicates that
switch operation is ineffective but does not indicate trouble.
Operation of fan reverse Turn key switch OFF to stop engine and turn battery relay OFF,
3 switch (if equipped) in and then set fan in fan cleaning or fan reverse mode again.
reverse prohibition period
Defective fan cleaning switch FAN1 (male) Switch Resistance
OFF Min. 1 Mz
Between (1) – (2)
CLN position Max.1 z
4 FAN2 (male) Switch Resistance
OFF Min. 1 Mz
Defective fan reverse switch
Possible causes (if equipped) Between (1) – (3) CLN position Min. 1 Mz
and standard (Internal disconnection) REV position Max. 1 z
value in normal
OFF Min. 1 Mz
state
Between (3) – (4) CLN position Max. 1 z
REV position Min. 1 Mz
[When standard cleaning ing without turning starting switch ON.
switch is employed]
Wiring harness between FAN1 (female) (1) – Resis-
Disconnection in wiring har- Max. 1 z
GND7 tance
ness
(Internal disconnection) Wiring harness between FAN1 (female) (2) – Resis-
Max. 1 z
STCN2 (female) (38) tance
5
[When optional reverse Wiring harness between FAN2 (female) (3) – Resis-
switch is employed] Max. 1 z
GND7 tance
ness Wiring harness between FAN2 (female) (4) – Resis-
Max. 1 z
(Internal disconnection) STCN2 (female) (38) tance
Wiring harness between FAN2 (female) (1) – Resis-
Max. 1 z
STCN2 (female) (2) tance
6 Defective steering controller tive.
(Since trouble is in system, troubleshooting cannot be carried out.)
58 D275A-5R
D275A-5R 59
E-29 Gear cannot be shifted 1

Trouble • Gear cannot be shifted (Shift switch does not work).
Related
—
information

a When no failure code related to shift operation switch is not dis-
played
Trouble in shift operation
Press shift operation switch for more than 10 seconds. If any of
switch
following failure codes is displayed at this time, carry out trouble-
• Shift-up switch shooting for it.
Possible causes 1
• Shift-down switch [DDK5KA], [DDK5KB], [DD12KA], [DD12KB], [DD13KA],
and standard
• Shift switch [DD13KB]
value in normal
(Optional-type lever)
state a When failure code related to shift operation switch is displayed
Carry out troubleshooting for displayed failure code.
If failure code of action code E03 or E04 is displayed, gear speed
2 Gear speed limit limit is applied. In this case, carry out troubleshooting for that fail-
ure code first.
3 Defect in transmission clutch Transmission clutch may have defect in it. Check it directly.
60 D275A-5R
D275A-5R 61
E-30 Electric priming pump does not operate or does not stop
automatically 1
Trouble • Electric priming pump does not operate or does not stop automatically
Relative
information

1 Low battery charge level Battery charge level may be low. Check battery directly.
Defective circuit breaker If circuit breaker (CB7) is turned OFF, circuit probably has ground
2
CB7 fault. (Check cause No. 5)
Disconnection in wiring a Prepare with battery ground cable disconnected, then connect it
harness (Power supply and carry out troubleshooting (since power supply is unswitched).
system)
3
(Disconnection in wiring or
defective contact in con- Between EPP (1) – (2) Voltage 20 – 30 V
nector)
a Prepare with battery ground cable disconnected, then connect
battery and turn electric priming pump ON and carry out trouble-
shooting.
harness • Lamp blinks but stops in about 5 seconds.
(Drive power supply sys- Between EG6 (1) – (2) Voltage 20 – 30 V
4
tem) (Disconnection in wir- a Prepare with battery ground cable disconnected, then carry out
ing or defective contact in troubleshooting without reconnecting (since power supply is
connector) unswitched).
Resis-
Between EPP (female) (2) – ground Max. 1 z
Possible causes tance
and standard a Prepare with battery ground cable disconnected, then carry out
value in normal troubleshooting without reconnecting (since power supply is
state unswitched).
Ground fault in wiring har- Wiring harness between EPP (female) (1) – Resis-
Min. 1 Mz
5 ness (Contact with ground circuit breaker B7L and ground tance
circuit) Wiring harness between EPP (female) (3) – Resis-
Min. 1 Mz
EG6 (female) (1) and ground tance
Wiring harness between EPP (female) (4) – Resis-
Min. 1 Mz
EG6 (female) (2) and ground tance
a Prepare with battery ground cable disconnected, then connect
battery and turn electric priming pump ON and carry out trouble-
shooting.
Between EPP (3) – (4) Voltage 20 – 30 V
Defective electric priming
6 pump switch (Malfunction • Lamp blinks but output voltage is improper.
or automatic stop failure) • Results of troubleshooting steps 1 – 4 are normal and lamp does
not blink.
a When electric priming pump does not stop automatically, electric
priming pump switch may be defective. (Turn toggle switch OFF to
stop pump and then replace switch.)
• Lamp blinks but stops in about 5 seconds.
Overload on electric prim-
7 * If pump is overloaded, power supply is turned OFF automatically to
ing pump
protect circuit (Priming switch is reset automatically).
62 D275A-5R

a Prepare with battery ground cable disconnected, then carry out
troubleshooting without reconnecting (since power supply is
Possible causes unswitched).
and standard Resis-
Between EG6 (male) (1) – (2) 1–3z
value in normal 8 Trouble in electric priming tance
state pump
Resis-
Between EG6 (male) (1) – pump body Min. 1 Mz
tance
Resis-
Between EG6 (male) (2) – pump body Min. 1 Mz
tance
D275A-5R 63
D275A-5R Bulldozer
© 2008 KOMATSU
All Rights Reserved
64 D275A-5R
SEN02765-00
D275A-5R

D275A-5R 35001 and up
Troubleshooting of hydraulic and
mechanical system (H-mode)
Information in troubleshooting table................................................................................................................ 3
H-1 No travel power (No drawbar pull) ........................................................................................................... 4
H-2 Machine does not move (At 2nd or 3rd speed) ........................................................................................ 5
H-3 Machine does not move in any speed range ........................................................................................... 6
H-4 Machine travels only in one direction forward or in reverse ..................................................................... 7
H-5 When gear is shifted or travel direction is changed, large time lag is made ............................................ 8
H-6 Steering is not possible ............................................................................................................................ 9
H-7 Steering is possible only on one side ..................................................................................................... 10
H-8 Steering overrun occurs ..........................................................................................................................11
H-9 Brake does not work .............................................................................................................................. 12
H-10 Overheat of power train oil temperature............................................................................................... 13
H-11 All work equipment speeds are slow .................................................................................................... 14
H-12 Work equipment does not move .......................................................................................................... 15
H-13 Blade lift speed is slow or lacks power................................................................................................. 16
D275A-5R 1
H-14 Blade tilt speed is slow or lacks power................................................................................................. 17

H-15 Ripper lift speed is slow or lacks power ............................................................................................... 18
H-16 Ripper tilt speed is slow or lacks power ............................................................................................... 19
H-17 Excessive hydraulic drift of blade lift .................................................................................................... 20
H-18 Excessive hydraulic drift of blade tilt .................................................................................................... 21
H-19 Excessive hydraulic drift of ripper lift .................................................................................................... 22
H-20 Ripper pin puller cylinder does not work (Giant ripper attachment machine) ....................................... 23
H-21 Blade pitch does not work (Dual tilt attachment machine) ................................................................... 24
H-22 Abnormal sound comes out from around work equipment pump......................................................... 25
H-23 Fan speed is abnormal (Sound and/or vibration of fan are/is abnormally large or engine overheats) . 26
2 D275A-5R
Information in troubleshooting table 1

a The following information is summarized in the troubleshooting table. Before carrying out troubleshoot-
ing, understand that information fully.
Trouble Trouble which occurred in the machine

Related
Information related to detected trouble or troubleshooting
information
Possible causes 2
and standard Possible causes of trouble
<Contents of description>
value in normal (Given numbers are refer-
• Standard value in normal state to judge possible causes
state ence numbers, which do
• Remarks on judgment
not indicate priority)
3
D275A-5R 3
H-1 No travel power (No drawbar pull) 1

Trouble • No travel power. (No drawbar pull)
Related
• Confirm that the oil quantity on the power train is normal before troubleshooting.
information

a Prepare with starting switch OFF, then drive the engine in high
idle mode for troubleshooting.
Defective engine or trans- Measurement conditions Number of engine rotations
1
mission F3 stall 1,510 rpm
Stall in F3 + Relief of work equip-
1,450 rpm
ment system (Pitch back)
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 – 1.0 MPa 0.49 ± 0.1 MPa
Full neutral
{5 – 10 kg/cm2} {5 ± 1 kg/cm2}
PCCS lever
pressure
Full neutral Min. 2.94 MPa {Min. 30 kg/cm2}
Defective set pressure of
4 transmission main relief a Prepare with the starting switch OFF, then carry out trouble-
Possible causes valve and internal defect shooting without turning the starting switch ON.
and standard Directly check that the spring length and the number of shims are
value in normal normal and also that the spool rotates smoothly.
state • Free length of large spring: 122 mm
• Free length of small spring: 108 mm
• Number of shims: 6
a Prepare with starting switch OFF, then drive the engine in low
Transmission clutch Clutch pressure
Defective transmission valve FWD Min. 2.65 MPa {Min. 27 kg/cm2}

5
(ECMV) function REV Min. 2.65 MPa {Min. 27 kg/cm2}
1ST Min. 2.65 MPa {Min. 27 kg/cm2}
2ND Min. 2.65 MPa {Min. 27 kg/cm2}
3RD Min. 2.65 MPa {Min. 27 kg/cm2}
6 Defective brake valve Parking brake lever Left brake pressure Right brake pressure
Min. 2.45 MPa Min. 2.45 MPa
Free
{Min. 25 kg/cm2} {Min. 25 kg/cm2}
If the result of the troubleshooting in cause 6 is abnormal, the park-
Defective parking brake lever
7 ing brake lever or brake pedal linkage is not assumed to be
or brake pedal linkage
adjusted normally. Directly check it.
Internally defective transmis- The transmission is assumed to be defective internally; directly
8
sion check it.
4 D275A-5R
H-2 Machine does not move (At 2nd or 3rd speed) 1

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
converter torque converter delivery pressure
0.49 – 1.0 MPa 0.49 ± 0.1 MPa
Full neutral
{5 – 10 kg/cm2} {5 ± 1 kg/cm2}
Possible causes Defective transmission valve Transmission clutch Clutch pressure
2
and standard (ECMV) function
value in normal
state 3RD Min. 2.65 MPa {Min. 27 kg/cm2}
Internally defective transmis- The transmission clutch (2nd or 3rd speed) is assumed to be
3
sion clutch defective internally; directly check it.
Defective parking brake The parking brake function is assumed to be defective (dragged);
4
function (Drag) check the linkage valves.
a Move to a flat place, and start the engine for troubleshooting.
Defective brake function
5 If the machine does not run by low idle + F2 operation, brake drag
(Drag)
occurs. (Carry out troubleshooting "H-8 Brake does not work.")
Internally defective transmis- The transmission is assumed to be defective internally; directly
6
sion check it.
D275A-5R 5
H-3 Machine does not move in any speed range 1

Trouble • Machine does not move in any speed range.
Related
information

PCCS lever
pressure
Defective and Internally Full neutral Min. 2.94 MPa {Min. 30 kg/cm2}
defective set pressure of a Prepare with the starting switch OFF, then carry out trouble-
2
transmission main relief shooting without turning the starting switch ON.
valve
Directly check that the spring length and the number of shims are
normal and also that the spool rotates smoothly.
• Free length of large spring: 122 mm
idle mode for troubleshooting. (Before this, confirm that the
transmission main relief pressure is normal.)
Possible causes Transmission clutch Clutch pressure
and standard Defective transmission valve FWD Min. 2.65MPa {Min. 27kg/cm2}
3
value in normal (ECMV) function
REV Min. 2.65MPa {Min. 27kg/cm2}
state
1ST Min. 2.65MPa {Min. 27kg/cm2}
2ND Min. 2.65MPa {Min. 27kg/cm2}
3RD Min. 2.65MPa {Min. 27kg/cm2}
Internally defective transmis- The transmission clutch (2nd or 3rd speed) is assumed to be
4
a Move to a flat place, raise the parking lever and drive the
engine in high idle mode for troubleshooting. (Before this, con-
firm that the transmission main relief pressure is normal.)
Brake hydraulic pressure
Brake pedal
5 Defective brake function (left/right)
Release Min. 2.45 MPa {Min. 25 kg/cm2}
Pedal 0 {0}
If oil pressure is abnormal, carry out troubleshooting in "H-8 Brake
does not work".
Carry out troubleshooting for failure codes [DDQ2KA], [DDQ2KB]
Defective parking brake lever
6 and [DDQ2L4]. Even if these failure codes are not displayed,
switch
check that switch input changes normally.
6 D275A-5R
H-4 Machine travels only in one direction forward or in reverse 1

Trouble • Machine travels only in one direction forward or in reverse.
Related
information

PCCS lever
pressure
valve or internal defect shooting without turning the starting switch ON.
Possible causes transmission main relief pressures is normal.)
and standard Transmission clutch Clutch pressure
value in normal
state 3
(ECMV) function
REV Min. 2.65 MPa {Min. 27 kg/cm2}
Defective transmission clutch When the troubleshooting in cause 3 is abnormal, the clutch seal is
4
seal assume to be defective; directly check it.
Internally defective transmis- The transmission clutch (forward or reverse) is assumed to be
5
a Stop machine on level ground, start engine, and carry out trou-
bleshooting.
6 Set transmission in F2 at low idle. If machine does not move at
(Dragging)
this time, brake is dragging (Carry out troubleshooting for H-8
"Brake does not work").
Defective function of direc-
7 tional potentiometer of travel Carry out troubleshooting related to directional potentiometer.
lever
D275A-5R 7
H-5 When gear is shifted or travel direction is changed, large time lag is
made 1
Trouble • When gear is shifted or travel direction is changed, large time lag is made.
Related
information

PCCS lever
pressure
valve or internal defect shooting without turning the starting switch ON.
Possible causes
and standard
value in normal
transmission main relief pressure is normal.)
state
Transmission clutch Clutch pressure
3
(ECMV) function
REV Min. 2.65 MPa {Min. 27 kg/cm2}
Defective transmission clutch When the troubleshooting in cause 3 is abnormal, the clutch seal is
4
seal assume to be defective; directly check it.
Internally defective transmis- The transmission clutch is assumed to be defective internally;
5
sion clutch directly check it.
a Move to a flat place, then start the engine for troubleshooting.
6 If the machine does not run by low idle + F2 operation, brake drag
(Drag)
occurs. (Carry out troubleshooting "H-8 Brake does not work.")
8 D275A-5R
H-6 Steering is not possible 1

Trouble • Steering is not possible.
Related • Before troubleshooting, check that the power train oil level is normal.
information • Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.)

a Prepare with starting the engine, then drive the engine in low
1 Defective operation of brake Raise machine with blade and ripper, drive it in F3 (or R3), and steer
it in direction in which machine cannot turn. If track shoe stops at
this time, brake is defective. (Carry out troubleshooting for "H-9
Brake does not work".)
PCCS lever Left stroke end Right stroke end
Possible causes Min. 2.45 MPa 0 MPa

Left clutch pressure
and standard {Min. 23 kg/cm2} {0 kg/cm2}
Defective operation of steer-
value in normal 2 0 MPa Min. 2.45 MPa
ing clutch valve (ECMV) Right clutch pressure
state {0 kg/cm2} {Min. 23 kg/cm2}
0 MPa Min. 2.45 MPa
Left brake pressure
{0 kg/cm2} {Min. 23 kg/cm2}
Min. 2.45 MPa 0 MPa
Right brake pressure
{Min. 23 kg/cm2} {0 kg/cm2}
Defective seal of steering When the cause 2 is not applicable, the clutch seal is supposed to
3
clutch be defective. Check it directly.
Internal defect of steering The inside of the steering clutch is supposed to be defective, check
4
clutch it directly.
Malfunction of steering
5 Carry out troubleshooting related to steering potentiometer.
potentiometer of travel lever
D275A-5R 9
H-7 Steering is possible only on one side 1

Trouble • Steering is possible only on one side.

1 Defective operation of brake Raise machine with blade and ripper, drive it in F3 (or R3), and steer
it in direction in which machine cannot turn. If track shoe stops at
this time, brake is defective. (Carry out troubleshooting for "H-9
Brake does not work".)
PCCS lever Left stroke end Right stroke end
Possible causes Min. 2.45 MPa 0 MPa

Left clutch pressure
and standard {Min. 23 kg/cm2} {0 kg/cm2}
value in normal 2 0 MPa Min. 2.45 MPa
ing clutch valve (ECMV) Right clutch pressure
state {0 kg/cm2} {Min. 23 kg/cm2}
0 MPa Min. 2.45 MPa
Left brake pressure
{0 kg/cm2} {Min. 23 kg/cm2}
Min. 2.45 MPa 0 MPa
Right brake pressure
{Min. 23 kg/cm2} {0 kg/cm2}
Defective seal of steering When the cause 1 is not applicable, the clutch seal is supposed to
3
clutch be defective. Check it directly.
Internal defect of steering The inside of the steering clutch is supposed to be defective, check
4
clutch it directly.
Malfunction of steering
5 Carry out troubleshooting related to steering potentiometer.
potentiometer of travel lever
10 D275A-5R
H-8 Steering overrun occurs 1

Trouble • Steering overrun occurs.

Possible causes
1 Defective operation of brake Lift the machine with the blade and the ripper and steer the wheel
and standard
value in normal for F3 travel (or R3 travel). If the track shoe stops, the brake is
state defective. (Execute the troubleshooting of “Brake does not work.”)
When the track shoe does not stop in the troubleshooting of the
2 cause 1, the steering clutch is defective. (Execute the troubleshoot-
ing clutch
ing of “Steering is not possible.”)
D275A-5R 11
H-9 Brake does not work 1

Trouble • Brake does not work.
Related • Confirm that the oil quantity on the power train is normal before troubleshooting.
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. 2.45 MPa
At release
{Min. 25 kg/cm2}
At pedaling 0 {0}
Possible causes
and standard Defective adjustment of If the troubleshooting in cause 1 is abnormal, the adjustment of the
2
value in normal brake pedal linkage brake pedal linkage is assumed to be abnormal; directly check it.
state If the troubleshooting in cause 1 is abnormal, the brake seal is
3 Defective brake seal
assumed 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.
a Start engine and carry out troubleshooting.
Lowering of brake perfor- Press brake pedal, set transmission in F2, and run engine at
5
mance high idle. If machine starts moving at this time, brake perfor-
mance has lowered.
12 D275A-5R
H-10 Overheat of power train oil temperature 1

Trouble • Overheat of power train oil temperature.
• Confirm that the value of the oil temperature of the power train matches the actual oil temperature
Related
before 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
1 Defective engine system engine output is assumed to be increased; see the Shop Manual:
Engine.
Defective power train pump a The power train pump is assumed to be defective or aired from
2
or air from suction circuit the suction circuit; directly check it.
3 PCCS lever
Possible causes converter torque converter delivery pressure
and standard 0.49 – 1.0 MPa 0.49 ± 0.1 MPa
Full neutral
value in normal {5 – 10 kg/cm2} {5 ± 1 kg/cm2}
state Defective transmission clutch The transmission clutch is assumed to be defective internally
4
function (Slip) (slipped); directly check it.
a Prepare with starting the engine for troubleshooting.
Defective brake function 1. Use the blades and ripper to float the machine from the ground.
5 2. Convert the drive position while low-idle.
(Drag)
3. If the track shoe does not rotate, brake drag occurs. (Carry out
troubleshooting "H-9 Brake does not work.")
a Prepare with starting the engine for troubleshooting.
6 Carry out F3 stall. If the machine does not stop completely, brake
(Slip)
slip occurs.
D275A-5R 13
H-11 All work equipment speeds are slow 1

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
1
unit of work equipment) defective; directly check it.
Defective work equipment The pump of the work equipment is assumed to be defective;
2
pump directly check it.
Defective unload valve func- Work equipment lever Unload pressure
3
tion
2.45 +1.37
+0 MPa
Full neutral
{25 +14
+0 kg/cm2}
Possible causes
and standard
Defective set pressure or idle mode for troubleshooting.
value in normal
state 4 defective function of main Work equipment lever Main relief pressure
relief valve 27.44 ± 1.37 MPa
Stroke end
{280 ± 14 kg/cm2}
Defective function of self- Original pressure of control
5 pressure reducing valve Work equipment lever
circuit
(PPC original pressure)
3.43 +0.49
–0.2 MPa
Full neutral
+5.0
{35 –2.0 kg/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.
14 D275A-5R
H-12 Work equipment does not move 1

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
1
unit of work equipment) defective; directly check it.
Defective work equipment The work equipment pump is assumed to be defective; directly
2
pump check it.
Defective unload valve func- Work equipment lever Unload pressure
3
tion
2.45 +1.37
+0 MPa
Full neutral
{25 +14
+0 kg/cm2}
Possible causes a Prepare with starting switch OFF, then drive the engine in high
and standard Defective set pressure or idle mode for troubleshooting.
value in normal 4 defective function of main Work equipment lever Main relief pressure
state relief valve 27.44 ± 1.37 MPa
Stroke end
{280 ± 14 kg/cm2}
Defective function of self- Original pressure of control
5 pressure reducing valve Work equipment lever
circuit
(PPC original pressure)
3.43 +0.49
–0.2 MPa
Full neutral
+5.0
{35 –2.0 kg/cm2}
Defective function of work
Check if PPC lock valve is operating normally by turning work
6 equipment lock lever and
equipment lock lever ON and OFF.
PPC lock valve
D275A-5R 15
H-13 Blade lift speed is slow or lacks power 1

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 "H-17 Excessive
hydraulic drift of blade lift."

Possible causes 1 Defective PPC valve function Blade lever PPC valve output pressure
and standard 3.14 – 3.92 MPa
value in normal Lift stroke end {32 – 40 kg/cm2}
state Defective function of blade The spool function of the blade lift operation valve is assumed to
2
lift operation valve (Spool) be defective; directly check it.
The blade lift cylinder is assumed to be aired; carry out the air
3 Aired blade lift cylinder
bleed and observe how the phenomenon changes.
16 D275A-5R
H-14 Blade tilt speed is slow or lacks power 1

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 "H-18 Excessive
hydraulic drift of blade tilt."

Possible causes 1 Defective PPC valve function Blade lever PPC valve output pressure
and standard 3.14 – 3.92 MPa
value in normal Lift stroke end {32 – 40 kg/cm2}
state Defective function of blade The spool function of the blade tilt operation valve is assumed to
2
tilt operation valve (Spool) be defective; directly check it.
The blade tilt cylinder is assumed to be aired; carry out the air
3 Aired blade tilt cylinder
D275A-5R 17
H-15 Ripper lift speed is slow or lacks power 1

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 "H-19 Excessive
hydraulic drift of ripper lift."

1 Defective PPC valve function Ripper lever PPC valve output pressure
3.14 – 3.92 MPa
Lift stroke end {32 – 40 kg/cm2}
Possible causes
and standard Defective function of ripper The spool function of the ripper lift operation valve is assumed to
value in normal 2
lift operation valve (Spool) be 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
a Replace the suction valve in the head with one at the bottom,
valve)
and observe how the phenomenon changes.
The ripper lift cylinder is assumed to be aired; carry out the air
4 Aired ripper lift cylinder
18 D275A-5R
H-16 Ripper tilt speed is slow or lacks power 1

Trouble • Ripper tilt 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 Defective PPC valve function Ripper lever PPC valve output pressure
3.14 – 3.92 MPa
Tilt stroke end {32 – 40 kg/cm2}
Possible causes
and standard Defective function of ripper The spool function of the ripper tilt operation valve is assumed to
value in normal 2
tilt operation valve (Spool) be 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
a Replace the suction valve in the head with one at the bottom,
valve)
and observe how the phenomenon changes.
The ripper tilt cylinder is assumed to be aired; carry out the air
4 Aired ripper tilt cylinder
D275A-5R 19
H-17 Excessive hydraulic drift of blade lift 1

Trouble • Excessive hydraulic drift of blade lift.
information • Confirm that no oil leaks the circuits in the work equipment before troubleshooting.

a Prepare with starting the engine, then stop the engine for trou-
bleshooting.
Follow the procedure below for troubleshooting. If the hydraulic
drift speed becomes high, the spool seal of the blade lift operation
Defective seal of blade lift valve is assumed to be defective.
1
Possible causes operation valve (Spool) 1. Prop up the machine using the blade lift, and lift the front of the
and standard machine.
value in normal 2. Stop the engine, and release the lock lever.
state 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;
2
cylinder directly check it.
Raise blade about 1,000 mm and check hydraulic drift of cutting
Defective fitting of quick drop
3 edge.
valve
• 300 mm/15 min
20 D275A-5R
H-18 Excessive hydraulic drift of blade tilt 1

Trouble • Excessive hydraulic drift of blade tilt.

bleshooting.
drift speed becomes high, the spool seal of the blade tilt operation
Defective seal of blade tilt valve 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
state 3. Set the blade lever to the right tilt side, and confirm how the
phenomenon changes.
Defective seal of blade tilt idle mode for troubleshooting.
2
cylinder Blade tilt cylinder Cylinder leak quantity
Right tilt stroke end 16 cc/min
D275A-5R 21
H-19 Excessive hydraulic drift of ripper lift 1

Trouble • Excessive hydraulic drift of ripper lift.
Related • Confirm whether the ripper is remodeled.

bleshooting.
drift speed becomes high, the spool seal of the ripper lift operation
Defective seal of ripper lift valve (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
state 3. Set the blade lever to the lift lowering side, and confirm how the
phenomenon changes.
Defective seal of ripper lift idle mode for troubleshooting.
2
cylinder Ripper lift cylinder Cylinder leak quantity
Lowering stroke end 16 cc/min
22 D275A-5R
H-20 Ripper pin puller cylinder does not work (Giant ripper attachment
machine) 1
Trouble • Ripper pin puller cylinder does not work.
Related
• Confirm that the main relief pressure for transmission is normal before troubleshooting.
information

Defective function of pin Measurement Pin puller working
Possible causes 1 Pin puller switch
puller solenoid position pressure
and standard
Push-in Cylinder bottom side Min. 2.45 MPa
value in normal
state Pull-in Cylinder head side {Min. 25 kg/cm2}
Internally defective pin puller The pin puller cylinder is assumed to be defective internally;
2
cylinder directly check it.
Defective fuse FS2-2 (20 A) Check fuse for breakage. If it is broken, circuit probably has short
3
for pin puller circuit. Check wiring harness of related circuit.
D275A-5R 23
H-21 Blade pitch does not work (Dual tilt attachment machine) 1
Trouble • Blade pitch does not work.
Related
information

Defective function of blade The spool of the blade pitch operation valve is assumed to be
1
pitch selection solenoid valve defective; directly check it.
Possible causes Defective function of blade The function of the blade pitch cylinder is assumed to be defective;
2
and standard pitch operation valve (Spool) directly check it.
value in normal Defective function of blade The function of the blade pitch selection solenoid valve is assumed
state 3
pitch cylinder to be defective; directly check it.
Carry out troubleshooting related to blade pitch switch.
Defective function of blade
4 Even if no failure codes are displayed, check that switch input
pitch switch
changes normally.
24 D275A-5R
H-22 Abnormal sound comes out from around work equipment pump 1
Trouble • Abnormal sound comes out 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;
2
and standard strainer directly check it.
value in normal Air is assumed to be inhaled in the suction circuit of the work
state 3 Air inhaled in suction circuit
machine pump; directly check the pipes.
Internally defective work The work equipment pump is assumed to be defective internally;
4
equipment pump directly check it.
D275A-5R 25
H-23 Fan speed is abnormal (Sound and/or vibration of fan are/is

abnormally large or engine overheats) 1
Trouble • Fan rotation is abnormal (Sound/Vibration of fan is abnormally large or engine overheats).
Related
• Before carrying out troubleshooting, check that oil level in hydraulic tank is normal.
information

a Start engine and carry out troubleshooting.
Measurement conditions Engine speed
Engine low idling 700 rpm
1 Defective engine rotation
Engine high idling 2,150 rpm
If engine speed is low, carry out troubleshooting for the engine
troubleshooting "S-5 Rotation is irregular".
Defective PTO (fan pump
2 Fan pump drive of PTO may be defective. Check it directly.
drive)
a Prepare with starting switch OFF, then run engine at high idle
Possible causes Fan pump EPC circuit basic
and standard Measurement conditions
pressure
value in normal
+0.49-
state 3.43 - 0.20 MPa
—
+5
{25 -2 kg/cm2}
Defect in fan pump or fan
3 and carry out troubleshooting.
motor
Measurement conditions Fan drive circuit pressure
17.17 – 20.60 MPa
Fan 100% mode
{175 – 210 kg/cm2}
Measurement conditions Defective fan
Fan 100% mode 1,250 – 1,350 rpm
4 Defective fan Fan may be broken or installed defectively. Check it directly.
26 D275A-5R
D275A-5R 27
D275A-5R Bulldozer
© 2007 KOMATSU
All Rights Reserved
28 D275A-5R
SEN02766-01
D275A-5R

D275A-5R 35001 and up
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart............................................................................................................ 3
S-1 Starting performance of engine is poor .................................................................................................... 6
S-2 Engine does not start ............................................................................................................................... 7
S-3 Engine does not pick up smoothly.......................................................................................................... 10
S-4 Engine stops during operation.................................................................................................................11
S-5 Engine does not rotate smoothly ............................................................................................................ 12
S-6 Engine lack output (or lacks power) ....................................................................................................... 13
S-7 Exhaust gas is black (incomplete combustion) ...................................................................................... 14
S-8 Oil consumption is excessive (or exhaust gas is blue) ........................................................................... 15
S-9 Oil becomes dirty quickly........................................................................................................................ 16
S-10 Fuel consumption is excessive............................................................................................................. 17
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................................... 18
S-12 Oil pressure drops ................................................................................................................................ 19
S-13 Oil level rises (Entry of coolant or fuel)................................................................................................. 20
S-14 Coolant temperature becomes too high (Overheating) ........................................................................ 21
S-15 Abnormal noise is made....................................................................................................................... 22
S-16 Vibration is excessive ........................................................................................................................... 23
D275A-5R 1
S-17 Air cannot be bled from fuel circuit ....................................................................................................... 24
2 D275A-5R
Method of using troubleshooting chart 1

The troubleshooting chart consists of the "ques-
Causes
tions", "check items", "causes", and "troubleshoot-
ing" blocks.
The questions and check items are used to pinpoint
high probability causes by simple inspection or
from phenomena without using troubleshooting
1 2 3 4
tools.
Next, troubleshooting tools or direct inspection are
applied to check the narrowed causes in order from
the most probable one to make final confirmation
according to the troubleshooting procedure.
[Questions] 1
Questions
Items to be drawn from the user or operator. 2
They correspond to A and B in the chart on the A
3
right. The items in A are basic ones. The
4
items in B can be drawn from the user or oper-
ator, depending on their level. 5
[Check items] B 6
Simple check items used by the serviceman to 7
narrow the causes. They correspond to C in C 8
the chart on the right.
Check items
9
[Causes]
10
Items to be narrowed from the questions and
check items. The serviceman narrows down 11
the probable causes from A, B, and C. Troubleshooting a
[Troubleshooting]
b
Items used to find out the true cause by verify-
ing the narrowed causes finally in order from c
the most probable one by applying trouble- d
shooting tools or direct inspection.
Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, and w.
E: Causes to be referred to for questions and check items
Q : Causes related to questions and check items
w : Causes highly probable among ones marked with Q
a When narrowing the "causes", apply the items marked with w before those marked with Q.
When narrowing the "causes", do not apply the items marked with E. (If no items have other marks and
the causes cannot be narrowed, however, you may apply them.)
D275A-5R 3
<Example of troubleshooting> Exhaust gas is black(Incomplete combustion)

Let us assume that a trouble of "Exhaust gas is black" occurred and we checked the [Questions] and
[Check items] and found the following 3 items to be the causal symptoms; "Exhaust gas slowly became
black", "Power slowly became weaker", and "Dust indicator is lighting red".
4 D275A-5R
There is a causal relationship between 3 items in the [Questions] and [Check items] sections and 6 items in
the [Causes] section.
The method of pinpointing the [Causes] from the causal relationship and approaching the [troubleshooting]
is explained according to Step 1 - Step 3 shown below.
D275A-5R 5
S-1 Starting performance of engine is poor 1

General causes why starting performance is poor Causes
Defective electrical system
Leaking or clogged fuel piping or entry of air

q
Clogged air breather hole of fuel tank cap

q Insufficient supply of fuel
Defective contact of valve and vale seat
Defective alternator (generator section)

Defective alternator (regulator section)
Insufficient intake of air
Stuck or seized supply pump plunger

q
Defective intake air heater system

q Improper selection of fuel
Defective or deteriorated battery

Clogged feed pump gauze filter
q Coolant in exhaust pipe
Clogged air cleaner element

a The common rail fuel injection system (CRI) recog-
Worn piston ring, cylinder

nizes the fuel injection timing electrically. Accordingly,
even if the starting operation is carried out, the engine
Clogged fuel filter
Defective injector
may not start until the crankshaft revolves 2 turns at
maximum. This phenomenon does not indicate a trou-
ble, however
Confirm recent repair history

Degree of use of
machine
Operated for long period E E E E
Became worse gradually Q w w Q Q

Starting performance
Engine starts easily when warm w w
Questions
Non-specified fuel is used Q Q Q Q

Filters have not been replaced according to Operation and Maintenance Manual w w w Q Q
Engine oil must be added more frequently w
When engine is preheated or when temperature is low, preheating monitor does not indi-
cate normally w
During operation, charge level monitor indicates abnormal charge w w

Dust indicator is red w
Air breather hole of fuel tank cap is clogged w
Fuel is leaking from fuel piping w Q
Priming pump is too light or too heavy to operate w Q Q
Starting motor cranks engine slowly w
When air bleeding plug of fuel filter is removed, fuel does not flow w w
While engine is rotated out
with starting motor
w
Check items
When spill hose from injector is disconnected, little fuel spills

Immediately after engine is started, temperature of exhaust manifold of a cylinder is low w
Engine does not pick up smoothly and combustion is irregular Q Q w
Engine hunts (rotation is irregular) Q w Q Q
Blow-by gas is excessive w
Inspect air cleaner directly q

Compression pressure is low q q
When air is bled from fuel system, air comes out q
Inspect fuel filter directly q
Troubleshooting
Inspect feed pump gauze filter directly q

Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indicated by
code q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
change q
When starting switch is turned to HEAT, intake air heater mount does not become warm q
Is voltage of 25 – 30 V generated between alternator terminals R and E Yes q
while engine is running at low idle? No q
Specific gravity of electrolyte and battery voltage are low q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
*1: Displayed failure codes: [CA559] and [CA2249]
6 D275A-5R
S-2 Engine does not start 1

a) Engine does not rotate Causes
General causes why engine does not rotate
Defective starting motor (safety relay section)

q Seized internal parts of engine
Defective connection of battery terminal
Defective starting motor (motor section)

o See "S-4 Engine stops during operation"
q Water hammer caused by coolant which entered cylinder

q Defective electrical system
Defective starting circuit wiring

q Trouble in power train
Broken flywheel ring gear

Defective battery relay
Defective power train

Questions
Degree of use of
Operated for long period E E
machine
When starting switch is Horn does not sound Q Q w
turned ON Horn volume is low w
Battery electrolyte level is low w
Battery terminal is loose w
When starting switch is turned ON, no operating sound comes out from battery relay Q w
When starting switch is turned to START, starting pinion does not move out Q Q w
Check items
Speed of rotation is low w

When starting switch is
turned to START, start- Makes grating noise w w
ing pinion moves out, Soon disengages again w
but
Makes rattling noise and does not turn Q Q w
Inspect flywheel ring gear directly q
Carry out troubleshooting on

Troubleshooting
There is not voltage (20 – 30 V) between battery relay terminals B q

and E
H-mode
E-mode
Turn starting switch When terminals B and C of starting switch are connected, engine
OFF, connect cables, q
starts
turn starting switch ON,
and carry out trouble- When terminals B and C at safety relay outlet are connected,
q
shooting engine starts
Even if terminals B and C at safety relay outlet are connected, q
engine does not start
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
—
D275A-5R 7
b) Engine rotates but no exhaust gas comes out Causes

General causes why engine rotates but no exhaust gas
Malfunction of overflow valve (Does not close)

comes out

Fuel is not supplied
Wrong connection of supply pump PCV

q
Seized or abnormally worn feed pump

q Supply of fuel is extremely small
Broken supply pump shaft or key

q Improper selection of fuel (particularly in winter)
Defective supply pump PCV

Clogged fuel filter element
Malfunction flow damper

Insufficient fuel in tank
Defective fuel injector

Use of improper fuel
Questions
Degree of use of
Operated for long period E E E
machine
Exhaust gas suddenly stopped coming out (when starting again) w Q w w w E E
Filters have not been replaced according to Operation and Maintenance Manual w w E Q
Fuel tank is empty w
There are rust and water in fuel drained from fuel tank Q Q Q Q Q
There is not fuel in removed fuel filter w w
Check items
Fuel is leaking from fuel piping w

When air bleeding plug of fuel filter is removed, fuel does Q Q w Q
While engine is not flow out
rotated with starting
motor When spill hose from injector is disconnected, little fuel Q w w w w Q
spills

Troubleshooting
Inspect feed pump directly q

Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indi-
cated by code q q q q
Carry out troubleshooting according to "PCV1 Short/Open Error (*2) or PCV2

q
Short/Open Error (*3)" indicated by code
Inspect overflow valve directly q
Engine can be started in reduced cylinder mode q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Remedy
Add
*1: Displayed failure codes [CA559] and [CA2249]

8 D275A-5R
c) Exhaust gas comes but engine does not start Causes
Defective coolant temperature sensor or wiring harness

(fuel is injected)
Worn dynamic valve system (Valve, rocker lever, etc.)

General causes why exhaust smoke comes out but engine
does not start
Leaking or clogged fuel system or entry of air

q Lack of rotating force due to defective electrical system


q Insufficient intake of air
Clogged injector or defective spray
Defective intake air heater system

Worn piston ring or cylinder liner

Use of improper fuel
Clogged fuel filter

Degree of use of machine Operated for long period E E E E
Suddenly failed to start w w Q
Questions
Non-specified fuel is used Q Q

Filters have not been replaced according to Operation and Maintenance Manual w w w
When engine is preheated or when temperature is low, preheating monitor does not indi-
cate normally w

There are rust and water in fuel drained from fuel tank w w
There is not fuel in removed fuel filter w
Starting motor rotates engine slowly w
When engine is rotated, abnormal sound comes out from around cylinder head w
Check items
When air bleeding plug of fuel filter is removed, fuel does not
While engine is rotated flow out Q w w
with starting motor,
When spill hose from injector is disconnected, little fuel spills w
Immediately after engine is started, temperature of exhaust manifold of a cylinder is low w

Inspect dynamic valve system directly q
Compression pressure is low q
Troubleshooting

code q
When injector unit is tested, spray condition is bad q

Coolant temperature gauge does not indicate normally q
When starting switch is turned to HEAT, intake air heater mount does not become warm q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Remedy
D275A-5R 9
S-3 Engine does not pick up smoothly 1

General causes why engine does not pick up smoothly Causes
Malfunction of flow damper (Large leakage from injector)

q
Seized turbocharger or interference of turbocharger

q Defective condition of fuel spray

q Control by controller in derate mode

Defective contact of valve and valve seat
(limiting injection rate (output) because of an error in elec-

trical system)
Clogged injector or defective spray


Improper valve clearance
Clogged fuel filter

Degree of use of
machine
Operated for long period E E E E E
Questions
Engine pick-up suddenly became worse w Q Q Q

Non-specified fuel is used w w w w
Filters have not been replaced according to Operation and Maintenance Manual w w w
Oil must be added more frequently w
Immediately after engine is started, temperature of exhaust manifold of a cylinder is low Q w
Blue under light load w
Exhaust gas color
Black w Q w w
Check items
When engine is rotated, interference sound comes out from around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is applied Q w w
Engine hunts (rotation is irregular) Q Q w Q
Blow-by gas is excessive w w

Inspect valve clearance directly q
Troubleshooting
Turbocharger is heavy to rotate with hand q

Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indicated by code q
change q q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
10 D275A-5R
S-4 Engine stops during operation 1

General causes why engine stops during opera- Causes
tion
Broken dynamic valve system (valve, rocker arm, etc.)
Broken auxiliary equipment (pump, compressor, etc.)

q Seized parts inside engine
Defective power supply wiring for engine controller

q Overheating
Broken or seized piston or connecting rod

q Trouble in power train

Broken or seized crankshaft bearing
Broken supply pump shaft or key

Defective starting switch wiring

Leaking or clogged fuel piping
Clogged fuel filter or strainer
Broken or seized feed pump

Broken or seized gear train
Trouble in power train

Degree of use of
machine Operated for long period E E
Made abnormal noise stopped suddenly w w w w Q w Q w w

w Q Q
Questions
Overheated and stopped

Engine
Stopped slowly w Q Q Q Q
Hunted and stopped w Q Q Q Q Q Q
Non-specified fuel is used Q Q Q Q
Filters have not been replaced according to Operation and
Maintenance Manual w w
Fuel level monitor indicates low level (if monitor is installed) w

There are metal particles in oil drained from oil pan w w w
Check items
Engine does not rotate at all w w

When engine is Engine rotates in opposite direction w
rotated with hand Engine moves by gear backlash w w
Supply pump shaft does not turn w
Engine rotates, but stops when load is applied to machine w

Carry out troubleshooting
Inspect piston and connecting rod directly q

Inspect crankshaft bearing directly q
on H-mode
Inspect gear train directly q

Troubleshooting

Inspect feed pump directly q
Carry out troubleshooting according to "Rail Press (Very) Low Error
(*1)" indicated by code q q
Engine rotates when pump auxiliary equipment (pump, compressor,

etc.) is removed q
Check power supply wiring for engine controller q

Check starting switch wiring q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
—
Add
D275A-5R 11
S-5 Engine does not rotate smoothly 1

General causes why engine does not rotate smoothly Causes
Air in fuel system
Malfunction of flow damper (Large leakage from injector)

q
q Defective speed sensor
Clogged injector or defective spray (dirt in injector)

(Error at degree that it is not indicated)
Defective Bkup speed sensor or wiring harness

Defective Ne speed sensor or wiring harness

Low setting of low idle speed
Clogged fuel filter

Degree of use of machine Operated for long period E E
Q Q Q
Questions
At a certain speed range

At low idle w Q Q Q Q Q Q Q
Engine hunts
Even when speed is raised Q Q Q
On slopes w Q Q
Filters have not been replaced according to Operation and Maintenance Manual w w
Check items
There are rust and water in fuel drained from fuel tank Q Q
Priming pump is too light or too heavy to operate w Q Q

Troubleshooting

Inspect fuel filter and strainer directly q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change q q
Carry out troubleshooting according to "Eng Ne Speed Sensor Error (*1)" indicated by code q
Carry out troubleshooting according to "Eng Bkup Speed Sensor Error (*2)" indicated by code q
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Clean
Remedy
Add
*1: Displayed failure code [CA689]

*2: Displayed failure code [CA778]
12 D275A-5R
S-6 Engine lack output (or lacks power) 1

General causes why engine lacks output Causes
Defective charge (boost) pressure sensor or wiring harness

q
Insufficient supply of fuel
Defective installation of charge (boost) pressure sensor

q
Defective spray condition of fuel
Air leakage from air intake piping or from aftercooler
Defective fuel temperature sensor or wiring harness

q
Clogged injector or defective spray (dirt in injector)

Defective drive of injector (signal or solenoid)

q Overheating

o See "S-14 Coolant temperature becomes

too high (Overheating)"

Leaking or clogged fuel piping
(limiting injection rate (output) because of an

error in electrical system)
Clogged fuel filter
(air leakage)
Degree of use of machine Operated for long period E E E E E
Suddenly Q Q Q Q
Questions
Power was lost

Gradually Q Q Q Q Q Q Q
Filters have not been replaced according to Operation and Maintenance
Manual w
Engine oil must be added more frequently Q Q Q
Output becomes insufficient after short stop of operation w
Black w w w
Exhaust gas is
Immediately after engine is started, temperature of exhaust manifold of a
cylinder is low w
When engine is rotated, interference sound comes out from around
turbocharger w
Check items
When engine is rotated, abnormal sound comes out from around cylinder
head w
High idle speed is too high Q
High idle speed under no load is normal, but speed suddenly drops when
load is applied w w Q
Engine does not pick up smoothly and combustion is irregular w Q Q w
Engine hunts (rotation is irregular) Q Q Q Q

Inspect air intake piping directly q
Boost pressure is low q q q
Troubleshooting

Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)"
indicated by code q
When a cylinder is cut out for reduced cylinder mode operation, engine
speed does not change q q
Inspect charge (boost) pressure sensor mount directly q
Carry out troubleshooting according to "Chg Air Press Sensor High (Low)
Error (*2)" indicated by code q
Carry out troubleshooting according to "Fuel Temp Sensor High (Low)
Error (*3)" indicated by code q
*1: Displayed failure code [CA559] and [CA2249]
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct

Adjust
Clean
Clean
Clean
Remedy
D275A-5R 13
S-7 Exhaust gas is black (incomplete combustion) 1

General causes why exhaust gas is black Causes
Leakage of air between turbocharger and cylinder head

q
q Excessive injection of fuel

q Defective condition of fuel injection
Clogged fuel spill piping (on cylinder head side)

Overheating

q
o See "S-14 Coolant temperature becomes too

high (Overheating)"
Improper fuel injection pressure

Improper fuel injection timing

Crushed or clogged muffler

(limiting injection rate (output) because of an error in
Clogged or seized injector

Abnormally worn injector

electrical syststem)

Suddenly became black w Q Q
w Q Q Q
Questions
Exhaust gas color Gradually became black

Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Muffler is crushed w
Air leaks between turbocharger and cylinder head or clamp is loosened w
Engine is operated in low-temperature mode at normal temperature Q Q Q
Immediately after engine is started, temperature of exhaust manifold of a cylinder is
low Q w
Check items
Torque converter stall speed or pump relief speed is high (Fuel is injected
excessively) Q Q
Exhaust noise is abnormal Q w Q
Engine does not pick up smoothly and combustion is irregular Q Q Q Q Q w
When spill hose from injector is disconnected, abnormally much fuel spills w

Troubleshooting
When muffler is removed, exhaust gas color improves q

code q q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
not change q
Inspect fuel spill piping (on cylinder head side) directly q
Carry out troubleshooting according to "Coolant Temp Sens High (Low) Error (*2)"
indicated by code q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Adjust
Clean
Remedy

14 D275A-5R
S-8 Oil consumption is excessive (or exhaust gas is blue) 1

General causes why oil consumption is excessive Causes
q Abnormal consumption of oil
Turbocharger
Worn or damaged valve (stem, guide, or seal)
Oil leakage from oil pan, cylinder head, etc.

q Long-time operation of engine at low idle or high idle
(Do not run engine at idle for more than 20 minutes
continuously)
Clogged breather or breather hose

Dust sucked in from intake system
q External leakage of oil

Worn seal at turbocharger end
Worn or damaged rear oil seal
Oil leakage from oil drain plug

q Wear of parts in lubrication system
Oil leakage from oil cooler
Oil leakage from oil piping

Worn seal at blower end
Oil leakage from oil filter

Broken piston ring
Broken oil cooler

E E E E
Questions
Degree of use of machine Operated for long period

Oil consumption suddenly increased w Q
Oil must be added more frequently w Q
Oil becomes dirty quickly Q Q w
Outside of engine is dirty with oil w w w w w
There are loose piping clamps in intake system w
Inside of turbocharger intake outlet pipe is dirty with oil w
Inside of turbocharger exhaust outlet pipe is dirty with oil Q w
Check items
There is oil in coolant w

Oil level in damper chamber is high w
Exhaust gas is blue under light load w w
Excessive Q Q Q w w
Amount of blow-by gas
None w
There is dust in intake manifold q

Inside of intake manifold is abnormally dirty q
Troubleshooting
Play of turbocharger shaft is excessive q q

Check breather and breather hose directly q
Inspect rear oil seal directly q
Leakage from oil cooler is detected by pressure test q q
Oil leaks out of engine q q q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
D275A-5R 15
S-9 Oil becomes dirty quickly 1

General causes why oil becomes dirty quickly Causes
q Entry of exhaust gas into oil due to internal wear
Clogged turbocharger lubrication drain tube

Defective seal at turbocharger turbine end
q Clogging of lubrication passage
q Use of improper fuel
Clogged breather or breather hose

q Use of improper oil

q Overload operation
Defective oil filter safety valve

Worn valve or valve guide
Exhaust gas color is bad

Clogged oil cooler
Clogged oil filter
Questions
Degree of use of machine Operated for long period E E E

Non-specified fuel is used Q
Even when engine oil temperature rises, oil filter clogging monitor indicates clogging w Q
There are metal particles in oil drained from oil filter Q Q
Inside of exhaust pipe is dirty with oil w
Engine oil temperature rises quickly w
Check items
Exhaust gas is
Black w
Comes out excessively Q Q w
Blow-by gas
Does not come out at all w
Play of turbocharger shaft is excessive q

Troubleshooting
See S-7
Inspect breather and breather hose directly q
Inspect oil cooler directly q
Inspect oil filter directly q
Spring of oil filter safety valve is hitched or broken q
Inspect turbocharger lubrication drain tube directly q
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Remedy
—
16 D275A-5R
S-10 Fuel consumption is excessive 1

General causes why fuel consumption is excessive Causes
Leakage of fuel

q
q Defective condition of fuel injection (fuel pressure or injection timing)
q Excessive injection of fuel
Fuel leakage from fuel filter, piping, etc.
Defective common rail pressure

Fuel leakage inside head cover
Defective supply pump plunger
Improper fuel injection timing

Defective feed pump oil seal
Defective spray by injector

Malfunction of injector
E E E
Questions

Is large compared to other machines of same model Q Q Q Q
Fuel consumption Gradually increased Q Q
Suddenly increased Q Q
There is external leakage of fuel from engine w
Combustion is irregular w
Engine oil level rises and oil smells of diesel fuel w w
Immediately after engine is started, temperature of exhaust manifold of a cylinder is low w w
Check items
Low idle speed is high Q

Torque converter stall speed or pump relief speed is high Q
Black Q Q Q Q
Exhaust gas is
White Q
Remove head cover and inspect inside directly q

Inspect feed pump oil seal directly q
Troubleshooting
Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indicated by code q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change q q
When spill hose from injector is disconnected, much fuel spills q
Carry out troubleshooting according to "Coolant Temp Sens High (Low) Error (*2)" indicated by
q
code
Confirm with real-time monitoring mode q q
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Remedy

D275A-5R 17
S-11 Oil is in coolant

(or coolant spurts back or coolant level goes down) 1
General causes why oil is in coolant Causes
q Internal leakage in lubrication system
Damaged cylinder liner O-ring or holes caused by pitting

q Internal leakage in cooling system
Broken hydraulic oil cooler or power train oil cooler

q Internal leakage in hydraulic oil cooler or power train oil cooler
Insufficient protrusion of cylinder liner

Broken cylinder head or head gasket
Broken oil cooler core or O-ring

Crack in cylinder block
E E
Questions

Suddenly increased Q Q Q
Oil level
Gradually increased Q Q
Hard water is used as coolant Q Q
Oil level has risen and oil is milky Q Q w
There are excessive air bubbles in radiator and coolant spurts back w w
Check items
Hydraulic oil or power train oil is milky w
When hydraulic oil or power train oil is drained, water flows out w

Leakage from cylinder head is detected by pressure test q
Troubleshooting
Inspect cylinder block and liner directly q q
H-mode
Inspect cylinder liner directly q
Leakage from oil cooler is detected by pressure test q

Replace
Replace
Replace
Replace
Replace
Remedy
—
18 D275A-5R
S-12 Oil pressure drops 1

General causes why oil pressure drops Causes
q Leakage from, clogging, or wear of lubrication system
Defective oil pressure sensor or wiring harness

Leaking, crushed, or clogged hydraulic piping
q Defective oil pressure control
q Selection of oil by the temperature etc. specified in the Opera-
tion and Maintenance Manual is not observed.
q Deterioration of oil due to overheating
Clogged or broken pipe in oil pan
Defective oil pump relief valve

Clogged strainer in oil pan
Worn journal of bearing
Coolant or fuel in oil

Lack of oil in oil pan
Defective oil pump
Clogged oil filter

E E E
Questions

Oil pressure monitor indicates low oil pressure Q w
Non-specified oil is used Q Q
Filters have not been replaced according to Operation and Maintenance Manual w
Indicates pressure drop at low idle w Q
Indicates pressure drop at low, high idle Q w w w Q
Oil pressure monitor
Indicates pressure drop on slopes w
Sometimes indicates pressure drop w Q
Oil level monitor indicates oil lever drop w w
Oil level in oil pan is low w
External hydraulic piping is leaking or crushed w
Check items
Oil is milky or smells of diesel oil w

There are metal particles in oil drained from oil pan w
There are metal particles in oil drained from oil filter w Q
There are metal particles in oil filter q

q q
Troubleshooting
Inspect oil pan strainer and pipe directly

See S-13
Oil pump is heavy to rotate or it has play q

Valve spring of oil pump relief valve is fatigued or damaged q
Inspect oil filter directly q
Carry out troubleshooting according to "Eng Oil Press Sensor High (Low) Error (*1)" indicated
q
by code
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Remedy
—
Add
*1: Displayed codes [CA135] and [CA141]
D275A-5R 19
S-13 Oil level rises (Entry of coolant or fuel) 1

General causes why oil level rises Causes
q Coolant in oil (milky)
Clogged water pump drain hole (breather hole) or defective seal
Defective seal of auxiliary equipment (pump and compressor)

q Fuel in oil (smells diluted diesel fuel)
a If oil is in coolant, carry out troubleshooting for "S-11 Oil is in

coolant"
Cracks inside cylinder head cover

Fuel leakage inside cylinder block
Broken oil cooler core or O-ring

Worn or damaged rear oil seal
Defective thermostat seat

Defects in supply pump
Questions

Fuel consumption has increased w w
Coolant must be added more frequently Q w
There is oil in coolant Q Q Q w
Oil smells of diesel fuel w w
Oil is milky Q w
When engine is started, water drops from muffler Q
When radiator cap is removed and engine is run at low idle, abnormally many bubbles come w Q
Check items
out or coolant spurts back

Exhaust gas is white Q Q
Water pump drain hole (breather hole) is clogged w
When water pump drain hole (breather hole) is cleaned, coolant flows out w
Oil level in damper chamber is low w
Oil level in hydraulic tank is low w

Remove and inspect head cover directly q
Inspect cylinder block and liner directly q q
Troubleshooting
Inspect rear oil seal directly q

Leakage from oil cooler is detected by pressure test q
Remove and inspect water pump directly q
Remove and inspect thermostat cover directly q
Remove and inspect supply pump directly q
Inspect seal of auxiliary equipment directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
20 D275A-5R
S-14 Coolant temperature becomes too high (Overheating) 1

General causes why coolant temperature becomes too Causes
high

q Lack of cooling air (deformation or damage of fan)
q Drop in heat dissipation efficiency
q Trouble in coolant circulation system
q Rise of oil temperature in power train
q Defect in fan drive pump or fan motor
Defective radiator cap (pressure valve)
Defective fan drive pump or fan motor

Defective coolant temperature gauge
Rise of power train oil temperature

Clogged or crushed radiator fins
Clogged or broken oil cooler
Deformed or damaged fan

Malfunction of thermostat
Clogged radiator core

Broken water pump
Low coolant level
Questions
Occurred suddenly Q w Q
Overheating
Has continued at low level Q w w Q
Rises quickly Q w
Coolant temperature gauge
Does not go down from red range w
Radiator coolant level monitor indicates low w
Engine oil level has risen and oil is milky w Q
Milky oil is floating on coolant w
There are many bubbles in radiator and coolant spurts back w
When light applied to radiator core, no light passes through w
Check items
Dirt and mud are accumulated in radiator shroud and undercover w w

Coolant is leaking because of cracks in hose or loose clamps w
Coolant flows out from radiator overflow hose w
Power train oil temperature enters red range faster than engine coolant
temperature (if oil temperature gauge and coolant temperature gauge are w w
installed)

Inspect cylinder liner directly q
Inspect oil cooler directly q

Temperature difference between upper and lower tanks of radiator is large q
Troubleshooting
on H-mode
on H-mode
Thermostat does not open at cracking temperature q

Temperature difference between upper and lower tanks of radiator is slight q
Inspect radiator core directly q
Cracking pressure of radiator cap is low q
Inspect fan directly q
Coolant temperature is normal q
Measured fan speed is low q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
—
—
Add
D275A-5R 21
S-15 Abnormal noise is made 1

General causes why abnormal noise is made Causes
q Abnormality due to defective parts
Leakage of air between turbocharger and cylinder head
Broken dynamic valve system (valve, rocker lever, etc.)

q Abnormal combustion
Interference of turbocharger or seized turbocharger
Defective inside of muffler (Removal of bulkhead)

q Air sucked in from intake system
a Judge if the noise is an internal noise or an external noise
Excessive wear of piston ring or cylinder liner

before starting troubleshooting.
a The engine is operated in the low-temperature mode while it
Removed or seized gear train bushing

is not warmed up sufficiently. Accordingly, the engine sound
becomes a little larger. This does not indicate abnormality,
however
Improper gear train backlash
Clogged or seized injector

a When the engine is accelerated, it is operated in the acceler-

ation mode and its sound becomes a little larger for up to
Deformed cooling fan
Dirt caught in injector

about 5 seconds. This does not indicate abnormality, how-
ever

Degree of use of machine Operated for long period E
Questions
Gradually increased Q Q
Abnormal noise
Suddenly increased Q Q Q
Non-specified fuel is used Q
There are metal particles in oil drained from oil filter w w
Air leaks between turbocharger and cylinder head w
When engine is rotated, abnormal sound comes out from around cylinder head w w
When engine is rotated, beat noise comes out from around muffler w
Check items
Immediately after engine is started, temperature of exhaust manifold of a cylinder is low w Q

Exhaust gas is
Black Q w Q
Engine does not pick up smoothly and combustion is irregular w
Abnormal noise is loud when engine is accelerated Q Q Q Q

When muffler is removed, abnormal noise disappears q
Troubleshooting

Inspect gear train directly q q
Inspect fan directly q
q q
change
Abnormal noise comes out only at start of engine q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Remedy
22 D275A-5R
S-16 Vibration is excessive 1

General causes why vibration is excessive Causes
q Defective parts (abnormal wear, breakage, etc.)
Stuck dynamic valve system (valve, rocker lever, etc.)

q Misalignment between engine and applicable machine
Loose engine mounting bolts or broken cushions

q Abnormal combustion
Worn main bearing or connecting rod bearing

a If abnormal noise is made and vibration is excessive, carry out trou-
bleshooting for "S-15 Abnormal noise is made", too
Misalignment of engine and power train

Worn front support spigot joint
Improper gear train backlash
Improper injection timing

Worn camshaft bushing
Broken parts in damper

E E E E
Questions

Suddenly increased Q Q
Vibration
Gradually increased Q Q Q Q
There are metal particles in oil drained from oil filter w w
There are metal particles in oil drained from oil pan w w
Oil pressure is low at low idle Q Q
Check items
Vibration occurs at medium speed Q Q

Vibration follows engine speed Q Q Q Q Q
Exhaust gas is black w

Inspect main bearing and connecting rod bearing directly q
Inspect gear train directly q
Troubleshooting
Inspect camshaft bushing directly q

Confirm with real-time monitoring mode q
Inspect engine mounting bolts and cushions directly q
Radial runout or facial runout is detected q
Inspect front support spigot joint directly q
Inspect inside of damper directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Adjust
Remedy
D275A-5R 23
S-17 Air cannot be bled from fuel circuit 1

(After filter is replaced or fuel is used up and then air is bled, engine does not start
or it starts but stalls.)
General causes why air cannot be bled Causes

q Electric priming pump does not operate.
Defective wiring harness of electric priming pump

Fuel is not supplied or is supplied very little.
Improper setting of air bleeding valve (Closed)

q
Fuel valve or air bleeding valve is not set properly.
Malfunction of electric priming pump switch

q
Leaking or clogged fuel piping or air in it

q Air bleeding piping is clogged.
Improper setting of fuel valve (Closed)

Fuel return piping is clogged.
Malfunction of electric priming pump

q
Clogged fuel tank cap breather hole
Clogged water separator screen

Clogged air bleeding piping
Low battery charge level

Clogged fuel filter
Low fuel level
Questions
Degree of use of
machine
Operated for long period EE
Fuel tank cap breather hole is clogged Q w
Switch lamp does not blink w w Q
Check items
When electric prim-

ing pump switch is Lamp blinks but pump operation sound is not heard w w
operated Pump operation sound is heard but fuel does not flow out of
hose soon Q Q w w w Q Q
Air bleeding valve is closed q

Fuel valve (supply side) is closed q
Fuel valve (return side) is closed q
Water drain valve and air intake plug of water separator are loosened q
Troubleshooting
Water drain valve of fuel prefilter is loosened q

There is flaw or dirt on sealing face of fuel prefilter or main filter q
Check air bleeding piping and orifice directly (See Note 1) q
Check fuel piping (supply side and return side) directly (for clogging and breakage) q
Check electric priming pump directly q
Check electric priming system directly (See E-30 in E-mode) q q
Check water separator screen directly q
Check fuel filter for clogging (Failure code CA559, Note 2) q
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Charge
Clean
Remedy
Add
24 D275A-5R
Note 1: Check of air bleeding piping for clogging
• Remove joint bolt (1) and blow clean compressed air into hole (b) of the orifice to check for clogging.
• Remove air bleeding piping (2) and blow compressed air against its both ends to check for clogging.
D275A-5R 25
D275A-5R Bulldozer
© 2008 KOMATSU
All Rights Reserved
26 D275A-5R
SEN03240-01
D275A-5R

D275A-5R 35001 and up
50 Disassembly and assembly1

General information on disassembly and
assembly
How to read this manual ................................................................................................................................. 2
Coating materials list....................................................................................................................................... 4
Special tool list ................................................................................................................................................ 7
Sketchs of special tools ................................................................................................................................ 15
D275A-5R 1
SEN03240-01 50 Disassembly and assembly
How to read this manual 1

1. Removal and installation of assemblies
Special tools Removal

q Special tools which are deemed neces- q The "Removal" section contains procedures
sary for removal or installation of parts are and precautions for implementing the work,
described as A1,•••X1 etc. and their part know how and the amount of oil or coolant to
names, part numbers and quantities are be drained.
described in the special tool list. q Various symbols used in the "Removal" section
q Also the following information is described are explained and listed below.
in the special tool list. k : Precautions related to safety in execution
1) Necessity of work.
t : Special tools that cannot be substi- a: This mark gives guidance or precautions when
tuted and should always be used doing the procedure.
(installed). [*1] : This mark shows that there are instructions or
q : Special tools that will be useful if avail- precautions for installing parts.
able and are substitutable with com- 6 : This mark shows the amount of oil or coolant
mercially available tools. to be drained.
2) Distinction of new and existing special 4 : Weight of part or component
tools
N: Tools newly developed for this
model. They respectively have a
Installation
new part number.
R: Tools with upgraded part numbers. q Except where otherwise instructed, installation
They are remodeled from already of parts is done in the reverse order of removal.
available tools for other models. q Instructions and precautions for installing parts
Blank: Tools already available for other are shown with [*1] mark in the "Removal" sec-
models. They can be used without tion, identifying which step the instructions are
any modification. intended for.
q Marks shown in the "Installation" section stand
3) Circle mark Q in sketch column:
for the following.
k : Precautions related to safety in execution
q The sketch of the special tool is pre-
sented in the section of "Sketches of
of work.
special tools".
a: This mark gives guidance or precautions when
q Part No. of special tools starting with
doing the procedure.
* *** **** 2 : Type of coating material
79 T- - :
3 : Tightening torque
means that they can not be supplied
from Komatsu in Japan (i.e. locally
5 : Quantity of oil or coolant to be added
made parts ).
a General tools that are necessary for Sketches of special tools

removal or installation are described as q Various special tools are illustrated for the con-
[1], [2]•••etc. and their part names, part venience of local manufacture.
numbers and quantities are not described.
2 D275A-5R
2. Disassembly and assembly of assem-

blies
Special tools Disassembly

q Special tools which are deemed neces- q In "Disassembly" section, the work procedures,
sary for disassembly and assembly of precautions and know-how for carrying out
parts are described as A1,•••X1 etc. and those procedures, and quantity of the oil and
their part names, part numbers and quan- coolant drained are described.
tities are described in the special tool list. q The meanings of the symbols used in "Disas-
q Also the following information is described sembly" section are as follows.
in the special tool list. k : Precautions related to safety in execution
1) Necessity of work.
t : Special tools that cannot be substituted a: This mark gives guidance or precautions when
and should always be used (installed). doing the procedure.
q : Special tools that will be useful if avail- 6: Quantity of oil or coolant drained
able and are substitutable with com-
mercially available tools.
2) Distinction of new and existing special
tools Assembly
N : Tools newly developed for this q In "Assembly" section, the work procedures,
model. They respectively have a precautions and know-how for carrying out
new part number. those procedures, and quantity of the oil and
R : Tools with upgraded part numbers. coolant added are described.
They are remodeled from already q The meanings of the symbols used in "Assem-
available tools for other models. bly" section are as follows.
Blank : Tools already available for other k : Precautions related to safety in execution
models. They can be used without of work
any modification. a: This mark gives guidance or precautions when
3) Circle mark Q in sketch column: doing the procedure.
q The sketch of the special tool is pre- 2 : Type of coating material
sented in the section of "Sketches of 3 : Tightening torque
special tools". 5 : Quantity of oil or coolant to be added
q Part No. of special tools starting with
* *** ****
79 T- - :
means that they can not be supplied
Sketches of special tools
q Various special tools are illustrated for the con-
from Komatsu in Japan (i.e. locally venience of local manufacture.
made parts ).
a General tools that are necessary for dis-

assembly and assembly are described
as [1], [2]•••etc. and their part names,
part numbers and quantities are not
described.
D275A-5R 3
Coating materials list 1

(Rev. 2007.06)
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate- Komatsu
Part number Q'ty Container Main features and applications
gory code
• Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
• Used for plastic (except polyethylene,
polypropylene, tetrafluoroethylene and vinyl
20 g Polyethylene
LT-1B 790-129-9050 chloride), rubber, metal, and non-metal parts
(2 pcs.) container
which require immediate and strong adhe-
sion.
Polyethylene • Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
790-129-9060
Adhesive: 1 kg • Used to stick and seal metal, glass, and plas-
LT-3 (Set of adhesive Can
Hardener: 500 g tics.
and hardener)
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs.
container
Holtz MH 705 790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.
• Quick-setting adhesive.
ThreeBond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics,
and woods.
• Quick-setting adhesive.
• Quick-setting type.
Aron-alpha Polyethylene
790-129-9130 2g (max. strength is obtained after 30 minutes)
201 container
• Used mainly to stick rubbers, plastics, and
metals.
• Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc • Used for fitted portions used at high tempera-
648-50 container
tures.
• Used to stick or seal gaskets and packings of
LG-1 790-129-9010 200 g Tube
power train case, etc.
• Used to seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nip-
ples of hydraulic piping.
• Features: Silicon-based heat and cold-resis-
Gasket sealant
tant sealant.
LG-6 790-129-9020 200 g Tube • Used to seal flange surfaces and threaded
portions.
• Used to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-setting sealant.
LG-7 790-129-9070 1 kg Tube • Used to seal flywheel housing, intake mani-
fold, oil pan, thermostat housing, etc.
• Features: Silicon-based, heat and cold-resis-
LG-8
tant, vibration-resistant, impact-resistant seal-
ThreeBond 419-15-18131 100 g Tube
ant.
1207B
• Used to seal transfer case, etc.
4 D275A-5R
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
• Used for rough surfaces such as the circle gear
LG-9 top seal which does not need to be clamped,
ThreeBond 790-129-9310 200 g Tube water resistance of the clearance at the welded
1206D area, etc.
• Can be coated with paint.
Gasket sealant
LG-10 • Used as lubricant/sealant when the radiator

ThreeBond 790-129-9320 200 g Tube hoses are inserted.
1206E • Can be coated with paint.
LG-11 • Feature: Can be used together with gaskets.
ThreeBond 790-129-9330 200 g Tube • Used for covers of the transmission case and
1121 steering case etc.
ThreeBond
790-129-9090 100 g Tube • Gasket sealant used to repair engine.
1211
Molybdenum
• Used to prevent scuffing and seizure of press-fit-

lubricant
disulfide
ted portions, shrink-fitted portions, and threaded

LM-P 09940-00040 200 g Tube
portions.
• Used to lubricate linkages, bearings, etc.
• Feature: Seizure and scuffing prevention com-

prevention
compound
pound with metallic super-fine-grain, etc.

Seizure
LC-G
— — Can • Used for the mounting bolt in the high tempera-
NEVER-SEEZ
ture area of the exhaust manifold and the turbo-
charger, etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI • Feature: Lithium grease with extreme pressure
SYG2-160LI
G0-LI Various Various lubrication performance.
SYGA-160CNLI
*: For cold district • General purpose type.
SYG0-400LI-A (*)
SYG0-160CNLI
(*)
• Used for parts under heavy load.
Caution:
Molybdenum SYG2-400M 400 g x 10 Bellows-type • Do not apply grease to rolling bearings like
disulfide grease SYG2-400M-A 400 g x 20 container swing circle bearings, etc. and spline.
LM-G (G2-M) SYGA-16CNM 16 kg Can • The grease should be applied to work equipment
pins at their assembly only, not applied for
greasing afterwards.
• Seizure resistance, heat resistance and water
Hyper White SYG2-400T-A
Grease
400 g Bellows-type resistance higher than molybdenum disulfide

Grease G2-T, SYG2-16CNT
container grease.
G0-T (*) SYG0-400T-A (*)
16 kg Can • Not conspicuous on machine since color is
*: For cold district SYG0-16CNT (*)
white.
Biogrease SYG2-400B
G2-B, G2-BT (*) SYGA-16CNB 400 g Bellows-type • Since this grease is decomposed by natural bac-
*: For use at high SYG2-400BT (*) container teria in short period, it has less effects on micro-
temperature and SYGA-16CNBT 16 kg Can organisms, animals, and plants.
under high load (*)
• Feature: Silicone grease with wide using tem-
G2-S perature range, high resistance to thermal-oxi-
ThreeBond — 200 g Tube dative degradation and performance to prevent
1855 deterioration of rubber and plastic parts.
• Used for oil seals of the transmission, etc.
• Feature: Urea (organic system) grease with heat
G2-U-S resistance and long life. Enclosed type.
427-12-11871 2 kg Can
ENS grease • Used for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
D275A-5R 5
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
SUNSTAR • Used as primer for cab side.
Glass
PAINT PRIMER 20 ml (Using limit: 4 months after date of manu-
container
580 SUPER facture)
SUNSTAR 417-926-3910
• Used as primer for glass side.
GLASS Glass
20 ml (Using limit: 4 months after date of manu-
PRIMER 580 container
facture)
Adhesive for cab glass

SUPER
• Used as primer for painted surface on cab
SUNSTAR
Glass side.
Primer
PAINT PRIMER 22M-54-27230 20 ml

container (Using limit: 4 months after date of manu-
435-95
facture)
• Used as primer for black ceramic-coated
SUNSTAR
surface on glass side and for hard polycar-
GLASS
22M-54-27240 150 ml Can bonate-coated surface.
PRIMER
(Using limit: 4 months after date of manu-
435-41
facture)
SUNSTAR • Used as primer for sash (Almite).
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months after date of manu-
container
GP-402 facture)
SUNSTAR • “S” is used for high-temperature season
PENGUINE and “W” for low-temperature season as
Polyethylene
SEAL 580 417-926-3910 320 ml adhesive for glass.
container
SUPER “S” or (Using limit: 4 months after date of manu-
“W” facture)
Adhesive
• Used as adhesive for glass.

Sika Japan, Polyethylene
20Y-54-39850 310 ml (Using limit: 6 months after date of manu-
Sikaflex 256HV container
Adhesive for cab glass
facture)
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manu-
SUPER 560 container) facture)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months after date of manu-
container
SEAL No. 2505 facture)
Caulking material
SEKISUI • Used to seal front window.

Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months after date of manu-
container
SEALANT facture)
• Used to seal joint of glasses.
GE TOSHIBA
Translucent white seal.
SILICONES 22M-54-27220 333 ml Cartridge
(Using limit: 12 months after date of manu-
TOSSEAL 381
facture)
6 D275A-5R
Special tool list 1

a Tools with number 79QT-QQQ-QQQQ cannot be supplied (they are items to be locally manufactured).
a Necessity : t ........... Cannot be substituted, should always be installed (used)
: q ........... Extremely useful if available, can be substituted with commercially available part.
a New/remodel : 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
a Tools marked Q in the Sketch column are tools introduced in special sketches (See Sketches of special
tools)
Necessity
New/remodel
Sketch
Qty
Component Symbol Part No. Part Name Nature of work, remarks
795-630-5500 Remover t 1
Removal of fuel supply pump
1 01010-81090 • Bolt 2
assembly
01643-31032 • Washer 2
795T-521-1111 Push tool t 1 R Q
Installation of Engine front
2 01050-31655 Bolt t 3
seal
01050-31635 Bolt t 3
3 795-931-1100 Seal puller t 1
795T-421-1270 Push tool t 1 Q
Installation of Engine rear seal
4 01050-31645 Bolt t 4
01643-31645 Washer t 8
795T-421-1240 Push tool t 1 Q
Installation of Engine rear seal
Engine assembly A 5 01050-31640 Bolt t 4
(Press fit of sleeve)
01643-31645 Washer t 4
6 790-331-1110 Wrench t 1 Tighten of cylinder head bolt
791-451-1000 Remover t 1
Puller
7 790-101-2102 t 1 Installation of radiator guard
(294kN {30ton})
790-101-1102 Pump t 1
795T-521-1150 Push tool t 1 Q Installation of Engine front
8
01050-31635 Bolt t 4 seal (Press fit of sleeve)
795T-421-1250 Push tool t 1 Q
9 01050-31645 Bolt t 4 Installation of Engine rear seal
01643-31645 Wrench t 8
791-612-1100 Installer t 1
Damper assembly B 790-101-4200 Puller (294kN {30ton}) t 1 Press fitting of bearing
790-101-1102 Hydraulic pump t 1

TORQFLOW trans-
D 799-301-1600 Oil leak tester t 1 Checking actuation of piston
mission assembly
791-622-1110 Bracket t 1
Removal, Installation of
Steering case 1 01010-62095 Bolt t 1
E Brake-carrier assembly
assembly 01016-61690 Bolt t 1
2 796-550-1301 Wrench t 1 Removal, Installation of lock nut
D275A-5R 7
Necessity
New/remodel
Sketch
Qty
790-337-1032 Lifting tool t 1

791-627-1320 Shackle t 2 Removal, Installation of final
1
791T-627-1810 Plate t 1 Q drive assembly
01010-82090 Bolt t 2
791-627-1400 Remover t 1
2 790-101-2102 Puller t 1 Pulling out sprocket bearing
790-101-1102 Pump t 1
791-627-1600 Remover t 1
Removal of planetary gear
3 790-101-2102 Puller t 1
shaft
790-101-1102 Pump t 1
Final drive assembly J
791-627-1200 Remover t 1
4 790-101-2102 Puller t 1 Removal of hub assembly
790-101-1102 Pump t 1
791-627-1300 Installer t 1
5 790-101-2102 Puller t 1 Press fitting of hub bearing
790-101-1102 Pump t 1
791-627-1500 Installer t 1
6 790-101-2102 Puller t 1 Press fitting of cover bearing
790-101-1102 Pump t 1
7 791-627-1280 Installer t 1 Installation of floating seal
791T-630-1310 Plate t 1 Q
791-630-1220 Rod t 4
790-101-2510 Block t 2
790-101-2570 Plate t 4
1 Press fitting of bushing
01643-31445 Washer t 4
Idler assembly 01580-01411 Nut t 4
790-101-2102 Puller (294kN {30ton}) t 1
790-101-1102 Pump t 1
3 791-630-1240 Push tool t 1 Press fitting of seal guide
L
4 791-601-1000 Oil pump t 1 Filling with oil
790-401-1761 Adapter t 1 Installation of No.1track roller
5
790-401-1540 Shackle t 2 assembly
790-401-1770 T-bolt t 2
Track roller assembly 6 791T-630-1320 Plate t 1 Q Press fitting of bushing
7 791T-630-1330 Push tool t 1 Q Installation of floating seal
8 791-651-1510 Installer t 1 Press fitting of seal guide
14 791T-630-1380 Bracket t 4 Q Secure bogie assembly
8 D275A-5R
Necessity
New/remodel
Sketch
Qty
10 790-102-1891 Nut wrench t 1 Removal, Installation of nut

Carrier roller assem- 11 791-675-1510 Installer t 1 Installation of floating seal
bly 12 791T-630-2410 Push tool t 1 Q Press fitting of seal guide
Track frame assembly 791T-630-1380 Bracket t 6 Q Secure bogie assembly
14
791T-630-1380 Bracket t 2 Q Secure bogie assembly
791-630-1360 Spacer t 1
790-101-2310 Block t 1
790-101-2360 Plate t 2
15 790-445-4130 Screw t 2 Removal of shaft, ring
791-112-1180 Nut t 2
790-101-4000 Puller (490kN {50ton}) t 1
790-101-1102 Pump t 1
790-201-2760 Spacer t 1
791-630-1370 Adapter t 1
790-434-1060 Screw t 2
16 01580-13024 Nut t 2 Removal of shaft, ring
01643-33080 Washer t 1
No. 2, 3, 4 Bogie 790-101-4000 Puller (490kN {50ton}) t 1
assembly
790-101-1102 Pump t 1
L
Check the airtight of the float-
18 790-701-3000 Seal checker t 1
ing seal
Adjustment procedure for car-
19 791T-630-1390 Guide t 1 Q
tridge pin hole
790-101-2310 Block t 1
790-445-4130 Screw t 2
796T-470-1130 Plate t 1 Q
Press fitting of cartridge pin
20 790-101-2360 Plate t 2
assembly
791-112-1180 Nut t 2
790-101-4000 Puller (490kN {50ton}) t 1
790-101-1102 Pump t 1
790-101-2310 Block t 1
790-445-4130 Screw t 2
796T-470-1130 Plate t 1 Q
Press fitting of cartridge pin
20 790-101-2360 Plate t 2
Bogie assembly assembly
791-112-1180 Nut t 2
790-101-4000 Puller (490kN {50ton}) t 1
790-101-1102 Pump t 1
D275A-5R 9
Necessity
New/remodel
Sketch
Qty
14 791T-630-1380 Bracket t 2 Q Secure bogie assembly

790-401-1700 Lifting tool t 1 Removal, Installation of track
22
No.1 Bogie assembly L 790-401-1761 Adapter t 1 roller assembly
791-630-1860 Bracket t 1
23 Pull up of No.1Bogie assembly
791-630-1870 Bracket t 1
791-730-1110 Bolt t 6
Disassembly of Idler yoke, re-
1 01580-12722 Nut t 6
coil cylinder
01643-32780 Washer t 6
Recoil spring assem- 791-685-8502 Compressor t 1
M
bly 790-201-2780 Spacer t 1
Disassembly, assembly of Re-
3 791-635-3160 Extension t 1
coil spring assembly
790-101-1600 Cylinder (686kN {70ton}) t 1
790-101-1102 Pump t 1
791T-650-1930 Spacer t 1 Q
792-900-1520 Plate t 1
791-520-4140 Screw t 1
Equalizer bar assem- 790-101-2470 Adapter t 1
1 Removal of center pin
bly 790-101-2540 Washer t 1
791-112-1180 Nut t 1
N
790-101-2102 Puller (294kN {30ton}) t 1
791-650-1800 Remover t 1
Removal, Installation of spher-
Equalizer bar bushing 2 790-101-2102 Puller (294kN {30ton}) t 1
ical bushing
Removal, Installation of pivot
1 790-401-1700 Lifting tool t 1
shaft assembly
Pivot shaft assembly P 791-650-1700 Installer t 1
2 790-101-4200 Puller (294kN {30ton}) t 1 Press fitting of seal
10 D275A-5R
Necessity
New/remodel
Sketch
Qty
1 791-646-7531 Plug remover t 1 Removal of pin plug

2 791-660-7460 Pin brush t 1 Cleaning of pin hole
3 791-646-7900 Push tool t 1 Press fitting of pin plug
4 791-932-1110 Push tool t 1 Press fitting of pin plug
790-701-3000 Seal checker t 1
5 Supply oil
791-601-1000 Pump t 1
6 791-632-1070 Installer t 1 Installation of seal assembly
791-680-9802 Remover & installer t 1
791-680-1520 Guide t 1
7 790-101-4200 Puller (294kN {30ton}) t 1 Disassembly of a link
790-101-4300 Cylinder (1470kN {150ton}) t 1
790-101-1102 Pump t 1
791-632-1500 Push tool assembly t 1
791-632-1420 • Adapter 1
791-632-1430 • Ring 1
791-632-1440 • Plate 1
791-632-1450 • Ring 1
8 791-632-1460 • Push tool 1
Track shoe assembly R
791-632-1470 • Adapter 1
791-632-1480 • Spring 1
791-685-5730 • Bar 1
01252-30650 • Bolt 1
01580-01210 • Nut 1
791-632-1400 Push tool assembly t 1
Assembly of a link
791-632-1410 • Adapter 1
791-632-1430 • Ring 1
791-632-1440 • Plate 1
791-632-1450 • Ring 1
9 791-632-1460 • Push tool 1
791-632-1470 • Adapter 1
791-632-1480 • Spring 1
791-685-5730 • Bar 1
01252-30650 • Bolt 1
01580-01210 • Nut 1
791-632-1490 Push tool t 1
10
791-685-5740 Push tool t 1
D275A-5R 11
Necessity
New/remodel
Sketch
Qty
790-434-1110 Adapter t 1
790-434-1610 Guide t 1
11
195-32-61210 Bolt t 1
01010-51440 Bolt t 2
790-101-4300 Cylinder (1470kN {150ton}) t 1
12
790-101-1102 Pump t 1
791-685-9510 Frame t 1
791-685-9520 Frame t 1
791-685-9530 Rod t 1
791-685-9550 Nut t 1
791-685-9560 Bolt t 4
13
791-632-1140 Adapter t 1
01010-51030 Bolt t 1
04530-12030 Eyebolt t 1
790-101-4300 Cylinder (1470kN {150ton}) t 1
790-101-1102 Pump t 1
791-685-9540 Rod t 1
14
Track shoe assembly R 791-685-9550 Nut t 1 Disassembly of a single link
791-685-9510 Frame t 1
791-685-9520 Frame t 1
791-685-9530 Rod t 1
791-685-9550 Nut t 2
791-685-9560 Bolt t 4
791-126-0150 Adapter t 1
791-680-5520 Guide t 1
15
791-126-0140 Pusher t 1
791-632-1140 Adapter t 1
01010-51030 Bolt t 1
04530-12030 Eyebolt t 1
791-685-9620 Extension t 1
790-101-4300 Cylinder (1470kN {150ton}) t 1
790101-1102 Pump t 1
791-680-1630 Spacer t 1
16 790-101-4200 Puller (294kN {30ton}) t 1
790-101-1102 Pump t 1
12 D275A-5R
Necessity
New/remodel
Sketch
Qty
791-680-5543 Adapter (for pin) t 1

791-680-9630 Adapter (for bush) t 1
17
790-101-4300 Cylinder (1470kN {150ton}) t 1
790-101-1102 Pump t 1
18 790-434-1130 Guide t 1
791-685-9510 Frame t 1
791-685-9520 Frame t 1
791-685-9530 Rod t 1
791-685-9540 Rod t 1
791-685-9550 Nut t 3
791-685-9560 Bolt t 4
19 791-126-0150 Adapter t 1
01010-51030 Bolt t 1
791-685-9620 Extension t 1
791-680-5543 Adapter t 1
791-680-5551 Guide t 1
790-101-4300 Cylinder (1470kN {150ton}) t 1
Track shoe assembly R 790-101-1102 Pump t 1 Assembly of a single link
791-685-9510 Frame t 1
791-685-9520 Frame t 1
791-685-9530 Rod t 1
791-685-9540 Rod t 1
791-685-9550 Nut t 3
791-685-9560 Bolt t 4
791-126-0150 Adapter t 1
20
01010-51030 Bolt t 1
791-685-9620 Extension t 1
791-680-5551 Guide t 1
790-434-1140 Adapter t 1
791-680-9630 Adapter t 1
790-101-4300 Cylinder (1470kN {150ton}) t 1
790-101-1102 Pump t 1
790-101-4200 Puller (294kN {30ton}) t 1
21
790-101-1102 Pump t 1
22 790-434-1160 Guide t 1
D275A-5R 13
Necessity
New/remodel
Sketch
Qty
791-685-9510 Frame t 1
791-685-9520 Frame t 1
791-685-9530 Rod t 1
791-685-9540 Rod t 3
791-685-9550 Nut t 4
791-685-9560 Bolt t 1
Track shoe assembly R 23 791-126-0150 Adapter t 1 Assembly of a single link
790-434-1151 Guide t 1
791-632-1140 Adapter t 1
01010-51030 Bolt t 1
790-434-1160 Guide t 1
790-101-4300 Cylinder (1470kN {150ton}) t 1
790-101-1102 Pump t 1
790-502-1003 Cylinder repair stand t 1 Disassembly, assembly of hy-
1
790-101-1102 Pump t 1 draulic cylinder
790-102-2303 Wrench t 1 Removal and assembly of
2
790-102-3802 Wrench t 1 round head
790-102-4300 Wrench t 1 Removal and assembly of
3
790-102-4310 Pin t 2 round head
790-201-1702 Push tool kit t 1
790-101-5021 • Clip 1 For press fitting coil bushing
01010-50816 • Bolt 1
4
790-201-1831 • Push tool 1 (Blade lift)
790-201-1851 • Push tool 1 (Blade tilt, ripper lift)
790-201-1841 • Push tool 1 (Ripper tilt)
Hydraulic cylinder as-
U 790-201-1500 Push tool kit t 1
sembly
790-101-5021 • Clip 1 For press fitting dust seal
01010-50816 • Bolt 1
5
790-201-1640 • Plate 1 (Blade lift)
790-201-1650 • Plate 1 (Blade tilt)
790-201-1660 • Plate 1 (Ripper lift, ripper tilt)
6 790-720-1000 Expander t 1 Expansion of piston ring
796-720-1670 Ring t 1 (Blade lift)
07281-01279 Clamp t 1 (Blade lift)
796-720-1690 Ring t 1 (Blade tilt, ripper lift)
7
07281-01919 Clamp t 1 (Blade tilt, ripper lift)
796-720-1680 Ring t 1 (Blade tilt)
07281-01589 Clamp t 1 (Blade tilt)
Operator’s cab glass
X1 793-498-1210 Lifter (Suction cup) t 2 Installation of window glass
(stuck glass)
14 D275A-5R
Sketchs of special tools 1

Note: We will not be liable for any result caused by a special tool made according to this drawing.
A2 Push tool
A4 Push tool
D275A-5R 15
A5 Push tool
A8 Push tool
16 D275A-5R
A9 Push tool
D275A-5R 17
J1 Plate
L1 Plate
18 D275A-5R
L6 Plate
L7 Push tool
D275A-5R 19
L12 Push tool
L14 Bracket
20 D275A-5R
L19 Guide
L20 Plate
D275A-5R 21
N1 Spacer
22 D275A-5R
D275A-5R 23
D275A-5R Bulldozer
© 2008 KOMATSU
All Rights Reserved
24 D275A-5R
SEN03241-01
D275A-5R

D275A-5R 35001 and up

Engine and cooling system
Removal and installation of fuel supply pump assembly ................................................................................ 2
Removal and installation of fuel injector assembly ......................................................................................... 7
Removal and installation of cylinder head assembly .................................................................................... 12
Removal and installation of engine front seal ............................................................................................... 23
Removal and installation of engine rear seal ................................................................................................ 27
Removal and installation of engine assembly ............................................................................................... 31
Removal and installation of radiator assembly
(including hydraulic oil cooler assembly and aftercooler assembly) ......................................................... 36
Removal and installation of hydraulic oil cooler assembly ............................................................................ 39
Removal and installation of aftercooler assembly......................................................................................... 41
Removal and installation of radiator guard assembly ................................................................................... 44
Removal and installation of fuel tank assembly ............................................................................................ 49
Removal and installation of engine hood assembly ...................................................................................... 51
Removal and installation of fan drive assembly ............................................................................................ 53
Removal and installation of fan motor assembly .......................................................................................... 55
D275A-5R 1
Removal and installation of fuel 3. Release the residual pressure in the fuel sys-
supply pump assembly 1 tem. For details, see Testing and adjusting,
"Releasing residual pressure in fuel system".
Special tools
4. Open the left side cover (2).
New/Remodel
Sym- 5. Remove left lower side cover (3).
Necessity
Part No. Part name
bol
Sketch
Q'ty
795-630-5500 Standard puller t 1
A1 01010-81080 Bolt t 2
01643-31032 Washer t 2
Removal
k Lower the work equipment to the ground and
stop the engine.
k Set the parking brake lever and work equip-
ment lock lever in the lock position.
k Disconnect the cable from the negative (–)
terminal of the battery. 6. Disconnect fuel hose (4).
1. Close the fuel valve. 7. Remove fuel prefilter (5) and fuel main filter
(6).
2. Remove undercover (1).
8. Disconnect connectors PCV1 (7), PCV2 (8)

and G (9).
9. Remove oil level gauge (10).
2 D275A-5R
10. Remove fuel tubes (11) and (12). [*1] 14. Remove stay (20) and clamp (21).
15. Remove 2 covers (22), 2 covers (23) and 2

high-pressure pipes (24). [*4]
11. Remove fuel tubes (13) and (14). [*2]
16. Remove engine front cover (25).
12. Remove lubrication tube (15) and fuel tubes

(16) and (17). [*3]
17. Rotate the crankshaft forward to set intermedi-

ate point (a) between the stamps of 2/5 TOP
and 3/4 TOP on damper (26) to pointer (27).
a Crank the crankshaft at hexagonal part (b)
of water pump drive shaft tip.
a Check that the forcing tap of the drive gear
is aligned with upper mounting bolt hole
(c) of cover (25) removed in the previous
step.
a If not, rotate the crankshaft 1 more turn.
13. Remove clamp (18) and gate-type frame (19).
D275A-5R 3
18. Remove mounting nut (28). [*5]

a Take care not to drop the mounting nut
into the gear case.
19. Remove mounting bolts (30) of fuel supply

pump assembly (29) and bracket (31).
a Keep bolts (30) tightened by 2 – 3 turns to
prevent the pump from falling.
20. Set tool A1 and tighten bolt B to remove gear

(32) from the shaft (33).
21. Remove remaining mounting bolts (30) and

fuel supply pump assembly (29).
a If tool A1 is removed, the gear falls.
Accordingly, keep tool A1 installed until
the pump is installed.
4 D275A-5R
Installation 1. Set fuel supply pump assembly (29).

k When handing the high-pressure piping a Before setting, check that key (d) of shaft
and clamp, pay attention to the following. aligns to the key slot (e) of drive gear.
q It is strictly prohibited to bend the high-
pressure piping to use it again or using it 2. Temporarily tighten four mounting bolts (30)
in other locations. and bracket (31) with fingers.
q Install the specified clamp securely in the 2 Mounting bolt:
specified position with the specified Liquid adhesive (LT-2)
torque.
q Don't apply lubricant and the like to the
high-pressure piping sleeve nut and the
threaded portion of the mating side.
a Axial force in the tightening can be
excessive, potentially damaging the
high-pressure piping.
k Before installing the high-pressure piping,
check it for the following defects. If there is
any of these defects, it can cause fuel leak-
age. Accordingly, replace the high-pressure
piping.
q Check the taper seal of the connecting
part (Part (a): Part of 2 mm from the end)
for visible lengthwise slit (b) and dent (c).
q Check part (d) (end of the taper seal: Part
at 2 mm from the end) for stepped-type
wear (fatigue) which your nail can feel.
D275A-5R 5
3. Temporarily tighten high pressure pipes (24) [*3]

with fingers and tighten permanently with the 3 Tube (15) cylinder block side joint bolt:
following torque. 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
3 Common rail side sleeve nut: 3 Tube (15) supply pump side joint bolt:
39.2 – 58.8 Nm {4 – 6 kgm} 7.9 – 12.7 Nm {0.8 – 1.3 kgm}
Supply pump side sleeve nut: 3 Tube (16) and (17) joint bolt (supply pump
39.2 – 49 Nm {4 – 5 kgm} side): 14.8 – 19.6 Nm {1.5 – 2.0 kgm}
4. Tighten permanently four mounting bolts (30). [*4]

a Install covers (22) and (23) with the notch in
5. Tighten bracket (31) permanently. the following direction.
3 Mounting bolt: q Cover (23): Cylinder block side
19.6 – 29.4 Nm {2.0 – 3.0 kgm} q Cover (22): Underside
6. Temporarily tighten clamps (18), (21) and (34), [*5]

and stays (19), (35) and (20), with fingers. 3 Nut (28): 176 – 196 Nm {18 – 20 kgm}
7. Tighten clamps (18), (21) and (34) perma- q Bleeding air

nently. Bleed air from the fuel system. For details, see
a Tighten clamps in the order of (18), (21) Testing and adjusting, "Bleeding air from fuel
and (34). system".
3 Clamping bolt:
9.8 ± 1 Nm {1 ± 0.1 kgm}
8. Tighten gate type frame (19), stays (35) and

(20) permanently.
a Tighten gate type frame and stays in the
order of (19), (35) and (20).
9. Carry out the subsequent procedure in the

reverse order of removal.
[*1]
3 Fuel tube joint bolt:
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
(Filter head side)
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
(Supply pump side)
[*2]
3 Fuel tube joint bolt:
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
3 Fuel tube sleeve nut (priming pump side):
43 – 47 Nm {4.4 – 4.8 kgm}
6 D275A-5R
Removal and installation of fuel

injector assembly 1
Removal
k Disconnect the cable from the negative (-)
terminal of the battery.
1. Remove the engine hood. For details, see

"Removal and installation of engine hood
assembly".
2. Remove the corrosion resistor assembly, fuel

filter assembly, prefilter assembly and oil filter
assembly according to the following proce- 3. Remove high-pressure pipe clamp (12)
dure. between the common rail and supply pump
1) Corrosion resistor and then remove stay (13).
1] Disconnect 2 corrosion resistor inlet/
outlet tubes (1). [*1] 4. Remove common rail cover (14).
2] Remove corrosion resistor bracket
assembly (2).
2) Fuel filter
1] Remove oil level gauge guide clamp
(3).
2] Loosen the upper joint bolt (on the air
vent assembly side) of fuel air bleed-
ing tube (4), remove the lower joint
bolt, and disconnect fuel air bleeding
t u be ( 4) f r o m f ue l fi l te r b r ac k e t
assembly (5). [*2]
3] Disconnect 2 fuel filter inlet/outlet
tubes (6). [*3]
4] Remove fuel filter bracket assembly a The following is the removal procedure for the
(5). No. 1 fuel injector assembly.
3) Prefilter
1] Remove prefilter inlet hose (7) and 5. Remove stay (15).
outlet tube (8). [*4] a If bracket (16) is removed, you can work
2] Remove prefilter bracket assembly easily.
(9).
4) Oil filter
1] Remove tube assembly (10) between
the oil filter and cylinder block. [*5]
2] Remove oil filter bracket assembly
(11).
a When removing the No. 1 fuel injector assem-

bly, you do not need to remove the prefilter
assembly.
a When removing one other than the No. 1 fuel
injector assembly, you do not need to remove
the corrosion resistor assembly and fuel filter
assembly.
D275A-5R 7
6. Remove clamp (17). 11. Rotate crankshaft forward, align damper

"1.6TOP" stamp line (c) to pointer (P), and then
7. Remove cover (18). [*7] set the No.1 cylinder to the compression top
dead center.
8. Loosen sleeve nut (19). a Crank the crankshaft at hexagonal part (d)
9. Remove stays (20) – (23).
12. Remove cover (25). [*7]
13. Remove mounting bolts (26) through (28), and

remove rocker arm and rocker shaft assembly
(29). [*8]
a Loosen lock nut (31), and loosen adjust-
ment screw (32) two or three turns to pre-
vent excessive force applied to push rod
(30), when installing rocker arm and
rocker shaft assembly.
10. Remove cylinder head cover (24). [*6]
8 D275A-5R
14. Loosen sleeve nut (33), and remove high pres- Installation
sure pipe (34) from injector. 1. Install fuel injector assembly.
1) Check that no foreign material stays inside
15. Remove wiring harness clamping bolt (35) and injector sleeve.
clip (36). [*9] 2) Install O-rings (41) and (42), and gasket
(43) to injector.
16. Remove two wiring harness capture nuts (37) a Take care not to install O-ring to
from fuel injector assembly. [*10] groove (b).
a Tighten nuts alternately.
17. Remove holder mounting bolt (38).
3) Set fuel injector assembly (39) with holder

(40) to cylinder head.
4) Attach spherical washer (44) to bolt (38),
18. Set L type bar [1] under fuel injector assembly and tighten temporarily bolt (38).
inlet connector (a), and remove slowly fuel 2 Spherical washer: Engine oil
injector assembly (39) with holder (40) using 5) Tighten temporarily high pressure pipe
leverage action. sleeve nuts (33) and (19).
a Do not pull out solenoid valve portion at k Install high pressure pipe after
the top of injector by pinching with pliers, checking the followings. If an
etc. abnormality takes place, it may
cause fuel leakage, and replace
high pressure pipe.
q Check visually taper seal portion (a
portion: within 2 mm from the tip) at
the joint section for visible vertical slit
scar (b) or patchy dent (c).
q Check the difference at (d) portion (tip
of taper seal portion: within 2 mm
from the tip) for any catches on a fin-
ger nail (no fatigue).
D275A-5R 9
6) Tighten bolts (38) to the specified torque. 9) Tighten high pressure pipe clamp, stay
3 Bolt (38): (22) and clamping bolts (50) through (54),
58.8 – 73.5 Nm {6 – 7.5 kgm} permanently.
7) Tighten sleeve nuts (33) and (19). 3 Clamping bolt:
3 Sleeve nuts (33) and (19): 9.8 ± 1 Nm {1 ± 0.1 kgm}
39.2 – 49 Nm {4 – 5 kgm} 10) Tighten permanently stay mounting bolt.
2. Install high pressure pipe clamp and stay. 3. Install the subsequent procedure in the reverse
1) Temporarily tighten high pressure pipe order of removal.
clamp, stay (23), clamping bolts (45)
through (49), and stay mounting bolt, with [*1]
fingers. 3 Corrosion resistor tube joint bolt:
2) Tighten permanently high pressure pipe 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
clamping bolt.
3 Clamping bolt: [*2]
9.8 ± 1 Nm {1 ± 0.1 kgm} 3 Fuel air bleeding tube joint bolt (Upper and
3) Tighten permanently stay mounting bolt. lower): 7.8 – 9.8 Nm {0.8 – 1.0 kgm}
4) Temporarily tighten high pressure pipe
clamp, stay (22), clamping bolts (50) [*3]
through (54), and stay mounting bolt, with 3 Fuel filter tube joint bolt (Inlet and outlet):
fingers. 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
5) Boot (18).
a Install with the notch toward cylinder [*4]
block side. 3 Prefilter inlet hose sleeve nut (7):
6) Install high pressure pipe clamp (17) and 84 – 132 Nm {8.5 – 13.5 kgm}
gate type frame (14) temporarily. Prefilter outlet tube sleeve nut (8):
7) Tighten clamping bolt for high pressure (Bracket side)
pipe clamp (17) permanently. 84 – 132 Nm {8.5 – 13.5 kgm}
3 Clamping bolt: (Tube side)
9.8 ± 1 Nm {1 ± 0.1 kgm} 43 – 47 Nm {4.4 – 4.7 kgm}
8) Gate type frame (14) permanently.
10 D275A-5R
[*5] a Adjust valve clearance referring to the section

Installation procedure for oil filter tube of Testing and adjusting, "Adjusting valve
1. Install tubes (55) and (56) temporarily to clearance".
bracket (58) with clip (57).
2. Install flange (59) and tubes (55) and (56) tem-
porarily.
3. Install the oil filter end of tubes (55) and (56) in
the hole of the oil filter bracket and tighten
bolts (60) temporarily.
4. Install flange (59) to the cylinder block tempo-
rarily with bolts (61).
5. Tighten bolts (60) on the oil filter side perma-
nently.
6. Tighten bolts (61) of flange (59) permanently.
[*9] [*10]
a Install wiring harness according to the follow-
ing procedure.
1) Install clip (36).
2) Tighten two capture nuts (37).
a Tighten capture nuts alternately.
3 Capture nut:
2 ± 0.2 Nm {0.2 ± 0.02 kgm}
3) Tighten wiring harness clamping bolt (35).
[*6]
29.4 – 34.3 Nm {3.0 – 3.5 kgm}
[*7]
a Install the covers with their notches in the fol-
lowing directions.
q Cover (18): Toward cylinder block side
q Cover (25): Down
[*8]
a When installing rocker arm and rocker shaft
assembly (29), check the ball portion of adjust-
ment screw (32) to be inserted securely into
socket of push rod (30), and tighten mounting
bolts.
a As 3 mounting bolts are different each other,
install them referring to the followings.
q Mounting bolt (26): Stem length 120mm
q Mounting bolt (27): Stem length 90 mm
q Mounting bolt (28): Stem length 75.2 mm
3 Mounting bolts (26), (27) and (28):
93 – 103 Nm {9.5 – 10.5 kgm}
D275A-5R 11
Removal and installation of

cylinder head assembly 1
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
A 6 790-331-1110 Wrench q 1
Removal
k Disconnect the cable from the negative (-)
3. Disconnect or remove the hoses according to
1) Remove solenoid valve cover (12).
2) Remove clips (13), (14) and (14a) and fuel
"Removal and installation of engine hood assem-
return tube (15). [*6]
bly".
3) Remove clamps (16) and (17) and then
remove fuel tube (18) between the fuel fil-
2. Remove the corrosion resistor assembly, fuel
ter and supply pump. [*7]
filter assembly, prefilter assembly and oil filter
assembly according to the following proce-
dure.
1) Corrosion resistor
1] Disconnect 2 corrosion resistor inlet/
outlet tubes (1). [*1]
2] Remove corrosion resistor bracket
assembly (2).
2) Fuel filter
1] Remove oil level gauge guide clamp
(3).
2] Loosen the upper joint bolt (on the air
vent assembly side) of fuel air bleed-
ing tube (4), remove the lower joint
bolt, and disconnect fuel air bleeding
t u be ( 4) f r o m f ue l fi l te r b r ac k e t
assembly (5). [*2]
3] Disconnect 2 fuel filter inlet/outlet
tubes (6). [*3]
4] Remove fuel filter bracket assembly
(5).
3) Prefilter
1] Remove prefilter inlet hose (7) and
outlet tube (8). [*4]
2] Remove prefilter bracket assembly
(9).
4) Oil filter
1] Remove tube assembly (10) between
the oil filter and cylinder block. [*5]
2] Remove oil filter bracket assembly
(11).
12 D275A-5R
4. Disconnect wiring clips (19) and (20) and 8. Remove breather tube (40).
remove heater wiring connector RHT (21).
9. Remove aftercooler outlet hose (41) and air
5. Remove wiring clips (22) - (34) and move the intake connector (42) together. [*8]
wiring aside.
10. Remove water tube (corrosion resistor outlet/

inlet tube) (43).
11. Remove venturi connector (44).
12. Remove housing (45).
6. Remove stay (35), air vent assembly (36) and

bracket (37) together.
7. Remove brackets (38) and (39).
13. Disconnect fuel hose (46).
D275A-5R 13
14. Remove clamp (47). 18. Remove 2 wiring harness clamps (54), upper
and lower, at the rear of the air intake manifold.
15. Remove mounting bolts of bracket (48) and
move bracket (48) breather (49) together.
19. Remove charge pressure sensor (55), plate

(56) and bracket (57) together.
16. Disconnect connectors TFUEL (50), TIM (51) a These parts must be removed to secure a
and PIM (52). space for loosening the turbocharger lubri-
cation tube clamp.
17. Remove spill tube (53). [*9]

20. Remove 5 stays (58) of the high-pressure pipe
clamps. [*10]
14 D275A-5R
21. Remove high-pressure pipe clamp stays (59), 2) Remove bracket (66).
(60), (61), (62) and (63). [*11]
3) Remove 4 muffler mounting bolts (67) and

22. Remove air intake manifold (64). [*12] lift off muffler (68).
4 Air intake manifold: 50 kg 4 Muffler: 55 kg
23. Remove the muffler according to the following 24. Remove the turbocharger assembly according
procedure. to the following procedure.
1) Remove heat insulation plate (65). 1) Remove air connector (69). [*13]
2) Remove heat insulation plates (70), (71)
and (72).
3) Remove bracket (73).
4) Remove muffler drain tube (74).
5) Remove water tube (75).
6) Remove the turbocharger-end mounting
bolt of oil tube (76).
D275A-5R 15
7) Remove bracket (77). 25. Disconnect connectors CN1 (79), CN2 (80),
CN3 (81), CN4 (82), CN5 (83) and CN6 (84),
and move wiring harnesses (85) and (86).
a To disconnect the connector, push in the
(X) direction with a flat-head screwdriver
[1] placed at the stepped portion (a) while
pressing stopper (b).
8) Remove oil tube (78). [*14]
9) Remove water tube (79).
10) Sling turbocharger and exhaust manifold

assembly (80).
11) Remove 24 mounting bolts (81) and lift off 26. Remove gate type frame (87) and clamp (88).
tu r bo ch ar g er a nd e x ha us t m an if ol d [*16]
assembly (80). [*15]
4 Turbocharger and exhaust manifold 27. Remove spill tube (89). [*17]
assembly: 80 kg
28. Remove cover (90) and high pressure pipe
(91) depending on the cylinder head assembly
to be removed. [*18]
16 D275A-5R
29. Remove water tube (92). [*19] 33. Remove fuel injector assembly.
1) Remove wiring harness clamping bolt
30. Remove cylinder head cover (93). [*20] (102) and clip (103). [*22]
2) Remove two wiring harness capture nuts
(104) from fuel injector assembly. [*23]
a Loosen nuts alternately.
3) Unscrew bolt (105) to remove holder
(106).
4) Push connecter (107) into rocker housing,
and remove injector wiring harness (108).
[*24]
a O-ring is installed in connector (107).
31. Rotate crankshaft forward, align damper

"1.6TOP" stamp line (c) to pointer (P), and then
set the No.1 cylinder to the compression top
dead center.
a Crank the crankshaft at hexagonal part (d)
5) Remove mounting bolt (110) of holder.

[*25]
6) Set L type bar [2] under fuel injector
assembly inlet connector (e), and remove
slowly fuel injector assembly (111) with
holder using leverage action. [*26]
a Do not grip the solenoid valve at the
top of the injector to pull off the injec-
tor.
32. Remove three mounting bolts (95) through

(97), and remove rocker arm and rocker shaft
assembly (98).
a Loosen lock nut (100), and loosen adjust-
ment screw (101) two or three turns to
prevent excessive force applied to push
rod (99), when installing rocker arm and
rocker shaft assembly. [*21]
D275A-5R 17
34. Remove two push rods (99). Installation

1. Install cylinder head assembly.
1) Install cylinder head gasket (118).
a Check that the mounting surface of
cylinder head and the inside of cylin-
ders are free from foreign material.
a Check that the gasket is free from
peeling or coming off of grommet.
35. Remove crosshead (113).
36. Remove three mounting bolts (114), three bolts

(115) and auxiliary bolt (116), and remove cyl-
inder head assembly (117).
2) Check cylinder head mounting bolts for

the following items, and if out of standard,
replace mounting bolt without reusing it.
q Bolt tightening should be 5 times or
less.
(The number of punch mark at the
head of bolt should be 5 or less.)
q Bolt under head length service limit
(a)
Short bolt: Less than 170.8 mm
Long bolt: Less than 205.8mm
18 D275A-5R
3) Install cylinder head assembly.

4) Tighten three mounting bolts (114), three
bolts (115) in order of 1 through 6 as shown
in the figure.
2 Mounting bolt:
Lubricant with molybdenum dis-
ulfide (LM-P)
3 Mounting bolt
1st time:
137 – 157 Nm {14 – 16 kgm}
2nd time:
284 – 294 Nm {29.0 – 30.0 kgm}
3rd time: Retighten 90° (+30°/0) with
tool A4. 2. After installing cross head (113), make adjust-
a When tool A4 is not available, put ment as follows.
marks (a) and (b) to bolt and cylinder 1) Loosen lock nut (100), and loosen adjust-
head, and retighten bolt 90° (+30°/0). ment screw (101).
5) Tighten auxiliary bolt (116) (tightening 2) Lightly push cross head (113) contact sur-
order: 7th) with the following torque. face (h) with rocker arm, and hold cross
3 Auxiliary bolt: head to contact with push rod (99) side
66.6 ± 7.4 Nm {6.8 ± 0.8 kgm} valve stem (119).
3) Screw slowly adjustment screw (101), and
check the position where adjustment
screw touches valve stem (120).
4) From the above condition, screw adjust-
ment screw (101) 20°.
5) While holding adjustment screw (101) with
a flat-head screwdriver, tighten locknut
(100).
3 Locknut:
58.7 ± 5.9 Nm {6.0 ± 0.6 kgm}
D275A-5R 19
3. Install push rod (99).

a Raise push rod slightly, and check that
push rod is securely inserted in cam fol-
lower.
[*7]
3 Supply pump-end joint bolt of fuel tube
between fuel filter and supply pump:
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
4. Carry out the rest of installation in the reverse
order of removal. [*8], [*13]
[*1] a Replace the MIKALOR clamps of 4 aftercooler
3 Corrosion resistor tube joint bolt outlet hoses (41) and 8 air connector (69) with
24.5 – 34.3 Nm {2.5 – 3.5 kgm} new ones.
a Install each MIKALOR clamp according to the
[*2] following procedure.
3 Fuel air bleeding tube joint bolt (Upper and 1) Set the hose to its original position.
lower): 7.8 – 9.8 Nm {0.8 – 1.0 kgm} 2) Set the bridge (BR) under the bolt (BC)
and reduce lapping area (b) over the band
[*3] (BD) to a minimum of 5 mm.
3 Fuel filter tube joint bolt (Inlet and outlet): 3) Tighten bolt (BC).
24.5 – 34.3 Nm {2.5 – 3.5 kgm} 2 Threaded part of bolt: Lubricating
oil (THREEBOND, PANDO 18B)
[*4] a Do not use an impact wrench.
3 Prefilter inlet hose sleeve nut (7): a When reusing the hose, install it to
84 – 132 Nm {8.5 – 13.5 kgm} the clamp mark on it.
Prefilter outlet tube sleeve nut (8): 3 Bolt (BC):
(Bracket side) 25 ± 5 Nm {2.55 ± 0.5 kgm}
84 – 132 Nm {8.5 – 13.5 kgm} a When using a new hose, tighten until
(Tube side) dimension BDG is as follows.
43 – 47 Nm {4.4 – 4.7 kgm} q Aftercooler outlet hose (41):
+0
23 –3 mm
+0
[*5] q Air connector (69): 10 –3 mm
Installation procedure for oil filter tube
Install the oil filter tube according to [*5] in
"Removal and installation of fuel injector assem-
bly".
[*6]
3 Fuel return tube joint bolts
Upper joint bolt (15a):
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
Lower joint bolt (15b):
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
20 D275A-5R
[*9] order and then tighten other bolts (4)

3 Joint bolt (53a): – (24) temporarily in the numeric
9.8 – 12.7 Nm {1.0 – 1.3 kgm} order. Then, tighten all bolts (1) – (24)
3 Joint bolt (53b): to the specified torque in the numeric
19.8 – 29.4 Nm {2.0 – 3.0 kgm} order.
2 Mounting bolt: Seizure pre-
vention compound (LC-G)
(NEVER-SEEZ (Bofik, Inc.) or
equivalent)
3 Mounting bolt:
59 – 74 Nm {6 – 7.5 kgm}
[*10] [*11] [*16] [*19]

a Install high pressure pipe, clamp, stay and gate
type frame referring to the section, "Removal
and installation of fuel injector assembly".
[*12]
a Tighten intake manifold mounting bolts in the [*17]
numerical order shown below. 3 Spill tube joint bolt:
3 Mounting bolt: 58.8 – 73.5 Nm {6 – 7.5 kgm} 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
[*18]
a Install cover with the notch downward.
[*19]
3 Water tube joint bolt:
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
[*20]
29.4 – 34.3 Nm {3.0 – 3.5 kgm}
[*14]
3 Oil tube cylinder block side joint bolt:
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
[*15]
Exhaust manifold and turbocharger assembly
1) Apply heat-resistant sealant to the fitting
parts (S) of the exhaust manifold (between
ports No. 2 and No. 3 and between ports
No. 4 and No. 5)
3 Fitting parts: Heat-resistant seal-
ant (HOLTS MH705)
2) Fit the gasket and sling and install exhaust
manifold (1).
3) Tighten the mounting bolts in the following
order.
a Tighten the 3 bolts of (1) – (3) shown
below temporarily in the numeric
D275A-5R 21
[*21]
a When installing rocker arm and rocker shaft
assembly (98), check the ball portion of adjust-
ment screw (101) to be inserted securely into
socket of push rod (99), and tighten mounting
bolts.
a As three mounting bolts are different each
other, install them referring the followings.
q Mounting bolt (97): Stem length 75.2 mm
3 Mounting bolt:
93 – 103 Nm {9.5 – 10.5 kgm}
a Adjust valve clearance referring to the section
of Testing and adjusting, "Adjusting valve
clearance".
[*22] [*23] [*24]

a Install injector wiring harness according to the
1) Install O-ring to injector wiring harness (108).
2) Install injector wiring harness (108) in rocker
housing, install holder (106) and tighten bolt
(105).
3) Install clip (103).
4) Tighten two capture nuts (104).
a Tighten capture nuts alternately.
3 Capture nut: 2 ± 0.2 Nm {0.2 ± 0.02 kgm}
5) Install wiring harness clamping bolt (102).
[*25] [*26]
a Install the fuel injector assembly referring to
the section, "Removal and installation of fuel
injector assembly".
22 D275A-5R
Removal and installation of a Take care in the removal not to damage

front seal (3) installation position on front
engine front seal 1 cover (4) and the seal contact face on
crankshaft (5).
Special tools
a Before removing, slightly drive the front seal
New/Remodel
in once to free it from fixation.
a When front seal (3) is fixed too hard to the
Necessity
Sym
Part No. Part name
front cover (4), carry out the following pro-
Sketch
bol
cedure.
Q'ty
1) Drill through a hole of approx. 3 mm dia.
795T-521-1111 Push tool t 1 R Q on front seal (3).
2 01050-31655 Bolt t 3 2) Replace the tip of tool A3 with the drill
01050-31635 Bolt t 3 type one.
A 3) Insert the top end of tool A3 into the
3 795-931-1100 Seal puller t 1 drilled hole, and remove the front seal
795T-521-1150 Push tool t 1 Q by the impact of slide hammer (SH).
8 (Apply the slide hammer evenly not to
01050-31635 Bolt t 4
tilt the front seal.)
a Remove the metal powders completely.
Removal
a When the sleeve is attached, cut sleeve (6)
1. Remove the radiator guard assembly. For
using a gad and hammer to remove it.
details, see Removal of radiator guard assembly.
a Take care not to damage crankshaft (5).
2. Sling damper pulley (1) temporarily and remove
the mounting bolts.
3. Lift off damper pulley (1).
• Tool A3
4. Remove front seal (3).
D275A-5R 23
Installation 1. Procedure for installing standard seal

a Check the seal by checking the wear of the a Before installing the seal, check that the
shaft and replace it with the "standard seal" or end corners and lip sliding surfaces of the
"sleeved seal". crankshaft are free from flaw, burr, and rust
If the shaft is worn to the degree of luster (If of the front cover.
wear which you feel with your finger is less than a When installing the seal, do not apply oil or
10 mmm) and does not have any flaw, install grease to the shaft and seal lip. Wipe off
"standard seal A". In other cases, install the oil from the shaft.
"sleeved seal B". a Never remove installation guide (7) of the
a (7): Plastic inside cylinder which is also used as replacement seal before installing the seal.
installation guide. 1) Set large inside diameter side (b) of instal-
a (6): Sleeve. lation guide (7) to the end of crankshaft (5).
a Do not remove installation guide (7) from front a Take care not to mistake the direction of
seal (3) before installing the front seal. the plastic inside cylinder.
a Handle front seal (3) and sleeve (6) as an
assembly and never separate them from each
other.
Standard spare seal Sleeved seal
24 D275A-5R
2) Tighten tool A2 until the bolts (55 mm) reach 2. Procedure for installing sleeved seal
the end. a When installing the front seal, do not apply
3) Remove tool A2 and installation guide (7). oil or grease to the shaft, inside cylinder
a When removing the inside cylinder, take surface of sleeve (6) and seal lip.
care not to damage the seal lip. 1) Set sleeve and front seal assembly (8) to
tool A8 (for fitting the sleeved seal).
2 Sleeve inside cylinder surface (6):
4) Tighten tool A2 with the bolts (35 mm) again

to press fit seal (3) until the end of tool A2
reaches the end of crankshaft (5).
a Seal driving distance (a) from crank-
2) Set the sleeve of the front seal assembly
shaft: 9.1 – 10.1 mm
(8) to the end of crankshaft (5) and tighten
a When press fitting the seal, take care
the 3 bolts evenly to press fit sleeve and
not to damage the lip of the seal with
rear seal assembly (8) until the end of tool
the tool set etc.
A8 (for press fitting the sleeved seal)
a After press fitting the seal, remove the
reaches the end of crankshaft (5).
red sealant layer from its periphery.
D275A-5R 25
3) Remove tool A8 (for press fitting the

sleeved seal) and install tool A2 (for press
fitting the seal).
4) Tighten the 3 bolts (35 mm) evenly to press
fit sleeve and front seal assembly (8) until
the end of tool A2 reaches the end of crank-
shaft (5)
a Seal driving distance (a) from crank-
shaft: 9.1 – 10.1 mm
the tool set etc.
3. Install damper pulley (1).

a Match the taper pin of the damper pulley
and tighten the 6 mounting bolts.
3 Mounting bolts:
245 – 309 Nm {25 – 31.5 kgm}
26 D275A-5R
Removal and installation of 5. Remove rear seal (2) according to the following
procedure.
engine rear seal 1 1) Before pulling out rear seal (2), drive in it a
little to separate it from the housing.
Special tools
New/Remodel
Necessity
Sym
Part No. Part name
Sketch
bol
Q'ty
3 795-931-1100 Seal puller t 1
795T-421-1270 Push tool t 1 Q
4 01050-31645 Bolt t 4
01643-31645 Washer t 8
795T-421-1240 Push tool t 1 Q
A
5 01050-31645 Bolt t 4
01643-31645 Washer t 4 2) If the seal is sleeved, cut and remove
sleeve (5) with a chisel and a hammer.
795T-421-1250 Push tool t 1 Q a When cutting, take care extremely not
9 01050-31645 Bolt t 4 to damage crankshaft (4).
01643-31645 Wrench t 8 3) Hitch the end of tool A3 to the metal ring of
rear seal (2) and pull out the seal with
impacts of slide hammer (SH).
Removal
a Do not use a drill etc. since chips may
1. Remove the damper assembly and hub assem-
enter the engine.
bly. For details, see "Removal of damper
a If chips were made, remove all of them.
assembly".
• Tool A3
2. Remove 1 mounting bolt of flywheel (1) and
install guide bolt [1].
3. Using eyebolt [1] (12 mm, P = 1.75), sling fly-

wheel (1) temporarily and remove the 8 mount-
ing bolts.
4. Move flywheel (1) toward this side and lift it off.

k Since the socket part of the flywheel is
shallow, it may fall suddenly. Take care
not to catch your fingers in the flywheel.
3 Flywheel: 65 kg
a Left: Standard seal, Right: Sleeved seal
D275A-5R 27
Installation 1. Procedure for installing standard seal

a Check the seal by checking the wear of the a When installing rear seal (2), do not apply
shaft and replace it with the "standard seal" or oil or grease to the shaft and seal lip.
"sleeved seal". 1) Set large inside diameter side (b) of instal-
If the shaft is worn to the degree of luster (If lation guide (3) of rear seal (2) to the end of
wear which you feel with your finger is less than crankshaft (4).
10 µm) and does not have any flaw, install stan- a Take care not to mistake the direction of
dard seal (A). In other cases, install sleeved the plastic inside cylinder.
seal (B).
a (3):Plastic inside cylinder which is also used
as installation guide.
a (5):Sleeve.
a Do not remove installation guide (3) from
rear seal (2) before installing the rear seal.
a Handle rear seal (2) and sleeve (5) as an
assembly and never separate them from
each other.
• Standard spare sealq • Sleeved seal
2) Hold the metal ring of rear oil seal (2) with

both hands and push it in evenly.
3) After pushing in the seal, remove installa-
tion guide (3).
a When removing the inside cylinder, take
care not to damage the seal lip.
a Clean, degrease, and dry the seal surface

on the flywheel housing side.
a Clean, degrease, and dry the seal lip sur-
face (periphery of the crankshaft).
a Before installing the seal, check that the
end corners and lip sliding surfaces of the
crankshaft are free from flaw, burr, and rust
of the housing.
28 D275A-5R
4) Tighten the 4 bolts evenly to press fit rear 2) Set sleeve of the rear seal to the end of
seal (2) until the end of tool A4 (for press fit- crankshaft (4) and tighten the 4 bolts of tool
ting the seal) reaches the end of crankshaft A5 evenly to press fit sleeve and rear seal
(4). assembly (6).
a Tighten tool A4 (for press fitting the a Tighten tool A5 (for press fitting the
seal) first without inserting any washer sleeved seal) with 1 washer inserted in
until the bolts reach the end and then each bolt until the bolts reach the end.
tighten with 2 washers inserted (in each
bolt).
the tool set etc.
3) Remove tool A5 (for press fitting the

sleeved seal) and install tool A9 (for press
fitting the seal).
4) Tighten the 4 bolts evenly to press fit sleeve
and rear seal assembly (6) until the end of
tool A9 (for press fitting the seal) reaches
the end of crankshaft (4).
2. Procedure for installing sleeved seal a Tighten the bolt of tool A9 (for press fit-
a When installing the rear seal, do not apply ting the seal) without washer until it
oil or grease to the shaft and sleeve inside reaches, and then tighten the bolt using
cylinder surface (C). 2 washers (for each bolt).
1) Set sleeve and rear seal assembly (6) to a After press fitting the seal, remove the
tool A5 (for fitting the sleeved seal). red sealant layer from its periphery.
2 Sleeve inside cylinder surface (C): a Seal driving depth from the end of
crankshaft:13.2 ± 0.2 mm
D275A-5R 29
3. Flywheel a After tightening, make 1 punch mark (9) on

Using eyebolt [1] (12 mm, P = 1.75), sling fly- each bolt head to indicate the number of tight-
wheel (1), install it to the crankshaft, and tighten ening time.
the bolts.
a When installing, set the dowel pin of the
crankshaft to the dowel hole of the flywheel.
a If there are 5 punch marks on a bolt, do not
use that bolt but replace it.
2 Threads and seat of bolt:
Engine oil SAE No. 30
4 Flywheel: 65 kg
a After installing the flywheel, measure the facial

runout and radial runout with dial gauge [1].
a Radial runout: Max. 0.13 mm
a Facial runout: Max. 0.20 mm
a Tighten the mounting bolts according to the fol-

lowing procedure.
3 Flywheel mounting bolts
1st time: 118 ± 4.9 Nm {12 ± 0.5 kgm}
2nd time: 1) When using tool A2 (See the tools
list)
Retighten each bolt by 90° +30° +0 in
the order of [1] – [8].
2) When not using tool A2
Make marks on each bolt and fly- • Carry out the following installation in the re-
wheel with paint, then retighten verse order to removal.
each bolt by 90° +30°
+0 in the order of
[1] – [8].
30 D275A-5R
Removal and installation of 5. Open undercover (4).

engine assembly 1 4 Undercover: 250 kg
Removal
stop the engine.
k Set the parking brake lever and work equip-
ment lock lever in the lock position.
k Collect the air conditioner refrigerant
(R134a) from air conditioner circuit in
advance.
a Ask professional traders for collecting and fill-
ing operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to the 6. Disconnect radiator lower tank inlet hose (5)
atmosphere. from the engine. [*1]
k If refrigerant gas (R134a) gets in your eyes,

you may lose your sight. Accordingly, put
on protective goggles while you are collect-
ing the refrigerant (R134a) or filling the air
conditioner circuit with the refrigerant
(134a). Collecting and filling work must be
conducted by a qualified person.
1. Drain the coolant.

6 Coolant: 110 l
2. Remove the engine hood assembly. For details,

see "Removal and installation of engine hood 7. Disconnect fuel hoses (6), (7) and (8).
assembly".
3. Remove the right and left covers (1) and right

and left step covers (2).
4. Remove right and left lower side covers (3).
D275A-5R 31
8. Remove cover (9). 12. Remove air connector (17) and hose together.
[*4]
13. Disconnect water connector (18) from the

engine. [*5]
9. Disconnect aeration hose (10), radiator inlet

hose (11) and aftercooler outlet hose (12). [*2]
14. Remove wiring harness (20) from bulkhead

(19).
15. Disconnect connector EG5 (21).
16. Disconnect heater hoses (22) and (23) and air

conditioner hoses (24) and (25) from the oper-
ator's cab. [*6]
10. Disconnect hoses (13) and (14) and remove

condenser (15). [*3]
11. Remove frame (16).
17. Remove connectors (26), (27), (28), (29) and

(30) from the bracket and then remove wiring
harness clamps (31) and (32).
32 D275A-5R
18. Remove cover (33) from the left front of the 22. Remove plate (39) and 2 bracket mounting
operator's cab. bolts (40).
a Similarly remove the plate and bolts on the
right side.
19. Disconnect terminal HT/B (34) and connectors

SSA (35) and PT1 (36).
23. Remove bulkhead (19).
4 Bulkhead: 180 kg
20. Disconnect battery terminal (37) from the start-

ing motor.
24. Sling universal joint assembly (42).
21. Disconnect ground wire (38).
25. Remove the mounting bolts and lift off the uni-
versal joint assembly. [*7]
4 Universal joint assembly: 30 kg
D275A-5R 33
26. Remove 4 engine mounting bolts (43) and (44) Installation

on the front and rear sides. [*8] [*1]
3 Hose clamp: 8.8 ± 0.5 Nm {90 ± 5 kgcm}
[*2], [*4]
3 Radiator inlet hose (11) clamp:
8.8 ± 0.5 Nm {90 ± 5 kgcm}
a Replace the MIKALOR clamps of 4 aftercooler

outlet hoses (12) and 8 air connector (17) with
new ones.
1) Set the hose to its original position.
2) Set the bridge (BR) under the bolt (BC)
27. Lift off engine assembly (45). and reduce lapping area (b) over the band
a Before lifting off, check that all the wirings (BD) to a minimum of 5 mm.
and pipings are disconnected. 3) Tighten bolt (BC).
2 Threaded part of bolt: Lubricating
4 Engine assembly: 2,050 kg
a Do not use an impact wrench.
a When reusing the hose, install it to
the clamp mark on it.
3 Bolt (BC):
25 ± 5 Nm {2.55 ± 0.5 kgm}
a When using a new hose, tighten until
dimension BDG is as follows.
q Aftercooler outlet hose (12):
23 +0
–3 mm
q Air connector (17): 10 +0
–3 mm
34 D275A-5R
[*3], [*6]
a When installing the air conditioner circuit
hoses, take care that dirt, dust, water, etc. will
not enter them.
a When tightening each joint of the air condi-
tioner hose, check that the O-ring is fitted to it.
a Check that each O-ring is free from a flaw and
deterioration.
2 O-ring: Compressor oil PAG 46 for R134a

or equivalent (DENSO: ND-OIL8,
ZEXEL: ZXL100PG)
3 Hose clamp (M6 bolt):

8 – 12 Nm {0.8 – 1.2 kgm}
3 Tightening torque for refrigerant gas pipes

Dimension in Width across
Tightening torque
screw flats
11.8 – 14.7 Nm
M16 x 1.5 19 mm
{1.2 – 1.5 kgm}
19.8 – 24.5 Nm
M16 x 1.5 24 mm
{2.0 – 2.5 kgm}
29.4 – 34.3 Nm
M16 x 1.5 27 mm
{3.0 – 3.5 kgm}
M6 bolt of 3.9 – 6.9 Nm
10 mm
receiver part {0.4 – 0.7 kgm}
M6 bolt of 7.8 – 11.8 Nm
10 mm
compressor piping {0.8 – 1.2 kgm}
[*5]
2 Water connector mounting face:
[*7]
98.10 – 123 Nm {10 – 12.5 kgm}
[*8]
3 Engine mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
q Refilling with coolant

Add coolant through the coolant filler to the
specified level. Run the engine to circulate the
coolant through the system. Then, check the
coolant level again.
5 Coolant: Approx. 110 l
q Filling of air conditioning gas

Fill the air conditioner circuit with refrigerant
(R134a).
a Quantity of refrigerant: 1,100 ± 100 g
D275A-5R 35
Removal and installation of 5. Open undercover (4).

radiator assembly (including 4 Undercover: 250 kg
hydraulic oil cooler assembly and
aftercooler assembly) 1
Removal
1. Drain the coolant and hydraulic oil.

6 Coolant: 110 l
Hydraulic oil: 130 l
2. Remove radiator top inspection cover (1).

6. Disconnect oil cooler hose (5) and radiator out-
let hose (6). [*1]
a Disconnect the hose and tubes together.
3. Move the radiator top inspection cover and dis-

connect headlamp wiring connector LHD (2).
7. Disconnect oil cooler hose (7) and radiator

lower tank inlet hose (8). [*2]
a Disconnect the hoses and tubes together.
4. Lift off radiator top cover (3).

4 Cover: 65 kg
36 D275A-5R
8. Disconnect wiring connector CN-RDG (9) and

clamp (10).
9. Disconnect sub-tank hose (11). [*3]
10. Remove the right and left wind breaking panels.
17. Remove mounting bolts (19) (4 pieces on each

of the right and left sides).

"Removal and installation of engine hood
assembly".
12. Disconnect aeration hose (12), radiator inlet

hose (13) and aftercooler outlet hose (14).
[*4]
13. Remove air conditioner condenser assembly

(15) and move it toward the engine. 18. Lift off radiator assembly (20).
4 Radiator assembly: 500 kg
14. Remove right and left brackets (16) and radia-
tor right and left mounting bolts (17).
15. Disconnect the aftercooler outlet hose. For

details, see "Removal and installation of after-
cooler assembly".
16. Remove the guard and fan net.

a Remove the mounting bolts of lowest
shroud (18) to make a space for removing
the mounting bolts on the front side of the
radiator.
D275A-5R 37
Installation
q Carry out installation in the reverse order to
removal.
[*1]
3 Radiator outlet hose (6) clamp:
8.8 ± 0.5 Nm {90 ± 5 kgcm}
[*2]
3 Radiator lower tank inlet hose (8) clamp:
8.8 ± 0.5 Nm {90 ± 5 kgcm}
[*3], [*4]
3 Reservoir hose clamp: q Refilling with coolant
Add coolant through the coolant fillers of the
34 ± 5 Nm {3.4 ± 0.5 kgm}
main radiator and sub-radiator to the specified
a Set insertion length (c) of hose (a) and tube
level. Run the engine to circulate the coolant
(b) to the following values.
through the system. Then, check the coolant
Hoses (11) and (12): Min. 25 mm
level again.
Hose (13): 60 mm
5 Coolant: 110 l
q Refilling with oil (Hydraulic tank)

Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then, check the oil level
again.
5 Hydraulic tank: 130 l

8.8 ± 0.5 Nm {90 ± 5 kgcm}

(BD) to a minimum of 5 mm.
3) Tighten bolt (BC).
3 Bolt (BC):
25 ± 5 Nm {2.55 ± 0.5 kgm}
+0
q Dimension BDG (3): 23 –3 mm
38 D275A-5R
Removal and installation of 5. Open the undercover (10).

hydraulic oil cooler assembly 1 4 Under cover: 250 kg
Removal
1. Drain the hydraulic oil.

6 Hydraulic oil: 130 l
2. Remove the radiator top cover. For details, see

"Removal and installation of radiator assembly
(including hydraulic oil cooler and aftercooler
assembly)".
3. Disconnect wiring connector CN-RDG (1) and 6. Remove hydraulic oil cooler lower cover (6).
sub-tank hose (2) and remove hydraulic oil
cooler top cover (3).
7. Remove lower hydraulic oil cooler hoses (7)

and (8).
4. Remove left lower side cover (4) and cover (5).
D275A-5R 39
8. Remove the 4 upper and lower mounting bolts Installation

and lift off hydraulic oil cooler assembly (9). q Carry out installation in the reverse order to
4 Hydraulic oil cooler assembly: 35 kg removal.

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.
40 D275A-5R
Removal and installation of 5. Loosen the clamp of stay (7) and disconnect
aftercooler inlet hose (8) from the aftercooler.
aftercooler assembly 1 [*2]
Removal
"Removal and installation of radiator assembly
(including hydraulic oil cooler and aftercooler
assembly)".
2. Disconnect radiator inlet hose (1), aeration

hose (2) and aftercooler outlet hose (3). [*1]
a Drain the coolant in advance to a degree
that the coolant will not leak when the radi-
ator inlet hose is disconnected.
6. Remove air conditioner condenser mounting

bolts (9) and put down condenser (10) toward
the engine.
a Do not disconnect the condenser hoses but
remove only the mounting bolts and put the
hoses aside.
7. Remove condenser bracket (11).
3. Open the right side cover and remove cover (4)

and step cover (5).
4. Remove right lower side cover (6).
8. Remove aftercooler upper mounting bolts (12).
D275A-5R 41
9. Open the undercover (15). Installation

4 Under cover: 250 kg q Carry out installation in the reverse order to re-
moval.
[*1]
8.8 ± 0.5 Nm {90 ± 5 kgcm}
a Set insertion length (c) of hose (a) and tube

(b) to the following values.
Hose (2): Min 25 mm
Hose (1): 60 mm
10. Remove aftercooler lower mounting bolt (13)

and lift off aftercooler assembly (14).
42 D275A-5R
[*1], [*2]
a Replace the MIKALOR clamps of 4 aftercooler
outlet hoses (3) and 4 aftercooler inlet hoses
(8) with new ones.
(BD) to a minimum of 5 mm.
3) Tighten bolt (BC).
3 Bolt (BC):
25 ± 5 Nm {2.55 ± 0.5 kgm}
q Aftercooler outlet hose (3):
+0
23 –3 mm
q Aftercooler inlet hose (8):
+0
10 –3 mm
q Refilling with coolant

Add coolant through the coolant fillers of the
main radiator and sub-radiator to the specified
level. Run the engine to circulate the coolant
through the system. Then, check the coolant
level again.
5 Coolant: 110 l
D275A-5R 43
Removal and installation of 2. Disconnect hose (3).

k Release the residual pressure in the hy-
radiator guard assembly 1 draulic circuit. For details, see Testing
and adjusting, "Releasing residual pres-
Special tools
sure in hydraulic circuit".
a Plug the piping to prevent dirt from entering
New/Remodel
it.
Necessity
Sym
Part No. Part name
Sketch
bol
Q'ty
790-451-1000 Remover t 1
Puller
A 7 790-101-2102 t 1
(294kN {30ton})
790-101-1102 Pump t 1
Removal
1. Remove blade lift cylinder cap (1).

a Check the thickness and quantity and of 3. Sling blade lift cylinder assembly (4), install the
shim (3). [*1] cylinder fitting to it, and fix it to the radiator
k Run the engine, retract the piston rod to guard.
the stroke end, and bind it with wires so
that it will not come off down.
4. Drain the coolant.

5 Coolant: 110 l
5. Remove the engine hood assembly. For details,

see "Removal and installation of engine hood
assembly".
44 D275A-5R
6. Disconnect wiring connector CN-RDG (5). 11. Disconnect oil cooler hose (12) and radiator
lower tank inlet hose (13). [*2]
7. Disconnect aeration hose (6), sub-tank hose a Disconnect the hose and tube together.
(7), radiator inlet hose (8) and aftercooler inlet
hose (9). [*2]
12. Disconnect oil cooler hose (14) and radiator

outlet hose (15). [*3]
8. Drain the hydraulic oil. a Disconnect the hoses and tubes together.
9. Remove right and left side covers (10).
13. Disconnect fan motor hoses (16), (17) and (18)

and blade lift cylinder hose (19).
10. Open undercover (11).

4 Undercover: 250 kg
D275A-5R 45
14. Remove hydraulic oil cooler lower cover (20). 18. Loosen the clamp of stay (26) and disconnect
aftercooler outlet hose (27) from the aftercooler.
15. Remove lower hydraulic oil cooler hoses (21)

and (22). 19. Sling the radiator guard assembly and remove
lock bolt (28) of the pin. Using tool A7, push
rear pin (29) toward inside of the radiator guard
to remove. [*4]
16. Remove air conditioner condenser mounting

bolts (23) and put down condenser (24) toward
the engine.
a Do not disconnect the condenser hoses but 20. Remove lock plate (30). Using tool A7, pull out
remove only the mounting bolts and put the front pin (31) toward outside of the radiator
hoses aside. guard to remove.
17. Remove condenser mounting bracket (25).
46 D275A-5R
21. Lift off radiator guard assembly (32). Installation

a Take care extremely not to damage the wir- q Carry out installation in the reverse order to re-
ing and piping. moval.
4 Radiator guard assembly: 2,450 kg
[*1]
q Install the blade lift cylinder according to the fol-
lowing procedure.
1) Sling the blade lift cylinder temporarily.
2) Run the engine and extend the piston rod
slowly to couple it with the blade assembly
by cap (1) at the lift cylinder end.
3) Adjust clearance (a) at the mating face of
the cap to the following value with shims.
q Standard clearance (a): 0.2 – 0.5 mm
q Standard shim thickness: 4 mm
a Check that the shims rotate smoothly.
[*2]
a Set insertion length (d) of hose (b) and tube (c)
to the following value.
Hoses (6) and (7): Min. 25 mm
Hose (8): 60 mm
D275A-5R 47
3 Radiator lower tank inlet hose (13) clamp: q Refilling with coolant
8.8 ± 0.5 Nm {90 ± 5 kgcm} Add coolant through the coolant filler to the
specified level. Run the engine to circulate the
3 Radiator inlet hose (8) clamp: coolant through the system. Then, check the
8.8 ± 0.5 Nm {90 ± 5 kgcm} coolant level again.
5
a Install each MIKALOR clamp according to the Coolant: 110 l
1) Set the hose to its original position. q Refilling with oil (Hydraulic tank)
2) Set the bridge (BR) under the bolt (BC) Add oil through the oil filler to the specified
and reduce lapping area (b) over the band level. Run the engine to circulate the oil
(BD) to a minimum of 5 mm. through the system. Then, check the oil level
3) Tighten bolt (BC). again.
3 Bolt (BC):
25 ± 5 Nm {2.55 ± 0.5 kgm}
+0
q Dimension BDG: 23 –3 mm
[*3]
3 Radiator outlet hose (15) clamp:
8.8 ± 0.5 Nm {90 ± 5 kgcm}
[*4]
a Tighten the locknut so that clearance (e)
between the radiator guard and nut will be in
the following range.
Clearance (e): 3 – 5 mm
48 D275A-5R
Removal and installation of fuel 6. Remove plate (6).

tank assembly 1 7. Disconnect wiring connectors CN-BKAL (11)
and CN-245 (12).
Removal
1. Remove step (1).
4. Close the fuel supply valve under the fuel tank.
5. Remove drain hose clamp (4) and drain block

(5).

4 Cover: 70 kg
D275A-5R 49
9. Disconnect fuel level sensor wiring connector Installation

CN-FLV (7). q Carry out installation in the reverse order to re-
moval.
10. Disconnect 3 fuel hoses (8).
11. Remove 4 mounting bolts (9).
12. Lift off fuel tank assembly (10).

4 Fuel tank assembly:
390 kg (When empty)
1,100 kg (When full)
50 D275A-5R
Removal and installation of 6. Remove the clamp and disconnect sub-tank

hose (5).
engine hood assembly 1
7. Remove left rear mounting bolt (6).
Removal
"Removal and installation of radiator assem-
bly".
2. Remove right and left covers (1).
8. Remove bracket (7).
9. Disconnect air hose (8).
3. Remove right and left side plates (2).
10. Disconnect wiring connector EG4 (9) and air

cleaner hose (10).
11. Disconnect muffler tube (11).

4. Disconnect sub-tank hose (3).
12. Remove right rear mounting bolt (12).
5. Remove front right and left mounting bolts (4).
D275A-5R 51
13. Lift off engine hood assembly (13). Installation

4 Engine hood assembly: 210 kg q Carry out installation in the reverse order to re-
moval.
52 D275A-5R
Removal and installation of fan 4. Remove the hose clamp and disconnect fan
motor hoses (3), (4) and (5).
drive assembly 1
5. Disconnect fan motor wiring connector FAR
Removal
(6).
1. Drain the hydraulic oil.
5 Hydraulic oil: 130 l 6. Remove lowest shroud (7).
a Put an oil stopper to the piping so that dirt
2. Remove the mounting bolts and radiator mask will not enter the piping.
(1).
4 Radiator mask: 92 kg 7. Sling fan drive assembly (8) and remove the
mounting bolts.
8. Lift off fan drive assembly (8).

4 Fan drive assembly: 135 kg
3. Remove fan net (2).
D275A-5R 53
Installation
q Carry out installation in the reverse order to re-
moval.

54 D275A-5R
Removal and installation of fan 5. Remove the 4 mounting bolts and fan motor
assembly (4).[*3]
motor assembly 1
4 Fan motor assembly: 25 kg
Removal
1. Remove the fan drive assembly. For details,
see "Removal and installation of fan drive
assembly".
2. Remove the mounting bolt and lock plate (1).

[*1]
3. Loosen nut (2). [*2]
4. Set puller [1]. While loosening the nut, pull out

fan (3).
D275A-5R 55
Installation
moval.
[*1]
Be sure to align the hole of lock plate (1) by rotating
nut (2) in the tightening direction.
[*2]
3 Mounting nut (2):
441 – 539 Nm {45 – 55 kgm}
a After tightening the nut, check dimension (d)
shown in the figure below.
q MIN: 1.2 mm
q MAX: 3.0 mm
[*3]
a Wipe off dirt from the engaging portions of the
fan motor and fan, and then degrease those
parts.
56 D275A-5R
D275A-5R 57
D275A-5R Bulldozer
© 2008 KOMATSU
All Rights Reserved
58 D275A-5R
SEN03242-00
D275A-5R

D275A-5R 35001 and up

Power train, Part 1
Removal and installation of damper assembly ............................................................................................... 2
Disassembly and assembly of damper assembly ........................................................................................... 5
Removal and installation of power train unit assembly ................................................................................. 10
Disconnection and connection of power train unit assembly ........................................................................ 14
Disassembly and assembly of PTO assembly .............................................................................................. 24
Disassembly and assembly of torque converter assembly ........................................................................... 31
Disassembly and assembly of torqflow transmission assembly ................................................................... 36
D275A-5R 1
Removal and installation of 5. Disconnect breather hose (22) and remove it

damper assembly 1 and oil level detection pipe (23) together.
Removal
k Collect the air conditioner refrigerant
(R134a) from air conditioner circuit in
advance.
a Ask professional traders for collecting and fill-
ing operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to the
atmosphere.

ing the refrigerant (R134a) or filling the air 6. Using hanging bolt [1], sling damper cover as-
conditioner circuit with the refrigerant sembly (24) temporarily.
(134a). Collecting and filling work must be
conducted by a qualified person. 7. Disconnect ground wire (25).
1. Drain the oil in damper case. 8. Remove the mounting bolts of damper cover as-
6 Damper case: 1.5 l sembly (24). [*2]
2. Remove the bracket (bulkhead). For details,

see "Removal and installation of engine
assembly".
3. Sling universal joint assembly (21).
4. Remove the mounting bolts and lift off universal

joint assembly. [*1]
4 Universal joint assembly: 30 kg
9. Using 2 forcing screws [2], lift off damper cover

assembly. [*3]
4 Damper cover assembly: 55 kg
2 D275A-5R
10. Using hanging bolt [3], sling damper assembly

(26) and remove the mounting bolts. [*4]
11. Using 2 forcing screws [4], lift off the damper as-
sembly.
4 Damper assembly: 75 kg
D275A-5R 3
Installation [*3]
q Carry out installation in the reverse order to re- a When installing the damper cover assembly, de-
moval. grease the shaft spline and apply dry lubricant A
and leave it as it is for 2 - 3 minutes. Then, apply
Air conditioner hose extreme pressure lithium grease containing mo-
a Install each hose so that it will not be twisted. lybdenum B to the shaft spline.
a When installing the air conditioner hoses, take A
Molybdenum disulfide
Sumiko, lubricant
care that dirt, dust, and water will not enter dry lubricant
them. Extreme pressure lith- • Kyodo Yushi, Molylex No. 2
a Before tightening each air conditioner hose con- B ium grease containing • Showa-Shell, Letinax AM
nector, check that the O-ring is fitted to it. molybdenum • Nihon Sekiyu Molytex
a Apply compressor oil (Showa-Shell, Sniso 4G or
5G) sufficiently to the O-rings.
[*4]
3 Tightening torque for refrigerant gas pipes 3 Damper assembly mounting bolt:
98.10 – 123 Nm {10 – 12.5 kgm}
Tightening torque
screw flats
q Refilling with oil
5
11.8 – 14.7 Nm
M16 x 1.5 19 mm Damper chamber oil: 1.5 l (TO30)
3
{1.2 – 1.5 kgm}
Drain plug: 58.8 – 78.5 Nm {6 – 8 kgm}
3
19.8 – 24.5 Nm Level plug:127 – 177 Nm {13 – 18 kgm}
M16 x 1.5 24 mm
{2.0 – 2.5 kgm}
29.4 – 34.3 Nm q Filling of air conditioning gas
M16 x 1.5 27 mm
{3.0 – 3.5 kgm} Fill the air conditioner circuit with refrigerant
M6 bolt of 3.9 – 6.9 Nm (R134a).
10 mm
receiver part {0.4 – 0.7 kgm} a Quantity of refrigerant: 1,100 ± 100 g
M6 bolt of 7.8 – 11.8 Nm
10 mm
[*1]
98.10 – 123 Nm {10 – 12.5 kgm}
[*2]
3 Damper cover assembly mounting bolt:
98.10 – 123 Nm {10 – 12.5 kgm}
4 D275A-5R
Disassembly and assembly of damper assembly 1
Special tools
New/Remodel
Sym-
Necessity
Part No. Part name

bol
Sketch
Q'ty
791-612-1100 Installer t 1
Puller
B 790-101-4200 t 1
(294kN {30ton})
D275A-5R 5
Disassembly 3) Bearing and oil seal

1. Disassembly of damper cover assembly (1). i) Remove oil seal (9) from cover (2), then
1) Coupling remove inner race (7-3) of bearing (7).
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
plastic hammer from the output side.
a 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).
6 D275A-5R
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).
a Perform this procedure only when the plug
needs to be replaced.
D275A-5R 7
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 lith- • Kyodo Yushi, Molylex No. 2
B ium grease containing • Showa-Shell, Letinax AM
molybdenum • Nihon Sekiyu Molytex
2) Install cushion (15).

a Apply grease (G2-LI) all over the cushion.
a 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}
8 D275A-5R
2) Press fit inner race (7-1) of bearing (7) to 5)Fit oil seals (8) and (9) to cover assembly
shaft (6) with tool B. (2).
2 Press fitting face of oil seal:
2 Oil seal lip: Grease (G2-LI)
a 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 se-

cure 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).
D275A-5R 9
Removal and installation of power 10. Remove cover (6).

train unit assembly 1
11. Disconnect the following 4 oil filter hoses.
Removal q (7): Power train oil filter inlet hose
k Disconnect the cable from the negative (–) q (8): Power train oil filter outlet hose
terminal of the battery. q (9): Steering oil filter inlet hose
q (10): Steering oil filter outlet hose
1. Drain the oil.
6 Hydraulic tank: Approx. 130 l
6 Power train case: Approx. 90 l
2. Remove the floor frame assembly. For details,

see "Removal of floor frame assembly".
3. Remove the fuel tank assembly. For details,

see "Removal of fuel tank assembly".
4. Remove the undercover.

4 Power train undercover: 320 kg
12. Remove 4 hose clamps (11).
5. Disconnect intermediate wiring connector FE2
(1) from bracket (2). 13. Remove clamp plate (12).
6. Remove bracket (2) and wiring harness. 14. Disconnect the following 4 ripper hoses.
q (13): Ripper tilt port A5
q (14): Ripper tilt port B5
q (15): Ripper lift port A4
q (16): Ripper lift port B4
7. Disconnect wire clamp (3).
8. Disconnect fan pump hose (4), (5), (40), (41)

and (42).
15. Disconnect intermediate wiring connector 241
9. Remove hose clamp (43). (17).
10 D275A-5R
16. Disconnect work equipment pump tube cou- 21. Disconnect pin puller solenoid valve hoses
pling (18). (26) and (27).
22. Disconnect oil cooler hose (28).

17. Disconnect the following 4 self-pressure reduc- a Remove the clamps of the oil cooler hose,
ing valves. too.
q (19): Work equipment pump hose (Port P1)
q (20): Work equipment pump hose (Port PC)
q (21): Fan pump hose (Port PR)
q (22): Work equipment pump hose (Port LS)
23. Sling universal joint assembly (29) temporarily.
24. Remove the mounting bolts and lift off univer-

sal joint assembly (29). [*1]
4
18. Disconnect oil cooler hose (23). Universal joint assembly: 30 kg
a Move the hose to a place where it will not
be an obstacle when the power train unit
assembly is lifted up.
19. Remove oil level detection pipe (24) for the

power train.
20. Remove oil filler pipe (25) for the power train.
D275A-5R 11
25. Disconnect torque converter outlet hose (30) 28. Remove both covers (34).
and transmission inlet hose (31).
29. Loosen coupling clamp (35) and move seal

26. Remove the mounting bolts and final drive (36) outward. [*2]
shaft cover (32).
a Remove the final drive shaft cover on the
opposite side, too.
30. Remove left (37) and right (38) mounting bolts

on the front side.
27. Pull out drive shaft (33) by the following

method.
Using forcing screw [1], pull out the drive shaft
until the spline on the steering case side is
separated.
a If the shaft is difficult to pull out, set a jack
under the shoe grouser and push up the
shoe grouse to find a point where the shaft
is pulled out easily.
a Pull out the drive shaft on the opposite
side, too.
12 D275A-5R
31. Lift off power train unit assembly (39). [*3] Installation
4 Power train unit assembly: 2.500 kg q Carry out installation in the reverse order to
removal.
[*1]
98.10 – 123 Nm {10 – 12.5 kgm}
[*2]
a Clamp the peak of the coupling seal securely
and set the clamp threads in parallel with the
cap mounting seat.
[*3]
a When installing the power train unit assembly,
take care extremely not to damage seal (36).

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.
q Bleeding air
Bleed air from the fan pump. For details, see
Testing and adjusting, "Bleeding air from fan
pump".
D275A-5R 13
Disconnection and connection of 5. Remove pin puller solenoid valve hoses (10)
power train unit assembly 1 and (11).
Disconnection 6. Remove steering lubricating oil supply hose

q Draining oil (12).
Before setting the power train unit assembly to
the block, drain the oil from the PTO case and
steering case.
1. Sling power train unit assembly (1) and set it to

block.
4 Power train unit assembly: 2,300 kg
7. Disconnect the following 6 wiring connectors.

q (13): SLC wiring connector (Left clutch
ECMV solenoid)
q (14): FLC wiring connector (Left clutch
ECMV fill switch)
q (15): FRC wiring connector (Right clutch
ECMV fill switch)
q (16): SRC wiring connector (Right clutch
2. Remove cover (2). ECMV solenoid)
q (17): STB wiring connector (Emergency
3. Disconnect the following 5 wiring connectors. stop prevention solenoid)
q (3): FRB wiring connector (Right brake q (18): TMI wiring connector (Bevel gear
ECMV fill switch) speed sensor.)
q (4): SRB wiring connector (Right brake
ECMV fill switch)
q (5): FLB wiring connector (Left brake
ECMV fill switch)
q (6): SLB wiring connector (Left brake
ECMV fill switch)
q (7): TMV intermediate connector
4. Disconnect the left brake and left clutch oil

pressure pickup hoses. [*1]
q (8): Left brake oil pressure pickup hose
(Color band: White)
q (9): Left clutch oil pressure pickup hose
(Color band: Black)
14 D275A-5R
8. Disconnect transmission oil pressure pickup 11. Disconnect the following 5 transmission oil
hose (19) (Color band: not used) [*1] pressure pickup hoses. [*1]
q (24): Transmission forward oil pressure
9. Disconnect the following 2 torque converter oil pickup hose (Color band: White/
pressure pickup hoses. [*1] Blue)
q (20): Torque converter outlet oil pressure q (25): Transmission 2nd oil pressure
pickup hose (Color band: White/ pickup hose (Color band: White/Yel-
Red) low)
q (21): Torque converter inlet oil pressure q (26): Transmission reverse oil pressure
pickup hose (Color band: Blue) pickup hose (Color band: Red/Blue)
q (27): Transmission 3rd oil pressure pickup
hose (Color band: Yellow/Black)
q (28): Transmission 1st oil pressure pickup
hose (Color band: Red)
10. Disconnect the right brake and right clutch oil

pressure pickup hoses. [*1]
q (22): Right brake oil pressure pickup hose
(Color band: Yellow)
q (23): Right clutch oil pressure pickup hose 12. Remove EPC valve basic pressure hose (29).
(Color band: White/Black)
13. Remove power train filter hose (30).
D275A-5R 15
14. Disconnect the following 2 wiring connectors.

q (31): FAC wiring connector (Fan pump
solenoid valve)
q (32): 453 wiring connector (Torque con-
verter oil temperature sensor)
15. Remove hose (33) between the transmission

and steering case.
16. Remove the 4 mounting bolts and fan pump

assembly (34).
4 Fan pump assembly: 30 kg
23. Remove steering filter hose (44) and power

train filter hose (45).
24. Disconnect pump drive gear lubrication tube

(46) and remove transmission lubrication tube
(47). [*2]
25. Disconnect suction tube (48) and remove block

(49).
26. Remove the 2 mounting bolts and lift off power

train and lubricating oil pump assembly (50).
17. Disconnect the following 3 work equipment 4 Power train lubricating oil pump assem-
pump hoses. bly: 30 kg
q (35): Work equipment pump hose (Port
PA1)
PP2)
PLS1)
18. Disconnect suction tubes (38) and (39).
19. Disconnect scavenging pump tube (40).
20. Remove the 2 mounting bolts and lift off work

equipment pump assembly (41).
4 Work equipment pump assembly: 70 kg
21. Remove the 2 mounting bolts and scavenging

pump (42).
22. Remove hose bracket (43).
16 D275A-5R
27. Remove 5 hose clamps (51) and oil pressure 31. Remove the 18 mounting bolts and lift off
pickup hose bracket assembly (52). steering case assembly (60).
4
a After removing the hose clamps, remove Steering case assembly: 950 kg
the disconnected hoses.
a Remove the oil pressure pickup hose
bracket assembly and oil pressure pickup
hose together.
32. Remove coupling (61).
28. Remove plate (53) and disconnect rod (54).

[*3]
29. Remove brackets (55) and (56) and hose

bracket (57).
33. Loosen the 6 mounting bolts and remove

retainer (62) by using 2 forcing screws [2]. [*4]
a Check the thickness and quantity of shims
(63).
30. Remove torque converter oil temperature sen-

sor bracket (58) and pull out 2 sleeves (59).
D275A-5R 17
34. Remove snap ring (64). 37. Sling the torque converter assembly tempo-
rarily and remove 11 mounting bolts (67). [*5]
35. Set the PTO, torque converter, and transmis-

sion assembly (65) with the PTO side up. 38. Lift off torque converter assembly (68).
4 Torque converter assembly: 160 kg
36. Remove the 19 mounting bolts and lift off PTO

assembly (66).
4 PTO assembly: 400 kg
18 D275A-5R
Connection a Measure clearance (a) at 4 places on

q Carry out connection in the reverse order to the periphery ((A), (B), (C), and (D))
disconnection. and obtain the average.
[*1]
a The adapters of the oil pressure pickup hose
have their respective color codes. (See the
connection of the centralized pressure pickup
hoses.)
[*2]
3 Joint bolt: 34.3 – 44.2 Nm {3.5 – 4.5 kgm}
[*3]
a Adjust the brake pedal. For details, see Testing
and adjusting, "Adjusting brake pedal and
parking brake lever". 3) Determine the thickness of the shims.
q Thickness of shims = (a) -0
-0.05 mm
[*4] q Types of shims:
a Adjust the shims of the retainer according to 0.15 mm, 0.2 mm, 0.5 mm
the following procedure. q Standard thickness of shims: 0.5 mm
1) Install retainer (62) and tighten the 6 4) Set the shims of the determined thickness
mounting bolts to the following torque and tighten the mounting bolts of retainer
without inserting any shim. (62) to the specified torque.
2 Oil seal: Grease (G2-LI) 2 Mounting bolts: Adhesive (LT-2)
3 Mounting bolt: 9.8 Nm {1 kgm} 3 Mounting bolt:
2) Using thickness gauges, measure clear- 58.8 – 73.6 Nm {6.0 – 7.5 kgm}
ance (a) between retainer (62) and PTO a Check that the thickness and quantity of
housing (69). the shims on both sides are the same.
q Standard clearance (a): a Set the shims as shown in the figure so
0.48 – 1.32 mm that they will not block the forcing tap of
the retainer.
D275A-5R 19
a Apply molybdenum disulfide lubricant

(LM-P) to part (P) of the PTO unit input
shaft and apply grease (G2-LI) to spline
(b).
[*5]
2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
98.10 – 123 Nm (10 – 12.5 kgm}
20 D275A-5R
D275A-5R 21
Connection diagram of centralized oil pressure pick-up hoses
22 D275A-5R
q (8): Left brake oil pressure pickup hose

(Color band: White)
q (9): Left clutch oil pressure pickup hose
(Color band: Black)
q (19): Transmission oil pressure pickup hose
(Color band: Not used)
q (20): Torque converter outlet oil pressure
pickup hose (Color band: White/Red)
q (21): Torque converter inlet oil pressure
pickup hose (Color band: Blue)
q (22): Right brake oil pressure pickup hose
(Color band: Yellow)
q (23): Right clutch oil pressure pickup hose
(Color band: White/Black)
q (24): Transmission forward oil pressure
pickup hose (Color band: White/Blue)
q (25): Transmission 2nd oil pressure pickup
hose (Color band: White/Yellow)
q (26): Transmission reverse oil pressure
pickup hose (Color band: Red/Blue)
q (27): Transmission 3rd oil pressure pickup
hose (Color band: Yellow/Black)
q (28): Transmission 1st oil pressure pickup
hose (Color band: Red)
D275A-5R 23
Disassembly and assembly of ii) Remove bearing inner race (3B) and
PTO assembly 1 bearing (6) from gear (7).
Disassembly
1. Lubrication tube
Remove shaft lubrication tube (1).
3. Hydraulic/HSS charge pump and power

train/lubrication pump drive gear, cover as-
sembly
1) Remove mounting bolts, then using forcing
2. HSS pump/fan pump drive gear, cover as- screws and guide bolts, remove pump drive
sembly gear and cover assembly (8).
1) Remove mounting bolts, then using forcing
screws and guide bolts, remove pump drive
gear and cover assembly (2).
2) Disassemble pump drive gear and cover as-

sembly as follows.
i) Remove cover (9) from gear and bear-
2) Remove bearing outer race and roller (3A) ing (10).
from PTO case.
3) Disassemble pump drive gear and cover as-
sembly as follows.
i) Remove cover (4) from gear and bear-
ing (5).
24 D275A-5R
ii) Remove 2 bearings (11) from gear (12). 3) Remove snap ring (15), then remove bear-
ing (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).
D275A-5R 25
a Bearing (19) and spacer (20) separate 7. Sleeve

from shaft (18) and gear (21) comes off. Remove sleeve (29) from PTO case.
a 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 re-
move.
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).

a 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.
26 D275A-5R
Assembly 2. Sleeve
a Clean all parts, check that there is no dirt or Install sleeve (29) to PTO case.
damage, and coat the sliding surfaces of all a Install the sleeve with the chamfered side
parts with engine oil before assembling. facing the inside of the PTO case.
a After press fitting the bearing, drop approx. 6 cc a Expand fit the sleeve.
of oil (EO30-DH or EO10-DH) on the bearing,
and rotate it 10 times.
a When expand fitting the bearing, before cool-
ing with dry ice, drop approx. 6 cc of oil (EO30-
DH or EO10-DH) on the bearing, and rotate it
10 times.
a 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

a 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).
D275A-5R 27
3) Assemble input shaft bearing and race as-

sembly (24) to PTO case.
2 Surface of inside circumference of
race:
Molybdenum disulphide lubricant
(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:
Thread tightener (LT-2)
3 Mounting bolt:
245.0 – 308.7 Nm {25.0 – 31.5 kgm}
4. Idler gear
a 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.
a 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.
28 D275A-5R
5. Scavenging pump drive gear 6. Hydraulic/HSS charge pump and power

1) Press fit bearing (16) to PTO case. train/lubrication pump drive gear, cover as-
2) Install snap ring (15). sembly
1) Using push tool [10], 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 [11], 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}
D275A-5R 29
7. HSS pump/fan pump drive gear, cover as- 8. Lubrication tube

sembly Install shaft lubrication tube (1).
1) Using push tool [12], press fit bearing (6) to
gear (7).
2) Using push tool [13], press fit bearing inner
race (3B) to gear (7).
3) Using push tool [14], press fit gear and bear-

ing (5) to gear (4).
4) Using push tool [15], 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}
30 D275A-5R
Disassembly and assembly of 2) Using forcing screws [3] from the turbine
torque converter assembly 1 side, remove bearing (6).
Disassembly
1. Input shaft
Remove the mounting bolts. Then, using hang-
ing bolt [1] remove input shaft (1).
3) Remove drive case (7) from turbine gear

(8).
2. Drive case assembly

Remove 36 mounting bolts (2) between the
drive case and pump. Then, using hanging bolt
[2], remove drive case assembly (3).
4. Stator
1) Remove snap ring (9).
3. Disassembly of drive case assembly

1) Remove snap ring (4) and spacer (5).
D275A-5R 31
2) Remove stator and boss assembly (10). 5. Pump

1) Remove pump assembly (14) from stator
shaft housing assembly (15).
3) Remove boss (11) from stator (12).
2) Remove the mounting bolts. Then,

remove retainer (16) and bearing outer
race (17) from pump (18).
6. Stator shaft housing assembly

1) Loosen the 3 mounting bolts gradually,
disconnect housing and shaft assembly
(19).
32 D275A-5R
2) Disassemble the housing and shaft Assembly

assembly according to the following pro- a Clean all parts, check that there is no dirt or
cedure. damage, and coat the sliding surfaces of all
i) Using forcing screw [4], remove shaft parts with engine oil before installing.
and bearing assembly (20). a After press fitting the bearing, drop approx. 6
cc of oil (E030-DH or E010-DH) on the bear-
ing, and rotate it 10 times.
a When expand fitting the bearing before cooling
with dry ice, drop approx. 6 cc of oil (E030-DH
or E010-DH) on the bearing, and rotate it 10
times.
a Check that the snap ring is fitted securely in
the groove.
1. Assembly of stator shaft housing assembly

1) Using push tool [5], fit bearing (22) to shaft
(23) with a press.
2) Install seal ring (24) to shaft (23).
ii) Remove snap ring (21). Then, remove a Fix the seal ring to the shaft with
bearing (22) from shaft (23). grease securely.
iii) Remove seal ring (24) from shaft (23). 3 Seal ring: Grease (G2-LI)
4) Install shaft and bearing assembly (20) to

housing (25).
3 Mounting bolt:
58.8 – 73.6 Nm {6.0 – 7.5 kgm}
D275A-5R 33
5) Set shaft and housing assembly (19) and 3) Install pump assembly (14) to stator shaft
install 3 mounting bolts (a). housing assembly (15).
a Tighten the 3 mounting bolts gradu- 2 Mounting bolt: Adhesive (LT-2)
ally and evenly. 3 Mounting bolt:
2 Mounting bolt: Adhesive (LT-2) 58.8 – 73.6 Nm {6.0 – 7.5 kgm}
3 Mounting bolt:
98.0 – 122.5 Nm {10.0 – 12.5 kgm}
3. Snap ring
Install snap ring (13) to the shaft.
6) Insert 11 mounting bolts (b) of the trans-
mission assembly and torque converter
assembly in the bolt holes before installing
the pump.
4. Stator
1) Install boss (11) to stator (12).
3 Mounting bolt:
2. Pump 58.8 – 73.6 Nm {6.0 – 7.5 kgm}
1) Press fit bearing outer race (17) to pump
(18).
2) Install retainer (16) to the pump.
3 Mounting bolt:
58.8 – 73.6 Nm {6.0 – 7.5 kgm}
34 D275A-5R
2) Install stator and boss assembly (10). 3) Using hanging bolt [2], install drive case
assembly (3).
a Match plug (26) of the pump to the oil
groove of the drive case.
3 Mounting bolt:
49.0 – 58.8 Nm {5.0 – 6.0 kgm}
3 Plug:
14.7 – 19.6 Nm {1.5 – 2.0 kgm}
3) Install snap ring (9) to the shaft.
4) Install spacer (5) and snap ring (4).
5. Assembly of drive shaft case

1) Set drive case (7) on turbine gear (8).
6. Input shaft
Use hanging bolt [1], install input shaft (1).
a Match plug (26) of the pump to the oil
groove of the drive case.
3 Mounting bolt:
98.0 – 122.5 Nm {10.0 – 12.5 kgm}
2) Using push tool [6], fit bearing (6) with a
press.
D275A-5R 35
Disassembly and assembly of 3. Transmission control valve assembly

torqflow transmission assembly 1 1) Remove 5 pressure detection nipples (126).
2) Remove cover (3).
Special tools
New/Remodel
Sym-
Necessity
Part No. Part name
bol
Sketch
Q'ty
D 799-301-1600 Oil leak tester t 1
Disassembly
a Store the discs and plates in a flat place to pre-
vent them from becoming deformed.
1. Elbow 3) Remove wiring connector (136) from cover.

Remove elbow (1). 4) Remove cover (137).
2. Main relief valve assembly 5) Remove flanges (138) and (139) and
Remove main relief valve assembly (2). sleeves (140) and (141).
36 D275A-5R
6) Remove 4 mounting bolts (4), then remove 2) Remove 13 tie bolts (8) used to tighten
transmission control valve assembly (5). transmission case.
a Do not remove 2 connecting bolts (6) a 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].
D275A-5R 37
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 ix) Remove snap ring (20), then knock in-
No. 1 carrier assembly as follows. put shaft (21) out from torque converter
i) Remove snap ring (12), then remove end, and remove from No. 1 carrier as-
No. 2 sun gear (13). sembly (118).
ii) Remove snap ring (14). x) Remove bearing (117) from input shaft
iii) Remove snap ring (15), then remove (21).
No. 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 re-
move from front cover (19).
38 D275A-5R
3) Disassemble No. 1 carrier assembly as fol- 3) Remove seal ring (145) from No. 1 housing
lows. (33).
i) Remove snap ring (22) from No. 1 carri- 4) Remove seal ring (146) from No. 1 piston
er assembly, then remove No. 1 ring (34).
gear (23).
ii) Remove shaft (24) and ball (28).
a 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),
and 7 No. 2 plates (39).
8. No. 1 discs, plates, springs
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.
D275A-5R 39
11. Sleeves 5) Remove snap ring (44).

Remove 17 sleeves (40). 6) Using push tool [8], push No. 2 carrier as-
sembly (45), and remove from No. 2 hous-
12. Lubrication relief valve ing (46).
Remove lubrication relief valve (41) and spring
(120).
7) Remove snap ring (58), then remove bear-

ing (59) from No. 2 housing (46).
13. No. 2 housing, No. 2 carrier assembly 8) Remove seal ring (57).
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).
40 D275A-5R
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).
iii) Remove 2 thrust washers (51), needle
bearing (53), and planetary gear (52).
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).

D275A-5R 41
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.
a 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 18. No. 4 discs, plates, springs, guide pins
(74). 1) Remove 6 guide pins (83).
vii) Remove snap ring (156), then remove 2) Remove 12 No. 4 springs (79).
bearing (157). 3) Remove 24 springs (80), 4 No. 4 discs (81),

1) Using eyebolts [10] remove No. 3 housing 19. No. 5 carrier, No. 4 ring gear assembly
(77). 1) Remove 8 mounting bolts (84).
2) Remove No. 3 piston (78). 2) Remove No. 5 carrier and No. 4 ring gear
assembly (85).

(77).
4) Remove seal ring (150) from No. 3 piston
(78).
42 D275A-5R
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
a 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 and 4 No. 5 plates (98).
No. 4 ring gear (92) from No. 5 carrier
(93).

(94).
2) Remove No. 4 piston (95).
D275A-5R 43
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

Remove No. 5 piston (106).
ing (111) from No. 5 housing.
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
a Clean all parts, check that there is no dirt or
damage, and coat the sliding surfaces of all
parts with engine oil before installing.
a After press fitting the bearing, drop approx. 6 cc
of oil (EO30-DH or EO10-DH) on the bearing,
and rotate it 10 times.
a When expand fitting the bearing, before cooling
with dry ice, drop approx. 6 cc of oil (EO30-DH
or EO10-DH) on the bearing, and rotate it 10
27. Output shaft, spacer times.
1) Remove spacer (108). a Check that the snap ring is fitted securely in the
2) Remove snap ring (155), then remove out- groove.
put shaft (107) from No. 5 housing (109). a Coat the blind plugs with thread tightener (LT-2),
then after assembling, caulk 2 places on diago-
nally opposite sides.
44 D275A-5R
1. No. 5 housing assembly 3) Install spacer (108) to shaft (107).

1) Install seal rings (116) and (115) to cage
(114).
2 Seal ring: Grease (G2-LI)
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).
a The seal ring must be installed facing in
the correct direction. Assemble as
shown in the diagram.
4) Install snap ring (112). 2) Install seal ring (153) to No. 5 housing (109).
5) Install snap ring (110). a The seal ring must be installed facing in
6) Using push tool [13], press fit bearing (111) the correct direction. Assemble as
until it contacts snap ring (110). shown in the diagram.
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 [14], then using push tool
[15], press fit output shaft with press.
a Press fit bearing (111) until it contacts
snap ring (155).
D275A-5R 45
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).

2) Install seal ring (151) to No. 4 housing (94).
7. Bearing, No. 4 sun gear, spacer the correct direction. Assemble as
1) Using push tool [16], press fit bearing (156) shown in the diagram.
to spacer (157). 2 Seal ring: Grease (G2-LI)
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 [11], install No. 4 housing
(94).
8. No. 5 discs, plates, springs, guide pins a Check that the spring is fitted securely in
1) Install guide pin (83). the groove.
2) Install 4 No. 5 plates (98), 3 No. 5 discs (97),
and 18 springs (99).
3) Install 12 springs (96).
a Free length of spring: 70 mm
46 D275A-5R
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).
a Be careful not to damage or dent the
thrust washers.
iii) Install shaft (86) and ball (90).
a Check that the gear rotates smoothly.

2) Using guide bolt [17], install No. 5 carrier the correct direction. Assemble as
and No. 4 ring gear assembly (85). shown in the diagram.
2 Mounting bolt: 2 Seal ring: Grease (G2-LI)
3 Mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
D275A-5R 47
3) Install No. 3 piston (78) to No. 3 housing 2) Align meshing of gears, then using eyebolts
(77). [9], install No. 3 and No. 4 carrier assembly
4) Using eyebolts [10], install No. 3 housing (65).
(77).
a Check that the spring is fitted securely in
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
planetary gear (70), put 2 thrust washers 15. No. 3 discs, plates, springs
(69) in contact on both sides, and set to 1) Install 5 No. 3 plates (63), 4 No. 3 discs (62),
No. 4 carrier. and 24 springs (61).
a Be careful not to damage or dent the 2) Install 12 No. 4 springs (60).
thrust washers. a Free length of spring: 68 mm
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).
vi) Install seal ring (66).
48 D275A-5R
16. No. 2 housing, No. 2 carrier assembly 2) Using push tool [18], 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 [19], press fit No. 2 housing

(46) to No. 2 carrier assembly (45).
ii) Assemble needle bearing (53) to plane- a Push the bearing inner race to press fit.
2 carrier.
thrust washers.
iii) Install shaft (50) and ball (54).
iv) Install No. 2 ring gear (48).

v) Install spacer (47).
a Install with the cut side facing the carrier.
D275A-5R 49

19. No. 2 discs, plates, springs, guide pins

1) Install guide pins (35).

(46).
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).
50 D275A-5R

(33).
4) Using eyebolts [4], align No. 1 piston (34)
with guide pin position, then install No. 1
housing (33).
a Check that the spring is fitted securely in
the groove.
4) Using push tool [21] 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-
2 carrier.
thrust washers.
ii) Install shaft (24) and ball (28).
a Check that the gear rotates smooth-
ly. 6) Install spacer (17).
iii) Set No. 1 ring gear (23) to No. 1 carrier, 7) 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 [20], press fit bearing
(117) to input shaft (21) with press.
D275A-5R 51
9) Fit No. 2 sun gear (13) and install snap ring 24. Front cover
(12) to input shaft. 1) Using push tool [22], press fit bearing (143)
to front cover (19).
10) 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). a Check that the spring is fitted securely in
the groove.
52 D275A-5R
5) Using push tool [23], 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). 2) Install remaining 13 tie bolts (8).
3 Tie bolt: 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. 2 O-ring: Grease (G2-LI)
Piston Standard stroke (mm)

No.1 6
No.2 8.8
No.3 6.4
No.4 6.4
No.5 6
D275A-5R 53
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).
a Coat both the cover and transmission
case with gasket sealant.
2 Cover: Gasket sealant (LG-6)
4) Fit wiring connector (136) to cover (137).
3 Mounting bolt:
39.6 – 42.4 Nm {4.0 – 4.3 kgm}
54 D275A-5R
D275A-5R 55
D275A-5R Bulldozer
© 2007 KOMATSU
All Rights Reserved
56 D275A-5R
SEN03243-00
D275A-5R

D275A-5R 35001 and up

Power train, Part 2
Removal and installation of scavenging pump................................................................................................ 2
Disassembly and assembly of steering case assembly.................................................................................. 3
Removal and installation of final drive assembly .......................................................................................... 18
Disassembly and assembly of final drive assembly...................................................................................... 20
D275A-5R 1
Removal and installation of Installation

scavenging pump 1 q Carry out installation in the reverse order to re-
moval.
Removal
1. Remove inspection cover (1). q Refilling with oil (Power train case)
2. Drain the power train oil.

3. Remove tube (2).
4. Remove the 5 mounting bolts and scavenging

pump assembly (3).
2 D275A-5R
Disassembly and assembly of 2) Remove 16 mounting bolts, then using

steering case assembly 1 tool E1, remove steering case assembly
(4).
Special tools a Do not remove the 4 hexagon socket
head bolts.
New/Remodel
a Remove the steering case assembly
Necessity
Sym- on the opposite side in same way.
Part No. Part name
Sketch
bol
Q'ty
791-622-1110 Bracket t 1
1 01010-62095 Boltn t 1
E
01016-61690 Boltn t 1
2 796-550-1301 Wrenchn t 1
Disassembly
1. Drain hose, joint
1) Remove drain hose (1).
2) Remove joint (2).
3. Disassembly of clutch, brake assembly
1) Disassembly of brake assembly
i) Remove flange (5).
ii) Remove collar assembly (6) and
bushing (7).
2. Clutch, brake assembly

1) To install tool E1 perpendicularly, use
block [1] and jack [2], and set steering
case assembly (3) at an angle of 15°.
iii) Remove plate (8).
D275A-5R 3
iv) Loosen 4 hexagon socket head bolts x) Using eyebolts, remove drum (15) to-
uniformly and remove, then using eye- gether with disc and plate.
bolts [3] remove case (9). xi) Remove 7 discs (16), 6 plates (17),
a The inner race of the bearing will and 7 springs (18) from drum (15).
come out.
v) Remove bearing (10) from case (9).
2) Disassembly of clutch assembly

i) Remove 22 mounting bolts and hub
vi) Remove 2 brake spring case (11). (19).
vii) Remove brake piston (12). ii) Remove bearing (20) from hub.
viii) Using puller [4], remove cylinder (13). iii) Remove snap ring (21) and stopper
a The outer race of the bearing will (22).
come out.
ix) Remove 3 seal rings (14) from hub.
4 D275A-5R
iv) Remove snap ring (23). 5. Steering control valve assembly

v) Remove the 24 mounting bolts and 1) Remove mounting bolts, then using eye-
hub (24). bolts [5], remove steering control valve
vi) Remove snap ring (25). assembly (34).
vii) Remove bearing (26) from hub (24). 2) Remove 2 sleeves (35) from steering
case.
viii) Remove piston (27) from the clutch

drum. 6. Suction tube
ix) Remove 7 discs (28) and 6 plates Remove suction tube (36).
(29).
x) Remove plate (30).
xi) Separate hub (31) and clutch drum
(32).
7. Bevel pinion assembly

1) Using guide bolts [6] and forcing screws
[7], remove bevel pinion assembly (37)
and shims (38).
a Check the number and thickness of
4. Tubes the shims, and keep in a safe place.
Remove 6 tubes (33).
a When removing the tubes, be careful not
to damage the O-rings.
D275A-5R 5
2) Disassemble bevel pinion as follows. iv) Support cage (42), and use push tool
i) Remove plate (39). [8] to remove bevel pinion and bearing
(43).
ii) Remove pin (40).

v) Remove bearing (44).
vi) Remove outer races (45) and (46)
from cage (42).
iii) Hole with press so that bevel pinion

does not move, and use tool E2 to re-
move locknut (41).
vii) Remove spacer (47) and bearing (48)
from bevel pinion (49).
6 D275A-5R
8. Bevel pinion output speed sensor 3) Remove outer race (53) from cage (51).
Remove bevel pinion output speed sensor (50)
together with flange.
4) Using forcing screws [10], disconnect

retainer (54) from case.
a When removing the bevel pinion output 5) Remove forcing screws [10], then using
speed sensor from the flange and replac- eyebolts [11], remove retainer (54).
ing it, measure distance (L) between the
flange and the tip of the speed sensor.
When replacing the speed sensor, install
so that the installation dimension of the
speed sensor is (L) ± 0.2 mm.
6) Lift off bevel gear shaft, bevel gear assem-

bly (55).
9. Bevel gear shaft, bevel gear assembly

1) Set with right side of steering case at top.
2) Remove mounting bolts, then using forc-
ing screws [9]. remove right cage (51) and
shims (52).
the shims, and keep in a safe place.
D275A-5R 7
7) Disassembly of bevel gear shaft, bevel 9) Remove outer race (63) from cage (61).
gear assembly
i) Using puller [12], remove bearing (57)
from bevel gear shaft (56).
ii) Remove reamer bolt (58), then re-
move bevel gear (59) from bevel gear
shaft (56).
iii) Using puller [13], remove bearing (60)

from bevel gear shaft (56).
8) Turn over steering case, then remove left

cage (61) and shims (62).
the shims, and keep in a safe place.
8 D275A-5R
Assembly 3) Set with right side of steering case at top.

a Clean all parts, check that there is no dirt or 4) Assemble bevel gear and shaft assembly
damage, and coat the sliding surfaces of all as follows.
parts with engine oil before installing. i) Using push tool [15], press fit bearing
a After press fitting the bearing, drop approx. 6 (60) to shaft (56).
cc of oil (E030-DH or E010-DH) on the bear-
ing, and rotate it 10 times.
a When expand fitting the bearing before cooling
with dry ice, drop approx. 6 cc of oil (E030-DH
or E010-DH) on the bearing, and rotate it 10
times.
a Check that the snap ring is fitted securely in
the groove.
a Coat blind plugs with thread tightener (LT-2),
then after assembly, caulk, 2 places on oppo-
site sides.
1. Bevel gear shaft, bevel gear assembly

1) Using push tool [14], press fit outer race ii) Set bevel gear (59) to bevel gear shaft
(63) to cage (61). (56), then fit reamer bolt (58) and
tighten nut.
3 Mounting bolt:
215.6 – 274.4 Nm {22 – 28 kgm}
iii) Using push tool [16], press fit bearing
(57) to shaft (56).
2) Assemble shim (62) and install cage (61).

a Assemble the same amount and
thickness of shims that was removed.
q Standard shim thickness: 2mm
q Types of shim thickness:
0.1 mm, 0.2 mm, 0.5 mm 5) Turn over steering case so that right side
3 Mounting bolt: is at top, then install bevel gear shaft and
98.1 – 122.6 Nm {10 – 12.5 kgm} bevel gear assembly (55).
D275A-5R 9
6)Using eyebolts [11] and guide bolt [17], 9) Set steering case assembly horizontally.
install retainer (54). 10) Adjust preload of cage bearing.
3 Mounting bolt: q Push tip of tooth of bevel gear (59)
98.1 – 122.6 Nm {10 – 12.5 kgm} with push-pull scale [19] and measure
rotating torque of bevel gear shaft.
a Standard value for rotating torque
(center of bevel gear shaft):
3.9 – 4.9 Nm {0.4 – 0.5 kgm}
a (At tip of bevel gear tooth):
18.6 – 23.7 Nm {1.9 – 2.4 kgm}
a When measuring the rotating torque,
rotate the bevel gear thoroughly (10 –
20 times) before measuring.
a If the rotating torque is not within the
standard value, adjust the shim thick-
ness at the left and right cages as fol-
lows:
7) Using push tool [14], press fit outer race If value is LOW, ADD shims
(53) to cage (51). If value is HIGH, REMOVE shims
8) Using guide bolt [18], install right case 2. Bevel pinion

(51) and shims (52). 1) Assemble bevel pinion as follows.
a Assemble the same amount and i) Using push tool [20], press fit bearing
thickness of shims that was removed. (48) to bevel pinion (49) with press.
q Standard shim thickness: 2mm ii) Install spacer (47).
q 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}
10 D275A-5R
iii) Using push tool [21], press fit outer vii) After tightening locknut, turn locknut in
race (46) to cage (42). direction of loosening to a point where
a Press fit outer race (46) in the same 1 of 5 pin insertion holes in pinion
way. shaft and 1 of 8 pin insertion holes in
locknut are aligned.
q Angle to loosen: 0 – 9°
viii) Install pin (40) in aligned hole.
iv) Install cage (42) to bevel pinion (49).

v) Using push tool [22], press fit bearing
(44) with press.
ix) Fit plate (39).
2 Mounting bolt:
3 Mounting bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
vi) Hold with press so that bevel pinion

does not move, use tool E2 to tighten
locknut (41).
a Rotate the cage while tightening.
a After tightening the locknut, check
that the bevel pinion rotates smoothly.
2 Locknut: Thread tightener (LT-2)
3 Mounting bolt:
392 – 441 Nm {40 – 45 kgm}
D275A-5R 11
2) Using guide bolt [6], install bevel pinion iii) If the result of the measurement
assembly (37) and shims (38). shows that the backlash is not correct,
a Assemble the same amount and adjust as follows.
thickness of shims that was removed. a When adjusting the shim thickness,
q Standard shim thickness: 2mm add or remove shims on the left or
q Types of shim thickness: right sides. However, to prevent the
0.1 mm, 0.2 mm, 0.5 mm preload of the bearing from changing,
3 Mounting bolt: always keep the same total thickness
98.1 – 122.6 Nm {10 – 12.5 kgm} of shims on the left and right. (Adjust
by moving shims from one side to the
opposite side.)
q When backlash is too small
Reduce the shim thickness on the
right side of the chassis and add the
same shim thickness to the left side.
(Move the bevel gear in direction (A).)
3. Adjusting backlash, tooth contact

1) Adjusting backlash
i) Put probe of dial gauge [23] 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-
tion). q When backlash is too large
q Standard value of backlash: Reduce the shim thickness on the left
0.25 – 0.33 mm side of the chassis and add the same
a Measure at 3 places on diametrically shim thickness to the right side.
opposite sides. (Move the bevel gear in direction (B).)
12 D275A-5R
2) Adjusting tooth contact Adjusting

Testing If the result of the inspection shows that
i) Coat the tooth face of the bevel pinion the correct tooth contact is not being
lightly with red lead (minimum), then obtained adjust again as follows.
rotate the bevel gear forward and i) When bevel pinion is too far from cen-
backward and inspect the tooth con- ter line of bevel gear:
tact pattern left on the bevel gear Contact is at small end of the convex
teeth. tooth face of the bevel gear and at the
ii) The standard value for the tooth con- big end of the concave tooth face.
tact is as follows. (from tip of bevel pin- q Correct as follows:
ion tooth) Adjust the shim thickness at the bevel
a. Center of tooth contact: pinion end and move the bevel pinion
20 – 40% of tooth width (from in direction (A).
small end) q Or, adjust the shim thickness and
b. Width of tooth contact: move the bevel gear in direction (B).
30 – 50% of tooth width. After adjusting, check the tooth con-
c. Center of tooth contact: tact pattern and backlash again.
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.
a If the gears are adjusted to this pat-
tern, the tooth contact will be correct
when load is applied.
ii) When bevel pinion is too close to cen-

ter 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.
q Correct as follows:
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 con-
tact pattern and backlash again.
D275A-5R 13
4. Bevel pinion output speed sensor 3) Install 6 tubes (33).

Install bevel pinion output speed sensor (50). 2 O-ring: Grease (G2-LI)
a Install the stamped make [CB UP] at the
rotation sensor flange portion so that it
faces to the top of the steering case.
a Adjust the transmission speed sensor. For
details, see Testing and adjusting, "Adjust-
ing transmission speed sensor".
7. Assembly of clutch, brake assembly

a Use the same procedure to assembly on
bolt the left and right sides.
1) Assembly of clutch assembly
i) Instal clutch drum (32) and hub (31) to
the shaft.
5. Suction tube ii) Install plate (30).
Install suction tube (36). iii) Install 6 plates (29) and 7 discs (28).
iv) Install piston (27) to clutch drum.
6. Steering control valve assembly

1) Install 2 sleeves (35) to steering case. v)Install seal rings (64) and (65) to hub
2 O-ring: Grease (G2-LI) (24).
2) Fit O-ring to steering case end, then using a Install the seal rings as shown in the
guide bolt [24] and eyebolts [5], install figure.
steering control assembly (34). 2 Seal rings: Grease (G2-LI)
14 D275A-5R
vi) Install bearing (26) and snap ring (25) 2) Assembly of brake assembly
to hub (24). i) Install seal rings (66) and (67) to cylin-
vii) Set hub (24) to the clutch drum, and der (13).
install snap ring (23). a The seal ring must be installed facing
viii) Install hub (24) with the 24 mounting in the correct direction. Assemble as
bolts. shown in the diagram.
3 Mounting bolt: 2 Seal rings: Grease (G2-LI)
98.1 – 122.6 Nm {10 – 12.5 kgm}
ii) Install 3 seal rings (14) to brake hub

ix) Install stopper (22) and snap ring (21) (19).
to the hub. iii) Install cylinder (13) to brake hub (19).
a The outer race of the bearing is press
fitted.
x) Install bearing (20) to hub (24).

xi) Install hub (19) with the 22 mounting
bolts. iv) Fit O-ring and install brake drum.
3 Mounting bolt: 2 O-ring: Grease (G2-LI)
157 – 196 Nm {16 – 20 kgm} v) Set brake outer drum (15) to clutch
outer drum.
vi) Assemble discs (16), plates (17), and
springs (18).
D275A-5R 15
vii) Install piston (12), and brake springs x) Install guide bolts [26] to cylinder (13).
(11).
a Install 2 pieces as 1 set.
a Install stamped mark (A) facing the
position shown in the diagram.
xi) Fit O-ring, then using eyebolts [3], in-

stall case (9).
xii) Using push tool [26], push inner side
of bearing (10) and press fit with
press.
a After press fitting with the press,
install 4 hexagon socket head bolts.
a After removing from the press, fully
tighten the hexagon socket head
bolts uniformly.
viii) Using push tool [25], press fit bearing

(10) to brake case (9).
ix) Install bushing (7) and collar assembly
(5).
16 D275A-5R
xiii) Install plate (8). 9. Drain hose, joint

3 Mounting bolt: 1) Install joint (2).
58.8 – 73.5 Nm {6.0 – 7.5 kgm} 2) Install drain hose (1).
xiv) Fit O-ring and install flange (5).
3 Mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
10. Cover
If cover (68) at rear of steering case has been
removed, install new gasket.
8. Clutch, brake assembly a Coat both surfaces of the gasket with gas-
1) To install tool E1 perpendicularly, use ket sealant.
block [1] and jack [2], and set steering 2 Gasket: Gasket sealant (LG-1)
case assembly (3) at an angle of 15°. a Tighten connector (69) of the bevel pinion
output s peed sensor with the cover
mounting bolts.
2) Fit O-ring using tool E1. Install brake and

carrier assembly (4).
3 Mounting bolt:
98.1 – 122.6 Nm {10 – 12.5 kgm}
D275A-5R 17
Removal and installation of final

drive assembly 1
Special tools
New/Remodel
Sym-
Necessity
Part No. Part name
bol
Sketch
Q'ty
791-627-1320 Shackle t 2
J1
791T-627-1810 Plate t 1 Q
01010-82090 Bolt t 2 6. Remove the 3 final drive bolts and install tool J1.
[*1]
Removal
1. Expand the track shoe assembly. For details, 7. Using tool J1, sling final drive assembly (5) tem-
see "Expanding track shoe assembly". porarily.
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. [*2]
5. Using a forcing screw, pull out the drive shaft (4).

a If the shaft cannot be pulled out, raise the
shoe grouser with a jack and move the
sprocket forward or in reverse until the
shaft can be pulled out.
a Pull out the shaft until it comes in contact
with the sprocket.
9. Remove the mounting bolts and lift off the final
drive assembly. [*3]
a Remove the sprocket teeth first so that the
mounting bolts can be removed easily.
4 Sprocket tooth: 25 kg
4 Final drive assembly: 1,700 kg
18 D275A-5R
Installation
moval.
[*1]
3 Mounting bolt:
456 – 569 Nm {46.5 – 58 kgm}
[*2] [*3]
3 Mounting bolt:
1,160 – 1,440 Nm {118 – 147 kgm}
3 Sprocket tooth mounting bolt:
1,080 – 1,270 Nm {110 – 130 kgm}
D275A-5R 19
Disassembly and assembly of 3. Cover

final drive assembly 1 Using hanging bolt [1], remove cover (4).
Special tools
New/Remodel
Necessity
Sym-
bol Part No. Part name
Sketch
Q'ty
791-627-1400 Remover t 1
2 790-101-2102 Puller t 1
790-101-1102 Pump t 1
791-627-1600 Remover t 1
3 790-101-2102 Puller t 1
4. Hub
790-101-1102 Pump t 1 1) Remove plate (5).
791-627-1200 Remover t 1 2) Using hanging bolt [2], remove hub (6).
4 790-101-2102 Puller t 1
J
790-101-1102 Pump t 1
791-627-1300 Installer t 1
5 790-101-2102 Puller t 1
790-101-1102 Pump t 1
791-627-1500 Installer t 1
6 790-101-2102 Puller t 1
790-101-1102 Pump t 1
7 791-627-1280 Installer t 1
Disassembly
1. Draining oilì 5. Sprocket assembly
Remove the drain plug and drain the oil from the 1) Remove holder (7).
final drive case.
6 Final drive case: 40 l
2. Sprocket, wear guard, and plate

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).
20 D275A-5R
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).
a Store the floating seal in a safe place so
that it will not be damaged.
5) Turn over the sprocket hub assembly and

remove floating seal cover (11) and outer
races (12) and (13).
6) Remove floating seal (14) from floating seal
cover (11).
a Store the floating seal in a safe place so
that it will not be damaged.
D275A-5R 21
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 accord-

ing to the following procedure.
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).
22 D275A-5R
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 as-
sembly.
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).
D275A-5R 23
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).
a 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
(52) from gear (53).
24 D275A-5R
Assembly 3. Gear assembly

a Clean the all parts and check them for dirt or 1) Using push tool [13], press fit bearings (52)
damage before installing. and (51) to gear (53).
a Coat sliding surfaces of each part with engine oil q Press fitting force for bearing:
before installing. 0.9 – 2.6 kN {9 – 25 tons}
a Check that each snap ring is fitted to the groove 2) Install gear assembly (50).
securely. a Lower and install the gear assembly
slowly so that the oil seal lip will not be
1. Oil seal damaged.
1) Using push tools [10] and [11], install oil
seals (56) and (55).
a Install the lower oil seal with the pres-
sure receiving side down and the upper
oil seal with the pressure receiving side
up.
a Apply gasket sealant thinly to the inside
of the housing hole and wipe off the pro-
jected part.
2 Oil seal lip: Grease (G2-LI)
2 Oil seal fitting surface:
4. Cage assembly
1) Assemble the cage assembly according to
i) Using push tools [14] and [15], install oil
seals (49) and (48).
a Install the lower oil seal with the pres-
sure receiving side down and the upper
oil seal with the pressure receiving side
up.
a Apply gasket sealant thinly to the inside
of the housing hole and wipe off the pro-
jected part.
2. Outer race 2 Oil seal lip: Grease (G2-LI)
Using push tool [12], press fit outer race (54). 2 Oil seal fitting surface:
q Press fitting force for outer race: Gasket sealant (LG-5)

1 – 13 kN {0.1 – 1.3 tons}
D275A-5R 25
2) Using push tool [16], press fit outer race

(47).
q 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}
26 D275A-5R
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
4.55 4.65 1 2 2.50 Thread tightener (LT-2)
4.65 4.75 7 1 1 2.55 3 Mounting bolt:
4.75 4.85 4 2 2.60 235 – 285 Nm {23.5 – 29.5 kgm}
4.85 4.95 1 1 2 2.65
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 [18], 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 q 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 [17], press fit bearing
(43).
11 – 32 kN {1.1 – 3.2 tons}
iii) Install collar (42).
D275A-5R 27
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.
a Direct the planetary gear end hav-
ing a projection out of the machine
6) Install gear (35) to hub (40). body.
2 Mounting bolt:
3 Mounting bolt:
235 – 285 Nm {23.5 – 29.5 kgm}
7) Install plate (36).
2 Mounting bolt:
3 Mounting bolt:
235 – 285 Nm {23.5 – 29.5 kgm}
iv) Using tool J3, press fit planetary gear

shaft (24).
a 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}
6. Carrier assembly a After tightening the holder bolts, check
1) Assemble the carrier assembly according to that the gear turns lightly.
a 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 [19], press fit 2 bearing
outer races (26D).
q Press fitting force for outer race:
5 – 20 kN {0.5 – 2 tons}
28 D275A-5R
vi) Using push tool [20], 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 [21], press fit sun gear shaft
(34) to sun gear (33) with a press.
q Press fitting force for shaft:
103 – 156 kN {10.5 – 15.9 tons}
2) Install holder (31).
2 Mounting bolt:
3) Using push tool [22], press fit inner race (32)
to sun gear shaft (34).
q Press fitting force for inner race:
13 – 25 kN {1.3 – 2.6 tons} 9. Cover assembly
1) Install ring gear (21) and plate.
a 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).
D275A-5R 29
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
a Degrease the O-ring and O-ring fitting floating seal cover (11).
surfaces thoroughly and dry them be- a Degrease the O-ring and O-ring fitting
fore installing. surfaces thoroughly and dry them be-
a After installing the floating seal, check fore installing.
that its slant is within 1mm. a After installing the floating seal, check
that its slant is within 1mm.
6) Install the O-ring and floating seal cover

(16). 2) Using push tool [23] press fit outer races
a Set the outside cut part of the floating (13) and (12).
seal cover down. q Press fitting force for bearing:
17 – 36 kN {1.7 – 3.7 tons}
7) Using a hanging bolt, install the O-ring and

cover assembly (15). 3) Install the O-ring and floating seal cover
a The mating faces of the case and cover (11).
must be free from bruise, rust, oil,
grease, dirt, and water.
3 Mounting bolt:
455 – 565 Nm {46.5 – 58 kgm}
30 D275A-5R
4) Set bearing (9) to sprocket hub assembly

(8).
11. Hub
1) Using hanging bolt [2], install hub (6).
5) Using hanging bolt [3], set sprocket hub as- 2) Install plate (5).
sembly (8) to the cover. 2 Mounting bolt:
a Check that the sliding surfaces of the Thread tightener (LT-2)
floating seal are free from dirt and apply 3 Mounting bolt:
engine oil to them thinly. 235 – 285 Nm {23.5 – 29.5 kgm}
6) Using tool J6, press fit bearing (9).
a Press fit the bearing, turning the sprock-
et hub assembly.
11 – 53 kN {1.1 – 5.4 tons}
12. Cover
Using hanging bolt [1], install the O-ring and
cover (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}
D275A-5R 31
13. Sprocket, wear guard, and plate

1) Install plate (3).
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:
1,078 – 1,274 Nm {110 – 130 kgm}
14. Refilling with oil (Final drive case)

Tighten the drain plug and add oil through the oil
filler.
a 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 l
32 D275A-5R
D275A-5R 33
D275A-5R Bulldozer
© 2007 KOMATSU
All Rights Reserved
34 D275A-5R
SEN03244-01
D275A-5R

D275A-5R 35001 and up

Undercarriage and frame, Part 1
Removal and installation of track frame assembly.......................................................................................... 2
Removal and installation of recoil spring assembly ........................................................................................ 6
Disassembly and assembly of recoil spring assembly .................................................................................. 10
Removal and installation of idler assembly ................................................................................................... 12
Disassembly and assembly of idler assembly .............................................................................................. 13
Removal and installation of track roller assembly ......................................................................................... 16
Disassembly and assembly of track roller assembly .................................................................................... 18
Removal and installation of carrier roller assembly ...................................................................................... 21
Disassembly and assembly of carrier roller assembly .................................................................................. 22
Removal and installation of 1st bogie assembly ........................................................................................... 25
Removal and installation of 2nd, 3rd and 4th bogie assembly...................................................................... 31
Disassembly and assembly of bogie assembly ............................................................................................ 37
D275A-5R 1
Removal and installation of 2) Set stands [2] on both sides of the front main
frame of the machine body.
track frame assembly 1 3) Set hydraulic jack [3] under the center of the
equalizer bar and raise the front part of the
Special tool
machine body.
New/Remodel
4) Set a block under the raised front part of the
track frame to secure safety during work.
Necessity
Sym
Part No. Part name
a After setting stands [1] and [2], set the jacks
Sketch
bol
or ripper again as auxiliary supports.
Q'ty
L14 791T-630-1380 Bracket t 6 Q
Removal
1. Remove the blade assembly. For details, see
"Removal of blade assembly".
2. Expand the track shoe assembly. For details,

see "Expanding track shoe 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 ma-
chine body.
2 D275A-5R
7. Remove the mounting nuts and cover (2). [*1] 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.
a Perform this step for only the right side of the
10. Pull out pin (5). [*2] single tilt specification or both track frames
a If the equalizer bar hole is not aligned with of the dual tilt specification.
the track frame hole, the pin cannot be
pulled out easily. Accordingly, adjust the 14. Remove the mounting bolts and pull out cover
slinging height of the track frame when pull- (11).
ing out the pin. a Take care since hoses are connected inside
k If the track frame assembly on the oppo- the cover.
site 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
D275A-5R 3
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. [*4]

a There are 2 mounting bolts on the track
frame side and 6 on the pivot shaft side.
a Take care not to damage the O-ring.
a Prepare an oil container to receive the oil
from the pivot shaft case.
6 l
Pivot shaft case: 10l
20. Lift off track frame assembly (18). [*5]

4 Track frame assembly: 5,050 kg
17. Remove seal (15) and cover (14) together.[*3]

single tilt specification or both track frames
of the dual tilt specification.
4 D275A-5R
Installation [*4]
q Carry out installation in the reverse order to a Degrease the fitting face of the seal and apply
removal. gasket sealant (LG-6) to it.
a Do not install the track frame with torsional de-
[*1] formation left in seal (19).
Installation procedure for cover (4)
1) Tighten the mounting bolts of cover (4) with fin-
gers.
2) Install cover (2) and secure it with the nuts.
3) Tighten the mounting bolts of cover (4) securely.
4) Install grease tube (3).
[*5]
2 Bushing contact surface of pivot shaft:
Lubricant containing molybdenum disul-
fide (LM-P)
a When replacing the pivot shaft bushing of the
track frame assembly, press fit a new bushing
[*2]
with the bushing mating face up.
k When aligning the pin holes, never insert
your fingers in the pin holes. q Refilling with oil (Pivot shaft case)
a Direct the grease holes of the pins down. Add oil through the oil filler to the specified
q Left pin: Outside of machine body level.
3
q Right pin: Inside of machine body
Plug: 127 – 177Nm {13 – 18kgm}
2
5
Equalizer bar side bushing: Grease (G2-LI) l (EO30-DH)
Pivot shaft case: 10l
[*3]
a When fitting the seal, degrease the fitting face
and apply gasket sealant (LG-6) to it.
a Do not fit the seal with torsional deformation left
in it.
D275A-5R 5
Removal and installation of recoil

spring assembly 1
Special tools
New/Remodel
Necessity
Sym
Part No. Part name
Sketch
bol
Q'ty
791-730-1110 Bolt t 6
M 1 01580-12722 Nut t 6
01643-32780 Washer t 6
6. Remove covers (4).
Removal a Remove both inside and outside covers.
1. Expand the track shoe assembly. For details, [*2]
k Never stand in front of the idler yoke to
7. Using hanging bolt [1], pull out pin (5). [*3]
prevent danger.
2. Using an oil pump, drain the oil from the recoil

cylinder.
6 Recoil spring chamber: Approx. 83l l
4. Loosen mounting bolts (2) of the guide plate.

[*1]
8. Lift off idler and recoil spring assembly (6).

a 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
6 D275A-5R
9. Disconnect recoil spring assembly (7) from idler

yoke assembly (8) according to the following
procedure. [*4]
1) Lower idler yoke assembly (8) to the ground
and sling recoil spring assembly (7).
a At this time, check that the welded parts of
recoil spring assembly (7) are not damaged.
a Protect the chromium-plated bushing by
covering it with cloths.
k If the loosening torque does not lower af-

ter 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 assembly can jump out for-
ward in this case, remove the bolts ac-
cording to the following procedure.
2) Loosen idler yoke assembly mounting bolts

(9) gradually in the diagonal order. [*5]
k Never stand in front of the idler yoke and
at the rear of the recoil cylinder to pre-
vent danger.
k Never stand in front of the idler yoke and

at the rear of the recoil cylinder to pre-
vent danger.
i) Prepare the following parts (Tool M1).
q Bolt [2] (6 pieces): 791-730-1110
q Nut [3] (6 pieces): 01580-12722
q Washer [4] (6 pieces): 01643-32780 (Re-
used)
k Since the installed load of about 372,700 ii) Remove the 6 bolts marked with * and install
N {38,000 kg} for the recoil spring is ap- bolts [2], nuts [3], and washers [4].
plied to the idler yoke, do not loosen the
mounting bolts suddenly but loosen
them gradually until clearance (a) be-
tween the idler yoke and recoil spring be-
comes 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.
a 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.
D275A-5R 7
a Check that dimension (L) is less than 361 11. Supply grease through lubricator (13) and re-
mm. move cylinder (14) and piston assembly (15).
a Tighten bolts [2] until they come in contact [*6]
with the bottom of the yoke threads.
iii) Remove the 12 bolts other than the ones
marked with *.
iv) Secure bolts [2] with a spanner and loosen
2 nuts [3] on a diagonal line simultaneously
and gradually.
a 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).
a 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).
8 D275A-5R
14. Remove holder (20) from the recoil spring as- Installation
sembly. q Carry out installation in the reverse order to re-
moval.
[*1]
a Adjust the clearance of the idler. For details, see
Testing and adjusting, "Adjusting clearance of
idler".
[*2]
2 Cover mounting bolt:
3 Cover mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
[*3]
your fingers in the pin holes.
a Before inserting the pin, align the recoil cylinder
hole with the track frame hole.
[*4]
a If the recoil spring set bolt is broken or the shaft
end nut has come off, assemble according to
Assembly of recoil spring assembly.
[*5]
2 Idler yoke assembly mounting bolt:
3 Idler yoke assembly mounting bolt:
1,150 – 1,440 Nm {118 – 147 kgm}
[*6]
a Supply grease to the cylinder to prevent air from
staying in the cylinder according to the following
procedure.
i) Supply grease of about 0.9 l into the cylinder.
ii) Set the cylinder with the drain hole up and loos-
en the lubricator.
iii) Push in the piston until it is stopped by the stop-
per to discharge air and excessive grease.
iv) Tighten the lubricator.
3 Lubricator: 59 – 88 Nm {6 – 9 kgm}

Pour engine oil (EO30) in the spring chamber up
to the center.
3 Plug: 127 – 177 Nm {13 – 18 kgm}
5 Recoil spring chamber (Each side):
l
Approx. 83l
D275A-5R 9
Disassembly and assembly of 3. Release the oil pressure gradually to reduce the
spring tension to 0 (zero).
recoil spring assembly 1
4. Remove rear pilot (5), spacer (6), bolt (7), and
Special tools
pilot (8) from spring (4).
New/Remodel
Necessity
Sym
Part No. Part name
Sketch
bol
Q'ty
791-685-8502 Compressor t 1
790-201-2780 Spacer t 1
791-635-3160 Extension t 1
M 3
Cylinder
790-101-1600 t 1
(686kN {70ton})
790-101-1102 Pump t 1
Disassembly
Assembly
1. Set recoil spring assembly (1) to tool M3.
1. Install pilot (8), bolt (7), spacer (6), and rear pilot
k Since the installed load of the spring is
(5) to spring (4) and set them to M3.
k Since the installed load of the spring is
large and dangerous, set the spring as-
sembly securely.
large and dangerous, set each part se-
a Installed load of spring: curely.
372,700 N {38,000 kg}
2. Apply oil pressure gradually and compress the
spring to the standard length.
a Installed length of spring (a):
Approx. 1,045 mm
a 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).
10 D275A-5R
3. Install nut (3) to bolt (7), then install lock plate

(2).
a 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.
D275A-5R 11
Removal and installation Installation

of idler assembly 1 q Carry out installation in the reverse order to re-
moval.
Removal
1. Remove the blade assembly. For details, see [*1]
"Removal of blade assembly". a Install both idler assemblies with the oil supply
plugs directed to the left.
2. Expand the track shoe assembly. For details, a Tighten the idler cap mounting bolts in the fol-
see "Expanding track shoe assembly". lowing order.
Tightening order:
3. Remove covers (1) and (2). 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: Thread tightener (LT-2)
3 Mounting bolt:
1,180 – 1,470 Nm {120 – 150 kgm}
a After tightening the idler cap mounting bolts,
check that clearance (c) between the idler cab
bottom and the yoke is 0.
4. Sling idler assembly (3) temporarily and remove

cap (4). [*1]
5. Lift off idler assembly (3).

4 Idler assembly: 340 kg
12 D275A-5R
Disassembly and assembly 6. Using puller [4], remove seal guide (6), retainer
(7), and plate (8).
of idler assembly 1
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
791T-630-1310 Plate t 1 Q
791-630-1220 Rod t 4
790-101-2510 Block t 2
790-101-2570 Plate t 4
1 01643-31445 Washer t 4
7. Remove seal guides (2) and (6) from retainers
01580-01411 Nut t 4
L (3) and (7).
Puller
790-101-2102 t 1
(294kN {30ton})
790-101-1102 Pump t 1
2 791-515-1520 Installer t 1
3 791-630-1240 Push tool t 1
4 791-601-1000 Oil pump t 1
Disassembly
1. Remove the oil filler plug and drain the oil.
6 l (G0140)
Idler: 0.8 – 0.9l
2. Set idler assembly (1) to block [1].

8. Remove floating seals (9) from seal guides (2)
3. Remove the mounting bolts, then remove seal and (6).
guide (2), retainer (3), and plate (4), using forc- a Keep the floating seals so that they will not
ing screw [2]. be damaged.
9. Remove floating seals (10) from seal guides (3)

and (7).
a Keep the floating seals so that they will not
be damaged.
4. Turn over the idler assembly.
5. Remove the mounting bolts, then remove shaft

(5) and retainer, using hanging bolt [3].
D275A-5R 13
10. Remove bushing (11) from idler (12).
3. Fit the O-ring and install retainer [3] and plate (4)
Assembly to the idler.
a Clean the all parts and check them for dirt or
damage.
1. Set bushing (11) and tool L1 to idler (12) to

press fit bushing (11).
a Center the bushing with a plastic hammer
first, then press fit it with the puller.
a Press fit the bushing so that distance (a)
from the idler end to the bushing top will be
as follows.
q Press fitting distance (a): 17 ± 0.5 mm
4. Using hanging bolt [3], set idler (12) to shaft (5).

a Set a block (about 200 mm) under the idler.
5. Turn over the idler assembly.

a 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).
a When installing the floating seals, thorough-
ly 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.
a After installing each floating seal, check that
its slant is within 1mm and its projection (a)
is 7 – 11 mm.
14 D275A-5R
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.
5
a For precautions for installing the floating Idler: 0.8 – 0.9l l (G0140)
3
seals, see a in step 2 above. 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.
q Press fitting force for seal guide:
49 – 83.4 kN {5 – 8.5 tons}
a Press fit the seal guide so that distance (b)

from the shaft end to the seal guide top will
be as follows.
q Press fitting distance (b): 96 ± 0.2 mm
a Turn over the idler assembly and press fit
seal guide (6) on the opposite side similarly.
D275A-5R 15

track roller assembly 1
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
790-401-1700 Lifting toolt t 1
790-401-1761 Adapter t 1
5
L 790-401-1540 Shackle t 2
790-401-1770 T-bolt t 2 Note 2: Sling and secure 1st bogie assembly
14 791T-630-1380 Bracket t 4 Q (1) with a lever block, etc.
A fixing tool can not be used for the 1st
bogie assembly.
Removal
1. Loosen the track shoe tension. For details, see
"Expanding track shoe assembly".
2. Install tool L14 and secure bogie assembly (1).
3. Operate the blade and ripper to raise the ma-

chine body until track roller assembly (2) is float-
ed above the track shoe.
a Operate the blade and ripper slowly with the
engine at low speed.
a When removing track roller assembly (2),
secure the related bogie assemblies accord- 4. Loosen the mounting bolts of roller cap (3). [*1]
ing to the following table. a Loosen both inside and outside mounting
Track roller Bogie assembly to be bolts.
assembly to be secured with tool a Do not remove the mounting bolts.
removed Location Related bogie
1st roller Note 1 2nd bogie
2nd roller 2nd bogie Note 2
3rd roller 2nd bogie 3rd bogie
4th roller 3rd bogie 2nd bogie
5th roller 3rd bogie 4th bogie
6th roller 4th bogie 3rd bogie
7th roller 4th bogie –
Note 1: Set block [1] to prevent 1st bogie
assembly (1) from lowering.
A fixing tool can not be used for the 1st
bogie assembly.
16 D275A-5R
5. Operate the blade and ripper to lower the ma- 3 Roller cap mounting bolt:
chine body. 824 – 1,030 Nm {84 – 105 kgm}
a Operate the blade and ripper slowly.
6. Remove the mounting bolts and roller cap.[*2]

a Take care not to damage the dowel pin.

chine body until track roller assembly (2) is sep-
arated from the bogie. [*3]
[*3]
Types of track roller assembly
S: Track roller assembly (Single flange)
D: Track roller assembly (Double flange)
a Install the track roller assembly with the oil filler
plug out.
8. Pull track roller assembly (2) out of the machine

body. [*4]
4 Track roller assembly (Single frange):
150 kg
4 Track roller assembly (Double frange):
165 kg
Installation
moval.
[*4]
[*1] [*2] When installing the 1st track roller assembly (single
Install the track roller assembly according to the fol- 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 to
a irect the oil filler of the track roller assembly 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.
a 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).
a Take care not to break the dowel pin.
2 Roller cap mounting bolt:
D275A-5R 17
Disassembly and assembly of 6. Using a press, remove seal guide (6), retainer
(7), and plate (8) from the shaft.
track roller assembly 1
7. Remove seal guides (2) and (6) from the retain-
Special tools
ers (3) and (7).
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
6 791T-630-1320 Plate t 1 Q
7 791T-630-1330 Push tool t 1 Q
L
8 791-651-1510 Installer t 1
9 791-601-1000 Oil pump t 1
Disassembly
6 l
Track roller: Approx. 0.75 – 0.85l 8. Remove floating seals (9) from seal guides (2)
and (6).
2. Set track roller assembly (1) to block [1]. a Keep the floating seals so that they will not
be damaged.
3. Remove the mounting bolts and remove seal
guide (2), retainer (3), and plate (4) together by 9. Remove floating seals (10) from seal guides (3)
using forcing screw [2]. and (7).
4. Turn over the track roller assembly. be damaged.
5. Remove the mounting bolts and remove shaft

(5) and retainer together by using hanging bolt
[3].
10. Remove 2 bushings (11) from roller (12).
18 D275A-5R
Assembly 5. Using tool L7, install floating seals (9) to seal

a Clean the all parts and check them for dirt or guides (2) and (6).
damage. a When installing the floating seals, thorough-
1. Set roller (12) to a press and press fit bushing them (hatched portion) and O-rings. Take
(11) by using tool L6. care that dirt will not stick to the contact sur-
a Center the bushing with a plastic hammer faces of the floating seals.
first, then press fit it with the press. a After installing each floating seal, check that
a Press fit the bushing so that distance (a) its slant is within 1mm and its projection (a)
from the roller end to the bushing top will be is 7 - 11 mm.
as follows.
q Press fitting distance (a): 17 ± 0.5 mm
q 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.
q 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.
a Check that the plates can be turned smooth-
ly with hand.
D275A-5R 19
a Press fit the seal guide so that distance (c)

be as follows.
Press fitting distance (c): 64.2 ± 0.2 mm
a After press fitting the seal guide, check that
its slant from the shaft is less than 0.4 mm.
a Turn over the track roller assembly and
press fit seal guide (6) on the opposite side
similarly.
7. Using tool L9, supply the specified quantity of oil

and tighten the oil filler plug.
5 l (G0140)
Track roller: 0.75 – 0.85l
3 Oil filler plug:
156.8 – 254.8 Nm {16 – 26 kgm}
20 D275A-5R

carrier roller assembly 1
Removal
2. Using hydraulic jack [1], raise the track shoe.
3. Lift off carrier roller assembly (1). [*1]

4 Carrier roller assembly: 60 kg
Installation
moval.
[*1]
2 Carrier roller assembly mounting bolt:
D275A-5R 21
Disassembly and assembly of 7. Remove bearing outer race (7) from the roller.
carrier roller assembly 1 8. Using puller [3], remove seal guide (8) and bear-
ing inner race (9) together.
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
10 790-102-1891 Nut wrench t 1
11 791-675-1510 Installer t 1
L
12 791T-630-2410 Push tool t 1 Q
13 791-601-1000 Oil pump t 1
Disassembly
9. Remove floating seal (10) from seal guide (8).
a Drain the oil, turning the shaft.
6 l
Carrier roller: Approx. 0.6 – 0.7l
2. Set carrier roller assembly (1) to block [1].
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.
22 D275A-5R
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.
a Press fit the bearing inner race, turning the 8. Using tool L11, install floating seal (10) to seal
roller. Continue press fitting until the roller guide (8).
becomes heavy to turn. a When installing the floating seals, thorough-
is 7 – 11 mm.
5. Using tool L10, tighten nut (4).

3 Nut: 98 Nm {10 kgm}
a After the nut is tightened, if the nut hole is
not aligned with the shaft hole, align them by
loosening the nut.
6. Install ring (3).

a Check that the end play (the clearance be-
tween the bearing and nut) is 0 – 0.22 mm.
D275A-5R 23
9. Fit the O-ring and install seal guide (8), match- 12. Using tool L13, supply the specified quantity of
ing it to the dowel pin. oil and tighten the oil filler plug.
5 Carrier roller: 0.6 – 0.7 l (GO140)

3 Oil filler plug:
157 – 255 Nm {16 – 26 kgm}
10. Using tool L11, install floating seal (12) to seal

guides (11).
a For precautions for installing the floating
seal, see a in step 8 above.
11. Using tool L12, press fit seal guide (11).

a Press fit the seal guide so that distance (b)
be 160 ± 0.2 mm.
a After press fitting the seal guide, check that
its slant from the shaft is less than 0.4 mm.
24 D275A-5R
Removal and installation of 1st

bogie assembly 1
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
14 791T-630-1380 Bracket t 2 Q
22
L 790-401-1761 Adapter t 1
791-630-1860 Bracket t 1 8. Set tool L22 and remove roller caps (3).
23
791-630-1870 Bracket t 1
Removal
1. Remove the undercover.
2. Using tool L14, secure 2nd bogie assembly (1).
9. Using tool L22, remove track roller assembly

(6).
a When removing the track roller assembly,
balance it.
4 Track roller assembly: 150 kg
3. Expand the track shoe assembly. For details,


chine body until the track roller of 2nd bogie as-
sembly (1) is floated above the track link.
k Set stands or blocks under the front and
rear parts of the frame so that the ma-
chine 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.
a 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.
a Take care not to damage dowel pin (5).
D275A-5R 25
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.
a 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.
q Pushing force (Reference):
275 – 490 kN {28 – 50 tons}
26 D275A-5R
5) Pull out spacer (11) and rings (12) and (13). Installation
q 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)
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
D275A-5R 27
2) Install spacer (11) and ring (12) to shaft (8) k 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]
q Press fitting force for ring (13): and 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.
a 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
floating seal.
6. Using tool L20, press fit cartridge pin assembly
(17).
2. Using the tool, sling and install 1st bogie (16).

a Keep 2nd bogie assembly (1) lowered.
a 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.
28 D275A-5R
a Press fit the cartridge pin assembly to the

machined surface (c) of the bogie.
2 Outside surface of pin:

Lubricant containing molybdenum
disulfide (LM-P)
a Press fitting force for cartridge pin assem-
bly: 275 – 490 kN {28 – 50 tons}
11. Install covers (7).

a Install 2 covers, outside and inside ones.
7. Using tool L21, supply the specified quantity of

oil to the cartridge pin assembly.
a Oil supply pressure: 0.49 MPa {5kg/cm2}
5 Cartridge pin assembly (81 – 95% of full lev-
el): 61 – 71 cc (GO140)
12. Using tool L22, sling and set track roller assem-
bly (6).
a 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.
D275A-5R 29
13. Install roller cap (3) and secure it with the bolts
temporarily.
a Direct roller cap protectors (b) out of the bo-
gie.
14. Align the dowel pin holes and tighten the bolts.
824 – 1,030 Nm {84 – 105 kgm}
15. Adjust the track shoe tension. For details, see

Testing and adjusting, "Testing and adjusting
track shoe tension".
30 D275A-5R
Removal and installation of 2nd, 3. Using tool L14, secure bogie assembly (1).
3rd and 4th bogie assembly 1 4. Remove cover (2).
a Remove the cover on the opposite side, too.
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
14 791T-630-1380 Bracket t 2 Q
791-630-1360 Spacer t 1
790-101-2310 Block t 1
790-101-2360 Plate t 2
790-445-4130 Screw t 2
15
791-112-1180 Nut t 2
Puller 5. Operate the blade and ripper to raise the ma-
790-101-4000 t 1
(490kN {50ton})
chine body until the track roller is floated above
790-101-1102 Pump t 1 the track link.
790-201-2760 Spacer t 1 k Set a block between the track roller and
791-630-1370 Adapter t 1 track link so that the machine body will

not lower.
790-434-1060 Screw t 2
01580-13024 Nut t 2
16 6. Set steel plate [4] on the track shoe and block
01643-33080 Washer t 1 [3].
L Puller a Set block [3] according to the height of the
790-101-4000 t 1
(490kN {50ton}) track link.
790-101-1102 Pump t 1
7. Operate the blade and ripper to lower the ma-
17 796-230-1120 Installer t 1
chine body until the track roller of the bogie as-
18 790-701-3000 Seal checker t 1 sembly comes in contact with steel plate [4].
19 791T-630-1390 Guide t 1 Q a Operate the blade and ripper slowly.
790-101-2310 Block t 1
790-445-4130 Screw t 2
796T-470-1130 Plate t 1 Q
790-101-2360 Plate t 2
20
791-112-1180 Nut t 2
Puller
790-101-4000 t 1
(490kN {50ton})
790-101-1102 Pump t 1
21 791-601-1000 Oil pump t 1
Removal
2. Remove the undercovers.

a Remove the following undercovers which
will be obstacles to removal of the bogie as-
sembly.
4 Engine undercover: 250 kg
D275A-5R 31
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.
q Pushing force (Reference):
275 – 490 kN {28 – 50 tons}
5) Pull out spacer (6) and rings (7) and (8).

q Pulling out force (Reference):
275 – 490 kN {28 – 50 tons}
6) Remove spacer (6).

7) Remove spacer (9) and floating seal (10)
between rings (7) and (8).
3) Remove floating seals (5) from the ends of a Keep the floating seals so that they will
rings (4) and (7). not be damaged.
a Keep the floating seals so that they will
not be damaged.
32 D275A-5R
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.
k 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.
D275A-5R 33
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].
q 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.
34 D275A-5R
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.
a Insert the cartridge pin assembly with arrow
(b) on its end face up (in the mounting state
4) Adjust front and rear hydraulic jacks [7] to on the machine body).
align the pin holes of the track frame and bo-
gie assembly.
a 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 oppo-
site track or applying a hydraulic jack to the
bogie assembly.
D275A-5R 35
8. Using tool L20, press fit cartridge pin assembly

(11).
a Press fit the cartridge pin assembly to ma-
chined surface (c) of the bogie.
disulfide (LM-P)
bly: 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.
a Install 2 covers, outside and inside ones.
12. Adjust the track shoe tension. For details, see

9. Using tool L21, supply the specified quantity of

a Oil supply pressure: 0.49 MPa {5kg/cm2}
5 Cartridge pin assembly
(81 – 95% of full level):
61 – 71 cc (GO140)
36 D275A-5R
Disassembly and assembly of 3. Cartridge pin assembly

Remove cartridge pin assembly (4) according to
bogie assembly 1 the procedure in Removal of bogie assembly.
a See step 8.
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
790-101-2310 Block t 1
790-445-4130 Screw t 2
796T-470-1130 Plate t 1 Q
790-101-2360 Plate t 2
20
L 791-112-1180 Nut t 2
Puller
790-101-4000 t 1
(490kN {50ton})
4. Bogie
790-101-1102 Pump t 1
Disconnect inner bogie (5) and outer bogie (6).
21 791-601-1000 Oil pump t 1
Disassembly
1) Turn over bogie assembly (1).
2) Remove the roller cap and lift off 2 track roll-
er 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 assem-
bly.
a See step 1.
2. Cover
Remove cover (3).
D275A-5R 37
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 a Oil supply pressure: 0.49 MPa {5kg/cm2}
5
1) Set tool L20. Cartridge pin assembly (81 – 95% of full lev-
el): 61 – 71 cc (GO140)
2) Press fit cartridge pin assembly (4).

a Press fit the cartridge pin assembly with the 5. Cartridge pin assembly (Opposite side)
cover. Press fit the cartridge pin assembly on the oppo-
a Insert the cartridge pin assembly with arrow site side according to steps 3 – 4 above.
(a) on its end face up (in the mounting state a After press fitting the cartridge pin assembly,
on the machine body). adjust it so that the inner bogie can slide
a Press fit the cartridge pin assembly to the lightly.
machined surface of the bogie.
6. Covers
Lubricant containing molybdenum Install covers (3).
disulfide (LM-P) a Install 2 covers, outside and inside ones.
bly: 275 – 490 kN {28 – 50 tons}
38 D275A-5R

1) Sling 2 track roller assemblies (2) and set
them on the bogie.
a 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.
a Direct roller cap protectors (b) out of the bo-
gie.
824 – 1,030 Nm {84 – 105 kgm}
D275A-5R 39
D275A-5R Bulldozer
© 2008 KOMATSU
All Rights Reserved
40 D275A-5R
SEN03245-00
D275A-5R

D275A-5R 35001 and up

Undercarriage and frame, Part 2
Expanding and installing track shoe assembly ............................................................................................... 2
Whole disassembly and whole assembly of track shoe assembly.................................................................. 5
Removal and installation of pivot shaft assembly ......................................................................................... 27
Removal and installation of equalizer bar assembly ..................................................................................... 28
Disassembly and assembly of equalizer bar bushing ................................................................................... 31
D275A-5R 1
Expanding and installing Expanding track shoe assembly

track shoe assembly 1 (Normal)
a If Checking before removal of track shoe as-
Check before expanding track shoe sembly shows that there is no abnormality, do
assembly as follows.
k Since it may be very dangerous to expand
1. Set master link (3) in position.
the track shoe assembly, check the following
a Bring the master link (3) above the idler (just
items in advance.
behind the center).
k Do not loosen the lubricator more than 1 a Set blocks [1] and [2] at the front end of the
turn. If the grease does not come out well, idler and between the carrier rollers so that
move the machine forward and in reverse. the mating faces of the master link (3) will
not open until the master bolt is removed.
1. Remove cover (1) and loosen lubricator (2) of
the adjustment cylinder to discharge the grease.
k Do not loosen the lubricator more than 1
turn.
2. Relieve track shoe tension. [*1]

k Never loosen lubricator (2) more than
one turn.
a If the track is not relieved by loosening the
2. After the shoe is loosened, perform Expanding lubricator, move the machine backwards
track shoe assembly (Normal). and forwards.
3. If the track shoe is not loosened by the above

work, perform Expanding track shoe assembly
(When track frame has internal trouble).
a The track frame may have an internal trou-
ble (damage of the recoil spring or recoil
spring set bolt, fall of the shaft end nut, etc.)
3. Remove track shoe (4). [*2]

a Loosen each of the 4 bolts by 1 – 2 turns.
Check that the 4 bolts can be turned lightly,
then pull them out. Do not pull out only 1 bolt
without loosening the other three.
2 D275A-5R
a If a bolt is turned forcibly while it cannot be 2. Loosen the track shoe. [*1]
turned lightly, the threads of it and master k Do not loosen the lubricator more than 1
link (3) may be damaged. turn.
a If the track shoe is not loosened by loosen-
ing the lubricator, move the machine forward
and in reverse to discharge the grease.
a 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).
a Length of track : Approx. 10.5 m
k 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 (3) between the
idler and front carrier roller.
a 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)
a If any abnormality is detected by Check before
expanding track shoe assembly, perform the fol-
lowing procedure.
k 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 out, and that can cause a se-
rious result. Accordingly, expand the track 4. Remove track shoe (4) and disconnect master
shoe according to the following procedure. link (3). [*2]
1. Remove the work equipment. For details, see 5. Move the machine slowly in reverse to expand
"Removal of work equipment assembly". track shoe assembly.
D275A-5R 3
Installation
q Carry out expansion (normal) in the reverse or-
der to removal.
[*1]
a Adjust the track shoe tension. For details, see
[*2]
a Tighten the shoe mounting bolts for the master
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}
3 2nd time: Retighten by 180° ± 10°
a Tighten the all 4 bolts with fingers until the mas-
ter link mating faces are fitted.
a If the bolts are tightened forcibly before the mas-
ter link mating faces are fitted, the threads of the
bolts and master link may be damaged.
4 D275A-5R
Whole disassembly and whole assembly of track shoe assembly 1

Special tools
New/Remodel
New/Remodel
Necessity
Sym-
Necessity
Sym- Part No. Part name
Part No. Part name bol
Sketch
bol
Sketch
Q'ty
Q'ty
1 791-646-7531 Plug remover t 1 Cylinder
790-101-4300 t 1
12 (1,470 kN {150ton})
2 791-660-7460 Pin brush t 1
Push tool
3 791-646-7900 t 1 791-685-9510 Frame t 1
(For large plug)
Push tool 791-685-9520 Frame t 1
4 791-932-1110 t 1
(For small plug) 791-685-9530 Rod t 1
790-701-3000 Seal checker t 1 791-685-9550 Nut t 1
5
791-601-1000 Oil pump t 1 791-685-9560 Bolt t 4
6 791-632-1070 Installer t 1 13 791-632-1140 Adapter t 1
Remover and 01010-51030 Bolt t 1
791-680-9802 t 1
installer
04530-12030 Eyebolt t 1
791-680-1520 Guide t 1
Cylinder
Puller 790-101-4300 t 1
7 790-101-4200 t 1 (1,470 kN {150ton})
(294kN {30ton})
Cylinder
790-101-4300 t 1 791-685-9540 Rod t 1
(1,470 kN {150ton}) 14
791-685-9550 Nut t 1
791-685-9510 Frame t 1
Push tool
791-632-1500 t 1 791-685-9520 Frame t 1
assembly
791-632-1420 • Adapter 1 791-685-9530 Rod t 1
791-632-1430 • Ring 1 791-685-9550 Nut t 2
791-632-1440 • Plate 1 791-685-9560 Bolt t 4
791-632-1450 • Ring 1 791-126-0150 Adapter t 1
8 791-680-5520 Guide t 1
791-632-1460 • Push tool 1
R 15 791-126-0140 Pusher t 1
R 791-632-1470 • Adapter 1
791-632-1480 • Spring 1 791-632-1140 Adapter t 1
791-685-5730 • Bar 1 01010-51030 Bolt t 1
01252-30650 • Bolt 1 04530-12030 Eyebolt t 1
01580-01210 • Nut 1 791-685-9620 Extension t 1
Push tool Cylinder
791-632-1400 t 1 790-101-4300 t 1
assembly (1,470 kN {150ton})
791-632-1410 • Adapter 1 790-101-1102 Hydraulic pump t 1
791-632-1430 • Ring 1 791-680-1630 Spacer t
791-632-1440 • Plate 1 Puller
16 790-101-4200 t 1
(294kN {30ton})
791-632-1450 • Ring 1
9 790-101-1102 Hydraulic pump t 1
791-632-1460 • Push tool 1
791-680-5543 Adapter (For pin) t 1
791-632-1470 • Adapter 1
Adapter
791-632-1480 • Spring 1 791-680-9630 t 1
(For bushing)
791-685-5730 • Bar 1 17
Puller
01252-30650 • Bolt 1 790-101-4300 t 1
(294kN {30ton})
01580-01210 • Nut 1 790-101-1102 Hydraulic pump t 1
791-632-1490 Push tool t 1 18 790-434-1130 Guide t 1
10
791-685-5740 Push tool t 1 791-685-9510 Frame t 1
790-434-1110 Adapter t 1 791-685-9520 Frame t 1
790-434-1610 Guide t 1 19 791-685-9530 Rod t 1
11 Bolt (Shoe bolt may 791-685-9540 Rod t 1
195-32-61210 t 1
be used)
791-685-9550 Nut t 3
01010-51440 Bolt t 2
D275A-5R 5
Whole disassembly
New/Remodel
1. Removal of shoe
Necessity
Sym-
Part No. Part name Sling the shoe assembly and set it with the shoe
bol
Sketch
up on the floor and remove the shoe by using a
Q'ty
shoe bolt impact wrench.
791-685-9560 Bolt t 4 a If a shoe bolt is not loosened after it is un-
791-126-0150 Adapter t 1 screwed by 1 turn (If its torque is not re-
01010-51030 Bolt t 1 duced to 0), loosen the other bolts first, and
791-685-9620 Extension t 1 it will be removed smoothly.
19 791-680-5543 Adapter t 1 a If a shoe bolt is turned forcibly while its
791-680-5551 Guide t 1 torque is not 0, bolt and link will adhere to
Cylinder each other and they will need to be repaired.
790-101-4300 t 1
(1,470 kN {150ton}) a When moving the shoe assembly, take care
790-101-1102 Hydraulic pump t 1 not to damage the master link.
791-685-9510 Frame t 1 a If it is obliged to cut a shoe nut with gas,
791-685-9520 Frame t 1 keep the seal temperature below 80°C to
791-685-9530 Rod t 1 prevent thermal deterioration of the seal and
791-685-9540 Rod t 1 take measures to prevent the spatters from
791-685-9550 Nut t 3 entering through the clearances among the
791-685-9560 Bolt t 4
links.
791-126-0150 Adapter t 1
20 01010-51030 Bolt t 1
791-685-9620 Extension t 1
791-680-5551 Guider t 1
790-434-1140 Adapter t 1
R 791-680-9630 Adapter t 1
Cylinder
790-101-4300 t 1
(1,470kN {150ton})
Puller
790-101-4200 t 1
21 (294kN {30ton})
22 790-434-1160 Guide t 1
791-685-9510 Frame t 1 2. Disassembly of link
1) Set the link assembly on a link press (Tool
791-685-9520 Frame t 1
R7) and hit it with a hammer so that the
791-685-9530 Rod t 1
bushing will be fitted to the jaw.
791-685-9540 Rod t 1
791-685-9550 Nut t 3
791-685-9560 Bolt t 4
791-126-0150 Adapter t 1
23
790-434-1151 Guide t 1
791-632-1140 Adapter t 1
01010-51030 Bolt t 1
790-434-1160 Guide t 1
Cylinder
790-101-4300 t 1
(1,470kN {150ton})
a When disassembling the track shoe, see "Parts

judgment guide, Undercarriage, Lubricated
track" and "Parts judgment guide, Undercar-
riage, Reversing procedure for lubricated track".
6 D275A-5R
a 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.
a 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.
a 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.
a If the bushing ends and sealing surfaces are
damaged, oil will leak. Accordingly, handle
them carefully.
a 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 simultaneous-
ly.
a 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 ob-
tained when reversed and assembled again.
a The wedge link is broken with a bang. This
sound does not indicate abnormality.
D275A-5R 7
3. Inspection a 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
a 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
a For the whole assembly of the track shoe, see
"Parts judgment guide, Undercarriage, Revers-
ing procedure for pin bushing".
2) Measure the outside diameter of the press
fitting parts of the pin and bushing and the
inside diameter of the pin and bushing fitting When recycling for lubricated track
parts of the link with a micrometer and a cyl- 1. Preparation work
inder gauge to see if the allowable fitting al- 1) Cleaning seal assembly
lowance is obtained. When using the pin, Remove the seal assembly from the link and
bushing, and link for a lubricated track, how- divide it into the seal ling and load ring, then
ever, secure the standard fitting allowance clean them.
between the pin and link. a Since the seal ring and load ring are deteri-
a If the allowable fitting allowance is not ob- orated easily by the cleaning liquid (trichlo-
tained, replace the parts with new ones. roethylene etc.), clean them quickly. After
a For the dimensional criteria, see Mainte- cleaning them, wipe off the cleaning agent
nance standard. from them.
8 D275A-5R
2) When reusing the pin, chamfer its end cor- iv) Drive in the bar with a hammer.
ners smoothly with a grinder. Remove the a Driving distance (a) from pin end: 10 ± 1 mm
nodules sticking to the press fitting parts a If the chamfered part of the pin hole has
with the grinder, too. been worn, chamfer it with a small-sized
a If the ends are worn and sharpened, they grinder (grindstone tip angle: 45°– 60°) so
may scuff the press fitting parts and cause that the plug will not be damaged.
oil leakage. a 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
a Since these parts rust easily, clean them just by using tool R6.
before assembling them. a If oil is sticking to the counterbore portion of
a 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
a Using tool R2, clean the pin hole in ad- care that oil not stick to the seal and coun-
vance. terbore 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.
D275A-5R 9
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.
a For the standard dimensions, see Dimen-
sions table of fitting jig of link press.
a 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.
a At this time, use the master links on the pin
side as supports.
a 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.
a 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.
a Pushing force of pin and bushing:
735 kN {75 tons}
3) Using the shoe bolt hole pitch gauge, press
Pushing force 1.8 x Average pressure
fit the master links until the distance be-
(Adjust the relief pressure of the link press to
tween the shoe bolt holes of both links is the
set the press cutting force.)
standard value.
a Remove the all steel chips caused by press
2. Assembly of link
fitting of the bushing with compressed air.
1) Apply oil (GO90) to the mating surfaces of
the pin and bushing with a clean brush and
4) Turn over the master links and check that
assemble them, then set them before the
they are press fitted in parallel.
jaw of the link press.
a 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).
10 D275A-5R
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.
a Adjust the press fitting jig of the link press so a Check that the seal surface and bushing
that the projections on both sides will be end are free from dirt and apply oil (GO90)
even. to them with a clean cloth or brush.
a When installing the spacer, wipe it with a
clean cloth.
6) Send the master links and set the next pin

and bushing.
a 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 a If the pin and bushing have play when they
direction 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.
a 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.
D275A-5R 11
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. a Actually, you cannot see from outside if the
a 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 Prepa-
ration work.
a Check that adjacent 2 links can turn around
each other.
11) Set the left link and install the spacer to the
pin.
a Apply oil similarly to the right link.
14) Using a shoe bolt hole pitch gauge, mea-

sure the distance between the shoe bolt
holes and check that the result is within the
standard range.
a If the distance between the shoe bolt holes
is longer than the standard range, disas-
semble and check for abnormality, then
press fit again.
a If the distance between the shoe bolt holes
is shorter than the standard range and the
shoe cannot be installed, the spacer or
bushing end may be worn more than the al-
12) Set the left jig on the receiving side and the
lowable limit. In this case, disassemble and
right one on the pushing side and press fit
replace the parts.
the left link.
a 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}
12 D275A-5R
a Perform steps 15) – 18) for only the model 18) Using jig R10, push in the ring.
having the ring. Pushing force for ring:
15) Install the ring to jig R8. 245 – 304 kN {25 – 31 tons}
16) Align the jig with plug hole and push it slowly 19) After each link is assembled, bleed air from
until a click is heard. the pin by using tool R5 and check the seal-
a A click is heard when the ring slides down on ing performance.
the jig and fits to the pin. a Keep the degree of vacuum inside the pin at
91 – 95 kPa {680 – 710 mmHg} for 5 sec-
onds 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.
D275A-5R 13
20) Using tool R5, supply oil (G090) until the oil
supply pressure rises to 196 – 294 kPa {2 –
3 kg/cm2}.
a In a cold or very cold district, supply Komat-
su genuine oil (150-09-19270 or 195-32-
61990) having better low-temperature char-
acteristics instead of G090.
a 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.
a Check that the master links on both sides
are press fitted in parallel.
3. Installation of shoe
1) Set the link assembly on the bed and install
the shoe with a shoe bolt impact wrench and
a torque wrench.
2
a Supply oil so that depth (L) of the hollow of Shoe bolt: Lubricant containing mo-
the pin hole will be in the following range lybdenum disulfide (LM-P)
when the link is left with the small plug side
3 Shoe bolt (Regular link)
up (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.
a Apply G090 around the small plug.
a Drive in the plug to the following depth.
Driving depth from end: 7.5 ± 1 mm
14 D275A-5R
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}
a 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.
a Since the seal ring and load ring are deteri-
orated easily by the cleaning liquid, clean
them quickly. After cleaning them, wipe off
the cleaning agent from them.
D275A-5R 15
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.
a 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.
a Driving distance (a) from pin end:
Small plug: 7.5 ± 1 mm
Large plug: 10 ± 2 mm
a 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 stalled dimensions of the seal within the
spacer, and ends and inside of the bushing standard range.
are dirty, clean them. a For the standard dimensions, see Dimen-
5) Apply grease to the outside of the pin and sions table of fitting jig of link press.
surfaces of the spacer. a If the pin end (part P) or link sides (parts Q
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.
a 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.
16 D275A-5R
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.
a 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.
a 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.
a 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.
a 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
direction of the side hole on the end face to
prevent a mistake.
a 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 be-
tween the shoe bolt holes of both links is the
standard value.
a 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.
D275A-5R 17
7) Set both links and operate both pushing jigs a Perform steps 9) – 12) for only the model
to press fit the pin and bushing simulta- having the ring.
neously. 9) Install the ring to jig R8.
a 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.
a 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 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, mea-

sure 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.
a Check that the master links on both sides
are press fitted in parallel.
18 D275A-5R
3. Installation of Shoe 2 Shoe bolt: Lubricant containing molyb-

1) Set the link assembly on the bed and install denum disulfide (LM-P)
3
the shoe with a shoe bolt impact wrench and Shoe bolt (Master link)
a torque wrench. Initial torque: 490 ± 49 Nm {50 ± 5 kgm}
2
3
Shoe bolt: Lubricant containing molyb- Retightening angle: 180° ± 10°
denum disulfide (LM-P)
a Tighten the bolts in the order of [1] – [4].
3 Shoe bolt (Regular link)
Initial torque: 784 ± 78 Nm {80 ± 8 kgm}
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-
ing faces of the links.
5) Check that shoe bolts (4) can be tightened
easily, then connect the links with the master
bolts.
D275A-5R 19
Dimensions table of fitting jig of link press
Unit: mm Precaution
1. The link receiving faces of jaw (5) must be verti-
Dimensions of jig cal.
2. Replaceable wear plate (6) is desirable.
a 4.2
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.
a If the pin end (part P) or link sides (parts Q
20 D275A-5R
Disassembly of 1 link in the field 4. Set tool R15 and apply oil pressure to pull out
k Only how to use the tools is explained below. pin (3).
For details of Disassembly and assembly, a After the cylinder reaches the stroke end, in-
see "Whole disassembly (or assembly) of stall extension tool R15 between the adapt-
track shoe". er and guide, then repeat the work.
1. Using 2 bolts (2), install tool R11 to link (1).
a 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
together and set them on the track.
3. Insert the rod of tool R14 from the cylinder side

and install it with 2 nuts.
a Install the rod through the hole of link (1).
D275A-5R 21
Assembly of 1 link in the field 3. Set link (4) on the opposite side and support it
1. Assembly of link sub-assembly with tool R18.
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.
a 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). a Press fitting force for bushing:
a 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.
22 D275A-5R
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)
a 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.

a For the procedure, see Assembly of link.
D275A-5R 23
Disassembly of master link

a For the method of using tool R7, see Disassem-
bly 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
24 D275A-5R
Assembly of master link 2) Set spacer (3) and seal assembly (4) to the
a For the method of using tool R7, see Disassem- counterbore of the link of the connecting
bly of 1 link in the field. part.
1. Assembly of bushing-side link
1) Press fit bushing-side master link (1) to
bushing (2) with a press.
a When press fitting both master links,
take care that they will be in parallel with
each other.
a Do not damage the mating surfaces of
the master links and end faces of the
bushing.
Unit: mm
L1 184.15 ± 0.7
L2 234.95 ± 0.7
Drill 30 in
D1
diameter 3) Match the pin hole and bushing hole to each
D2 27 x 2.0 other and connect the pin and bushing with
guide pin [1].
2. Installation of bushing-side link

4) Press fit pin (5) with tool R7 and install bush-
1) Expand the center of the link tread with tool
ing-side master link (1).
R7 as shown in the figure. (Expand the link
end by 10 mm.) 2 Apply gasket sealant (198-32-19890)
(a): 5 mm to the pin hole of the link.
a Set the pin with its side hole on the link tread
side.
D275A-5R 25
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
a For the procedure, see Assembly of link. both sides with tool R7.
3) Using tools R7, R8, R9, and R10, install the
6) Install the shoe to the link of the connecting ring.
part. a For the procedure, see steps 9) - 12) in
Assembly of link.
7) Drive large plug (6) with tool R3 and supply
oil with tool R5, then drive small plug (7) with 4) Drive large plug (13) with tool R3 and supply
tool R4. oil with tool R5, then drive small plug (14)
a When press fitting both master links, with tool R4.
take care that they will be in parallel with
each other (Bushing side and pin side).
a Do not damage the mating surfaces of
the master links and end faces of the
bushing.
a Take care that dirt and sand will not stick
to the seal, spacer, end of bushing, and
tap-hole mating face of the master link.
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 ing faces of the links.
1) Set spacer (3) and seal assembly (4) to the 4) Check that the shoe bolts can be tightened
counterbore of the master link. easily, then connect the links with the master
bolts.
2 Shoe bolt:
disulfide (LM-P)
3 Shoe bolt (Master link)
Initial torque:
490 ± 49 Nm {50 ± 5 kgm}
Retightening angle: 180° ± 10°
26 D275A-5R

pivot shaft assembly 1 q Carry out installation in the reverse order to re-
moval.
Special tools
[*1]
New/Remodel
a Using tool P2, press fit seal (2) to the pivot
Necessity
Sym-
Part No. Part name
shaft.
2
Sketch
bol
Press fitting face of seal:
Q'ty
1 790-401-1700 Lifting tool t 1 a Check that press fitting distance (a) of the
791-650-1700 Installer t 1 seal from the shaft end is as follows.
P Puller q Press fitting distance (a):
2 790-101-4200 t 1
(294kN {30ton}) 493.5 ± 1.0 mm
Removal
1. Remove the track frame assembly. For details,
see "Removal of track frame assembly".
2. Using tool P1, sling pivot shaft assembly (1)

temporarily.
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). [*1]
D275A-5R 27
Removal and installation of 4. Remove mounting nuts and cover (2). [*1]
equalizer bar assembly 1 5. Disconnect grease tube (3).
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
791T-650-1930 Spacer t 1 Q
792-900-1520 Plate t 1
791-520-4140 Screw t 1
790-101-2470 Adapter t 1
N 1 790-101-2540 Washer t 1
791-112-1180 Nut t 1
Puller
790-101-2102 t 1
(294kN {30ton})
790-101-1102 Hydraulic pump t 1 7. Pull out side pin (5). [*2]
a If the equalizer bar hole is not aligned with
the track frame hole, the pin cannot be
Removal
pulled out easily. Accordingly, adjust the
1. Remove the engine undercover and power train
height of the equalizer bar side with hydrau-
undercover.
lic jack [2].
4 Engine undercover: 250 kg a Remove the pin on the opposite side by re-
4 Power train undercover: 320 kg peating steps 3 – 7.
2. Set stand [1] and hydraulic jack [2] under the ra-
diator guard.
28 D275A-5R
8. Operate hydraulic jack [2] slowly to lower the 13. Sling equalizer bar (8) and lower it, bypassing
machine body until the equalizer bar touches both track frames.
both track frames. k 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).
Installation
11. Using tool N1, remove center pin (8). [*3] q Carry out installation in the reverse order to re-
a If the equalizer bar hole is not aligned with moval.
the main frame hole, the pin cannot be
pulled out easily. Accordingly, adjust the [*1]
height of the main frame side with the hy- Installation procedure for cover (2)
draulic jack. 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) perma-
nently.
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.
D275A-5R 29
[*2]
a 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.
a Set the grease holes of the pins in the following
directions.
q Left pin: Outside of machine body
q Right pin: Inside of machine body
2 Equalizer bar side bushing:
Grease (G2-LI)
[*3]
a Before installing the center pin, sling the equal-
izer bar and align the equalizer bar hole with the
main frame hole.
2 Equalizer bar center bushing and main frame
bushing: Grease (G2-LI)
30 D275A-5R
Disassembly and assembly of 3) Using tool N2, remove spherical bushing (5)
from equalizer bar (6).
equalizer bar bushing 1 a Remove the parts on the opposite similarly.
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
791-650-1800 Remover t 1
Puller
N 2 790-101-2102 t 1
(294kN {30ton})
Disassembly
1. Center bushing
Assembly
Remove center bushing (1).
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).
a 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.
D275A-5R 31
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).
a 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).
32 D275A-5R
D275A-5R 33
D275A-5R Bulldozer
© 2007 KOMATSU
All Rights Reserved
34 D275A-5R
SEN03246-00
D275A-5R

D275A-5R 35001 and up

Hydraulic system
Removal and installation of work equipment pump assembly ........................................................................ 2
Removal and installation of power train and steering lubricating oil pump assembly ..................................... 4
Removal and installation of fan pump assembly............................................................................................. 6
Removal and installation of control valve assembly ....................................................................................... 8
Disassembly and assembly of work equipment control valve assembly....................................................... 12
Disassembly and assembly of hydraulic cylinder assembly ......................................................................... 13
D275A-5R 1
Removal and installation of work 5. Remove floor plate (6).

equipment pump assembly 1 4 Floor plate: 35 kg
Removal
1. Remove the mounting bolts and open undercov-

er (1).
6. Disconnect tubes (7) and (8).
7. Disconnect plate (9).
8. Disconnect 2nd pump pressure input hose (10)

and load pressure input hose (11).
9. Disconnect discharge hose (12) and drain hose

(13).
10. Remove the 2 mounting bolts and lift off work

3. Disconnect wiring connectors DCL (3) and BRK equipment pump assembly (14).
4
(4).
Work equipment pump assembly: 70 kg
4. Disconnect brake linkage (5) from the turnbuck-
le. [*1]
a Before disconnecting the linkage, measure
its installed length.
2 D275A-5R
Installation
moval.
[*1]
and adjusting, "Adjusting brake pedal and park-
ing brake lever".
D275A-5R 3
Removal and installation of power

train and steering lubricating oil
pump assembly 1
Removal

er (1).
5. Remove plate (6).

a Plate (6) may be removed altogether with
operator’s seat sliding plate (5).
2. Remove mounting nuts (2) and operator’s seat

assembly (3).
4 Operator’s seat assembly: 40 kg
7. Disconnect wiring connectors DCL (8) and BRK

(9).
8. Disconnect brake linkage (10) from the turn-

buckle. [*1]
9. Remove floor plate (11).

4 Floor plate: 35 kg
4. Remove the mounting bolts and operator’s seat

sliding plate (5).
a 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
4 D275A-5R
10. Disconnect suction tube (12). Installation

moval.
[*1]
ing brake lever".
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 steering lubricating oil pump assembly
(17).
4 Power train and steering lubricating oil
pump assembly: 30 kg
D275A-5R 5
Removal and installation of fan

pump assembly 1
Removal

er (1).
5. Remove plate (6).

a Plate (6) may be removed altogether with
operator’s seat sliding plate (5).
2. Remove mounting nuts (2) and operator’s seat

assembly (3).
4 Operator’s seat assembly: 40 kg
7. Disconnect wiring connectors DCL (8) and BRK

(9).
8. Disconnect brake linkage (10) from the turn-

buckle. [*1]
9. Remove floor plate (11).

4 Floor plate: 35 kg
4. Remove the mounting bolts and operator’s seat

sliding plate (5).
a 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
6 D275A-5R
10. Disconnect hose clamps (12), (13). Installation

moval.
[*1]
ing brake lever".
q Bleeding air
Bleed air from the fan pump. For details, see
Testing and adjusting, "Bleeding air from fan
pump".
11. Disconnect wiring connectors FAC (14).
12. Disconnect EPC valve main pressure hose (15).
13. Disconnect suction tube (16).
14. Disconnect discharge hose (17) and drain hose

(18).
15. Remove the 4 mounting bolts and fan pump as-

sembly (19).
4 Fan pump assembly: 30 kg
D275A-5R 7
Removal and installation of 4. Disconnect 3 PPC hose clamps and plate (5).
control valve assembly 1
Removal
release the residual pressure from the pip-
ing, referring to Testing and adjusting, Re-
l e a s i ng r e s i d u a l p r e s s u r e f r o m w o r k
equipment cylinders. Then, set the lock le-
ver in the LOCK position.
a Plug the disconnected pipes and hoses to pre-
vent foreign matter from entering them.
5. Disconnect hydraulic tank return hose (6).
a Put tags to the disconnected pipes to prevent a
mistake in re-connecting them.
6. Disconnect blade PPC hose (7) and ripper PPC
hose (8).
1. Drain the oil from the hydraulic tank.
q (7): Coupler (Color band: Blue)
6 Hydraulic tank: Approx. 130 l q (8): Coupler (Color band: Blue)
2. Remove covers (1), (2), and (3) from the right

side of the machine body.
3. Disconnect hydraulic oil pressure sensor wiring

connector HHP (4).
8 D275A-5R
7. Disconnect PPC hoses (9) on the right side. [*1] 9. Disconnect accumulator hose (PPC main pres-
a There 5 PPC hoses in the dual tilt machine sure port) (11).
and 4 in the single tilt machine.
The PPC hoses are as follows from the top
(Dual tilt machine).
q Ripper tilt BACK hose
(Color band: Brown) (Coupler) (Port PA5)
q Ripper lift LOWER hose
(Color band: Black) (Coupler) (Port PA4)
q LEFT tilt cylinder hose
(Color band: Yellow) (Port PA3)
q Blade lift LOWER hose
(Color band: Not colored) (Port PA2)
q RIGHT tilt cylinder hose
(Color band: Brown) (Coupler) (Port PA1)
10. Remove accumulator bracket (12).
8. Disconnect PPC hoses (10) on the left side. [*2]

a 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 (Du-
al tilt machine).
q Ripper tilt BACK hose
(Color band: White) (Coupler) (Port PB5)
q Ripper RAISE hose
(Color band: Not colored) (Coupler) (Port
PB4)
q LEFT tilt cylinder hose
(Color band: Green) (Port PB3)
q Blade lift RAISE hose
(Color band: Black) (Coupler) (Port PB2)
q RIGHT tilt cylinder hose
(Color band: White) (Port PB1)
D275A-5R 9
11. Disconnect the work equipment hoses. 16. Remove the 4 mounting bolts. Using hanging
a There are 10 work equipment hoses for the bolt [1], lift off control valve assembly (20).
4
dual tilt machine and 8 for the single tilt ma- Control valve assembly: 155 kg
chine.
q Hoses (13) are as follows from the top (Dual
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)
q 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.
[*1], [*2]
a Since the connecting positions of the PPC hos-
es are indicated by their band colors, check the
band colors when connecting those hoses.
q 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 q PPC hose band colors (Single tilt machine)
LS) (19).
10 D275A-5R

q Bleeding air
Bleed air from the piping. For details, see Test-
ing and adjusting, "Bleeding air from work
equipment cylinders".
D275A-5R 11
Disassembly and assembly of

work equipment control valve
assembly 1
a This chapter deals only with precautions to be
followed when reassembling the Disassembly
and assembly of work equipment control valve
assembly.
a Only the precautions for assembling the work
equipment control valve assembly are de-
scribed below.
a 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.
a When assembling the suction valve, check
that the spring is installed in the sleeve nor-
mally.
a 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.
a After installing the main relief valve assem-
bly, adjust it. For details, see Testing and
adjusting, "Testing and adjusting work
equipment oil pressure".
12 D275A-5R
Disassembly and assembly of Disassembly

hydraulic cylinder assembly 1 1. Cylinder tube
Remove the cylinder tube.
Special tools
2. Quick drop valve
New/Remodel
q Perform this procedure for only the blade lift
Necessity
Sym cylinder.
Part No. Part name
Sketch
bol 1) Remove quick drop valve (1).
Q'ty
2) Disassemble the quick drop valve assembly
Cylinder repair
790-502-1003 t 1 i) Remove block (2).
1 stand
ii) Remove spring (3), spacer (4), valves
790-101-1102 Pump t 1
(5) and (6), and collar (7).
Other than
790-102-2303 Wrench t 1
2 blade lift
790-102-3802 Wrench Blade lift t 1
790-102-4300 Wrench Ripper lift t 1
3
790-102-4310 Pin Ripper tilt t 2
790-201-1702 Push tool kit t 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
4 790-201-1831 Blade lift 1
• Push Blade tilt
790-201-1851 1
tool Ripper lift
U 790-201-1841 Ripper tilt 1

3. Piston rod assembly
790-201-1500 Push tool kit t 1 q Blade lift cylinder
790-101-5021 • Grip 1 1) Set the cylinder assembly to tool U1.
01010-50816 • Bolt 1 2) Using a hydraulic pump or a power wrench
5 790-201-1640 and tool U2, remove head assembly (8).
Blade lift 1
3) Pull piston rod assembly (9) out of cylinder
790-201-1650 Blade tilt 1 (10).
• Plate
Ripper lift a Put an oil pan under the cylinder to re-
790-201-1660 1
Ripper tilt ceive the oil.
6 790-720-1000 Expander t 1
796-720-1670 Ring t 1
Blade lift
07281-01279 Clamp t 1
796-720-1690 Ring Blade tilt t 1
7
07281-01919 Clamp Ripper lift t 1
796-720-1680 Ring t 1
Ripper tilt
07281-01589 Clamp t 1
D275A-5R 13
q 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).
a Put an oil pan under the cylinder to receive
the oil.
q Ripper lift and ripper tilt cylinders

1) Set piston rod assembly (12) to tool U1.
4. Piston assembly
q 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).
q Screw size: M12 x Pitch 1.75
5) Disassemble the piston assembly according

i) Remove wear rings (19).
a 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.
a Do not remove 2 seats (21) and
valve (22).
14 D275A-5R
a 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 ton rod (17) or (25).
it.
2) Disassemble the head assembly according

3) Using tool U3, remove piston assembly (23) to the following procedure.
from piston rod (25). 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
q Perform this procedure for only the blade
lift cylinder and blade tilt cylinder.
Remove O-ring and backup ring (35) from
piston rod (17).
D275A-5R 15
Assembly
a Take care not to damage the packings, dust
seals, O-rings, etc.
a Clean each part and block the piping ports and
pin holes so that dirt will not enter them.
1. O-ring and backup ring

q Perform this procedure for only the blade lift
cylinder and blade tilt cylinder.
Install O-ring and backup ring (35) to piston rod
(17).
a 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.
a When installing the backup ring, 3) Using tool U7, shrink piston ring (28).
warm it in water at 50 – 60°C.
16 D275A-5R
4) Install wear ring (27). ii) Install screw (24).

5) Install backup ring and O-ring (26). a Before installing the screw, degrease and
a When installing the backup ring, warm it in dry it well.
water at 50 – 60°C. a 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
q Ripper lift cylinder and ripper tilt cylinder
1) Set piston rod assembly (12) 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.
a Apply the drill to the groove in the threads
between the piston and piston rod and cut
2) When reusing piston rod (25) and piston as- threads horizontally.
sembly (23), install them according to the q Thread cutting dimensions (mm):
following procedure. Tap drill diameter: 10.3
a Remove burrs and fins from the threads with Tap drill depth: 27
a file. Tap size: 12 x 1.75
a Clean the parts thoroughly and remove met- Tapping depth: 20
al chips and dirt. iii) After making the screw hole, remove
i) Using tool U3, tighten piston assembly chips and dirt and clean thoroughly.
(23) in piston rod (25) until the screw
holes are matched.
D275A-5R 17
iv) Install screw (24). 5. Piston rod assembly

a Before installing the screw, degrease and q Blade tilt cylinder, ripper lift cylinder, and
dry it well. ripper tilt cylinder
a 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: a Push in the piston rod to the stroke end.
Adhesive 2 Sealing part: Grease (G2-LI)
(LOCTITE No. 262 or equivalent) 2) Tighten the mounting bolts of head assem-
3 Screw: bly (11).
58.9 – 73.6 Nm {6 – 7.5 kgm} 3 Mounting bolt (Ripper tilt):
250 ± 24.5 Nm {25.5 ± 2.5 kgm}
3 Mounting bolt
(Blade tilt, ripper lift):
343 ± 34.3 Nm {35 ± 3.5 kgm}
q Blade lift cylinder and blade tilt cylinder

1) Install retainer (18) and piston assembly
(16) to piston rod (17).
2) Install 4 valves (15).
3) Install 2 spacers (14).
q Blade lift cylinder
a Clean and degrease the piston and threads
1) Set cylinder (10) to tool U1.
of the mounting bolts thoroughly.
2) Install piston rod assembly (9) to cylinder
a After tightening the mounting bolts, leave
(10).
them for about 30 minutes.
a Push in the piston rod to the stroke end.
2 Apply hardener (LOCTITE Primer T or
2 Sealing part: Grease (G2-LI)
equivalent) to the piston and 6 mount-
ing bolts, then apply adhesive (LOC- 3) Using tool U2, tighten head assembly (8).
TITE No. 262 or equivalent) to the 3 Head assembly:
piston and 6 mounting bolts by 0.5 – 1,010 ± 2.9 Nm {103 ± 0.3 kgm}
0.7 cc each.
3 Mounting bolt:
98.1 – 122.6 Nm {10 – 12.5 kgm}
18 D275A-5R
6. Quick drop valve

q Perform this procedure for only the blade
lift cylinder.
1) Assemble the quick drop valve assembly
i) Install collar (7), valves (6) and (5),
spacer (4), and spring (3).
ii) Install block (2).
2) Install quick drop valve assembly (1).
D275A-5R 19
D275A-5R Bulldozer
© 2007 KOMATSU
All Rights Reserved
20 D275A-5R
SEN03247-01
D275A-5R

D275A-5R 35001 and up

Work equipment
Removal and installation of blade assembly ................................................................................................... 2
Disassembly and assembly of ripper assembly .............................................................................................. 4
D275A-5R 1
Removal and installation of blade 3. Using plate (3), fix the lift cylinder assembly to
the radiator guard.
assembly 1 a Bind the piston rod with wires so that it will
not come out.
Removal
k Lower the work equipment to a level place
and set blocks [1] under both blade assem-
bly (7) securely.
4. Similarly, disconnect the lift cylinder assembly

on the opposite side from the blade.
k After stopping the engine, release the resid-
ual pressure from the piping, referring to
1. Remove cap (1) from the lift cylinder. [*1] Test and adjusting, Releasing residual pres-
a Check the quantity and thickness of the in- sure from hydraulic circuit.
serted shims.
5. Remove both covers (4).
6. Disconnect hose (5).

a Plug the openings so that dirt will not enter
the piping.
a Hose (5) is connected to only the right side
of the single-tilt machine and to both sides of
the dual-tilt machine.
7. Remove both trunnion caps (6). [*2]
2. Sling lift cylinder assembly (2) temporarily. Start

the engine and retract the piston rod fully.
2 D275A-5R
8. Remove blade assembly (7). [*3] [*3]

a Start the engine and move the machine in a Adjust height (b) and width (c) of both straight
reverse slowly to disconnect the blade as- frames to the following values with block [1], etc.
sembly from the trunnion. • Trunnion height (b): Approx. 860 mm
• Frame width (c)
• Semi U-dozer, U-dozer: approx. 3,115mm
• Sigma-dozer: approx. 3,140 mm
Installation
• Carry out installation in the reverse order to re-
moval.
[*1]
a Adjust clearance (a) at the mating face of the
cap to the following value with shims and check
that the shims rotate smoothly.
• Standard clearance (a): 0.2 – 0.5 mm
• Standard shim thickness: 4 mm
a After installing the blade, adjust its tilting dis-
tance, referring to Testing and adjusting, Adjust-
ing blade.
• Refilling with oil (Hydraulic tank)

• Bleeding air
Bleed air from the work equipment cylinders.
For details, see Testing and adjusting, "Bleeding
air from work equipment cylinders".
[*2]
a Adjust the shims of the trunnion, referring to
Testing and adjusting, Adjusting blade.
D275A-5R 3
Disassembly and assembly of 5. Set stand [2] between the arm and beam.
ripper assembly 1 6. Sling lift cylinder assembly (3) temporarily.
Disassembly
7. Remove the lock plate and pin (4).
1. Remove right step (1).
a 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).

a 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.
k Lock the brake securely.
3. Sling shank (2) temporarily and operate the pin

puller cylinder to pull out the pin.
a The pin puller cylinder is installed to only the
giant ripper machine.
a Remove the pins on the opposite side simi-
4. Start the engine and raise the ripper assembly larly.
fully, then lower and remove shank (2) gradually.
4 Shank (Multi-shank ripper): 10. Sling beam (7) temporarily and remove the lock
350 kg (1 piece) plate.
4 Shank (Giant ripper): 500 kg
11. Using forcing screw [3], pull out both pins (8).
12. Lift off beam (7).

4 Beam: 1,750 kg
4 D275A-5R
k Release the residual pressure from the work

equipment cylinders, referring to Testing
and adjusting, Releasing residual pressure
from 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
a 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
a Remove the lift cylinder assembly on the op-
posite side similarly.
D275A-5R 5
Assembly 6. Connect lift cylinder hose (10) and tilt cylinder

1. Set a stand under arm (13) and set arm (13) in hose (9).
position.
2. Install pins (14) to both sides and secure them

with the lock plates.
a 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).
a After installing the lift cylinder assembly,
lower it onto the arm.
a Install the lift cylinder on the opposite side
similarly.
a 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.
a When installing the tilt cylinder hose clamp,
set the distance between the machine body
4. Set tilt cylinder assembly (5) in position. rear block adapter and the tilt cylinder hose
clamp to (c) (560 mm).
5. Install pin (11) and secure it with the lock plate.
a After installing the tilt cylinder assembly,
lower it onto the lift cylinder assembly.
a Install the tilt cylinder on the opposite side
similarly.
6 D275A-5R
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 k 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.

a 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).
a 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.
a Install the pin on the opposite side similarly.
ÅD
q Bleeding air
a Bleed air from the work equipment cylin-
ders. For details, see Testing and adjusting,
"Bleeding air from work equipment cylinder".
a Supply grease (G2-LI) to each connecting
pin.
15. Set block [1] and drive the machine over it and
lower the blade.
k Lock the brake securely.
16. tart the engine and raise the ripper assembly ful-
ly.
D275A-5R 7
D275A-5R Bulldozer
© 2008 KOMATSU
All Rights Reserved
8 D275A-5R
SEN03248-01
D275A-5R

D275A-5R 35001 and up

Cab and its attachments
Removal and installation of ROPS guard ....................................................................................................... 2
Removal and installation of operator's cab assembly ..................................................................................... 3
Removal and installation of operator's cab glass (Stuck glass) ...................................................................... 5
Removal and installation of air conditioner unit assembly ............................................................................ 14
Removal and installation of floor frame assembly ........................................................................................ 17
D275A-5R 1
Removal and installation of ROPS

guard 1
Removal
1. Sling the ROPS guard temporarily and remove
mounting bolts (1). [*1]
2. Lift off ROPS guard (2).

4 ROPS guard: 600 kg
Installation
moval.
[*1]
3 Mounting bolt:
1,180 – 1,470 Nm {120 – 150 kgm}
2 D275A-5R
Removal and installation of 5. Remove covers (6) and (7).

operator's cab assembly 1 6. Remove step (8) and covers (9) and (10).
a Remove these parts from both sides.
Removal
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.
a Remove the bolts from both sides.
3. Disconnect intermediate wiring connectors (CN-

19) (2) and cab power supply connectors (CN-
20) (3) and (12VS) (4).
a After disconnecting the connectors, pull out
the wires from inside of the operator's cab.
4. Disconnect 4 windshield washer hoses (5). [*1]

a 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.
D275A-5R 3
9. Remove cigarette lighter cover (14) and discon- Installation

nect accessory socket wiring connector CN-D. q Carry out installation in the reverse order to re-
moval.
10. Remove garnishes (15), (16), and (17).
[*1]
a When connecting the windshield washer hoses,
match the colors of their bands.
11. Remove mounting bolts (18) inside the opera-

tor's cab.
a 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
4 D275A-5R
Removal and installation of operator's cab glass (Stuck glass) 1
* Among the panes of window glass of the opera- (1): Front window glass
tor's cab, the 3 panes of (1) and (2) on both (2): Left door window glass
sides are stuck. In this section, the procedure : Right door window glass
for replacing the stuck glass is explained. (3): Both-sided adhesive tape
(4): Trim seal
(5): Door handle
D275A-5R 5
Special tools (The following figure shows the operator's cab

of a wheel loader.)
New/Remodel
Necessity
Sym
Part No. Part name
Sketch
bol
Q'ty
Lifter
X 1 793-498-1210 t 2
(Suction cup)
Removal
* Remove the window glass to be replaced
1. Using seal cutter [1], cut the adhesive between

broken window glass (6) and operator's cab
(metal sheet) (7). a If the window glass is broken finely, it may
be removed with knife [4] and a screw-
driver.
a Widening the cut with a screwdriver, cut the
adhesive and both-sided adhesive tape
with knife [4].
(The following figure shows the operator's cab

of a wheel loader.)
a If a seal cutter is not available, make holes

on the adhesive and both-sided adhesive
tape with a drill and pass a fine wire (piano
wire, etc.) [2] through the holes. Grip the
both ends of the wire with priors [3], etc. (or
hold them by winding them onto something)
and move the wire to the right and left to cut
the adhesive and both-sided adhesive tape.
Since the wire may be broken by the fric- 2. Remove the window glass.
tional heat, apply lubricant to it.
6 D275A-5R
Installation 3. Stick both-sided adhesive tape (3) along the

1. Using a knife and scraper [5], remove the inside edges of the front window glass sticking
remaining adhesive and both-sided adhesive section and both door window glass sticking
tape from the metal sheets (glass sticking sur- sections.
faces) of the operator's cab. a Do not remove the release tape of the both-
a Remove the adhesive and both-sided adhe- sided adhesive tape on the glass sticking
sive tape to a degree that they will not affect side before sticking the glass.
adhesion of the new adhesive. Take care a When sticking the both-sided adhesive
not to scratch the painted surfaces. tape, do not touch the cleaned surface as
(If the painted surfaces are scratched, long as possible.
adhesion will be lowered.) a Take care that the both-sided adhesive tape
will not float at each corner of the window
(The following figure shows the operator's cab frame.
of a wheel loader.) a Do not lap the finishing end of both-sided
adhesive tape (3) over the starting end but
make clearance (a) of about 5 mm between
them.
2. Remove oil, dust, dirt, etc. from the sticking sur-

faces of cab (7) and window glass (8) with white
gasoline.
a If the sticking surfaces are not cleaned well,
the glass may not be stuck perfectly.
a Clean the all black part on the back side of
the window glass.
a After cleaning the sticking surfaces, leave
them for at least 5 minutes to dry.
D275A-5R 7
4. Install trim seals (4) to both door window 5. Position the new window glass.
glasses (2). 1) Using tool X1, set the window glass to the
sticking position. Check the clearance
between the window glass and the opera-
tor's cab on the right, left, upper, and lower
sides, and then adjust it evenly.
a Position front window glass (1) from
inside of operator's cab (7). Adjust it so
that the difference between black
coated part and the metal sheet of oper-
ator's cab (7) will be even on the right,
left, upper, and lower sides.
a When positioning each door window
glass (2), align handle holes (d) of door
(9) (on the glass side and door metal
sheet side) first. Then, adjust the door
a Install each trim seal (4) so that its finishing window glass so that the positional rela-
end and starting end will be jointed at posi- tionship between it and door metal
tion (c) and dimension (b) between the cor- sheet will be even all around the win-
ner and position (c) will be 90 mm. dow.
2) After positioning the glasses, stick tapes [6]

between front window glass (1) and opera-
tor's cab (7) and the right, left, and lower
parts of each door window glass (2) and
each door (9), and then draw positioning
line (e).
3) Cut the tapes between window glasses (1)

and (2) and operator's cab (7) with a knife,
and then remove the window glasses.
a Do not remove the tapes left on the win-
dow glasses and operator's cab before
installing the window glasses.
8 D275A-5R
1) Break aluminum seal (11) of the outlet of

adhesive cartridge (10) and install the noz-
zle.
6. Apply adhesive.
2 Adhesive: Sikaflex 256HV manufactured
by Sika Japan
a Do not use primer. 2) Cut the tip of the adhesive nozzle (12) so
a The using limit of the adhesive is 6 months that dimensions (f) and (g) will be as fol-
after the date of manufacture. Do not use lows.
the adhesive after this limit. q Dimension (f) : 10 mm
a Keep the adhesive in a dark place where q Dimension (g): 15 mm
the temperature is below 25°C.
a Never heat the adhesive higher than 30°C.
a When reusing the adhesive, remove the all
hardened part from the nozzle tip.
3) Set adhesive cartridge (10) to caulking gun

[7].
a An electric caulking gun is more effi-
cient.
D275A-5R 9
4) Remove release tape of the both-sided a Apply adhesive (13) to dimensions (h) and
adhesive tape (3a) on the glass side. (j) of both-sided adhesive tape (3) of opera-
tor's cab (7).
q Dimension (h): 10 mm
q Dimension (j) : 15 mm
a Apply adhesive (13) higher than both-sided
adhesive tape (3).
a Apply the adhesive evenly.
5) Apply adhesive (13) to the outside of both-

sided adhesive tape (3) of the operator's
cab.
7. Install the front window glass.

1) Using tool X1, match front window glass (1)
to line (e) on positioning tapes [6] drawn in
step 5 and install it to operator's cab (7).
a Since the window glass cannot be
removed and stuck again, stick it very
carefully.
a Stick the glass within 5 minutes after
applying the adhesive.
2) After sticking the window glass, press all
around it until it is stuck to the both-sided
adhesive tape.
a Press the corners of the window glass
firmly.
10 D275A-5R
3) Mask front window glass (1) and operator's

cab (7) with masking tapes [8].
4) Fill the clearance between front window
glass (1) and operator's cab (7) with caulk-
ing material (14) all around the window.
2 Caulking material:
SEKISUI SILICONE SEALANT
a The usable period of the following
caulking material is 6 months after the
date of manufacture. Do not use the
caulking material after its usable period.
8. Install both door window glasses.

1) Using tool X1, match both door window
glasses (2) to lines (e) on positioning tapes
[6] drawn in step 5 and install them to both
doors (9).
a Since the window glass cannot be
removed and stuck again, stick it very
carefully.
a Stick the glass within 5 minutes after
applying the adhesive.
2) After sticking each window glass, press all
5) After applying caulking material (14) to front around it until it is stuck to the both-sided
window glass (1), form it with the fingers as adhesive tape.
shown in the following figure. a Press the corners of each window glass
a Use rubber spatula [9] to form the firmly.
caulking material around the handrail,
etc. where it is difficult to form with the
fingers.
D275A-5R 11
a If adhesive (13) is projected from the

trim seals (4) of stuck door window
glasses on both sides, remove it with
rubber spatula [9].
9. Fix the window glasses.

1) Using styrene foam blocks [10] and rubber
bands [11], fix the front window glass to fit it
completely.
3) Fill the clearance between each door win- a You may use sealing tapes to fix the
dow glass and trim in the range of dimen- front window glass.
sion (k).
i) Mask the range of dimension (k) of (The figure shows the operator's cab of a
each door window glass. hydraulic excavator.)
ii) Fill clearance (m) between each door
window glass (2) and trim seal (4) with
caulking material.
a The usable period of the following
caulking material is 6 months after the
date of manufacture. Do not use the
caulking material after its usable period.
a Apply the caulking material to joint (c) of
the trim seal, too.
2 Caulking material:
SEKISUI SILICONE SEALANT
12 D275A-5R
2) Immediately after sticking both door window

glasses, install door handles (5), and lock
the doors to fix the glasses.
10. After installing the window glasses, remove the

primer and adhesive from them and the opera-
tor's cab.
a Using white gasoline, wipe off the adhesive
before it is dried up.
a When cleaning the glasses, do not give an
impact to them.
11. Protect the stuck window glasses.

1) Keep the stopper rubbers, styrene foam
blocks, and rubber bands installed for 10
hours (at temperature of 20°C and humidity
of 60%).
2) After applying the adhesive, wait for at least
24 hours, before operating the machine
actually.
D275A-5R 13
Removal and installation of air

conditioner unit assembly 1
Removal
k Collect the air conditioner refrigerant (R134a)
from air conditioner circuit in advance.
a Ask professional traders for collecting and filling
operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to the at-
mosphere.
5. Disconnect wiring connectors (CN-213) (6),
(CN-214) (7), (CN-215) (8), (CN-216) (9), and
(CN-DL1) (10).
(R134a). Collecting and filling work must be
1. Remove the operator's cab assembly. For de-

tails, see Removal of operator's cab assembly.
2. Remove covers (1), (2), and (3).
6. Remove covers (11) and (12).
3. Disconnect 2 air conditioner hoses (4). [*1]

a Disconnect the hoses from the air condition-
er and move them toward the engine.
a Plug the hoses to prevent dirt, water, etc. will
not enter them.
a Take care not to damage or miss the O-
rings.
4. Disconnect 2 heater hoses (5).

a Close the heater valve on the engine side.
14 D275A-5R
7. Remove steps (13) and covers (14). 12. Disconnect bracket (22) and clamp (23).
8. Remove panel (15) and cover (16).
13. Disconnect relays (CN-R1) (24), (CN-R2) (25),

and (CN-R3) (26) in the right part of the dash-
9. Remove ducts (17) and (18).
board and connector (CN-M26) (27).
10. Remove monitor (19) and cover (20).

14. Remove air conditioner unit (28).
15. Remove blower motor (29).
11. Remove inside filter (21).
D275A-5R 15
Installation q Filling of air conditioner gas

q Carry out installation in the reverse order to re- Fill the air conditioner circuit with refrigerant
moval. (R134a).
[*1]
a Connect the hoses so carefully that they will not q Refilling with coolant
be twisted. Add coolant through the coolant filler to the
a When installing the air conditioner circuit hoses, specified level. Run the engine to circulate the
take care that dirt, dust, or water will not enter coolant through the system. Then, check the
them. coolant level again.
a When installing each air conditioner hose, check
that O-ring (70) is fitted to it.
a Check O-ring (70) for a flaw and deterioration.
a When connecting each refrigerant pipe, apply
compressor oil for new refrigerant (R134a)
(DENSO: ND-OIL8 or ZEXEL ZXL100PT
(equivalent to PAG46) to O-ring (70)).
3 Tightening torque for air conditioner refriger-

ant piping

Tightening torque
screw flats
11.8 – 14.7 Nm
M16 x 1.5 19 mm
{1.2 – 1.5 kgm}
19.8 – 24.5 Nm
M22 x 1.5 24 mm
{2.0 – 2.5 kgm}
29.4 – 34.3 Nm
M24 x 1.5 27 mm
{3.0 – 3.5 kgm}
M6 bolt of 3.9 – 6.9 Nm

10 mm
M6 bolt of 7.8 – 11.8 Nm

10 mm
16 D275A-5R
Removal and installation of floor 3. Remove left cover (8), armrest (9), and right
cover (10).
frame assembly 1
Removal
release the residual pressure from the pip-
ing, referring to Testing and adjusting, Re-
leasing residual pressure from work
equipment cylinders.
k In the case that you do not drain the coolant,
if you disconnect the heater hose when the
coolant temperature in the radiator is high,
you may be scalded. In this case, wait until
4. Remove bracket (11).
the coolant temperature lowers and then dis-
connect the heater hose.
k Collect the air conditioner refrigerant (R134a)
from air conditioner circuit in advance.
a Ask professional traders for collecting and filling
operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to the at-
mosphere.
(R134a). Collecting and filling work must be 5. Remove cover (12).
1. Remove the operator's cab. For details, see

"Removal of operator's cab".
2. Remove covers (1), (2), (3), and (4).
D275A-5R 17
6. Disconnect brake linkage (15) from the turn- 10. Lift off floor plate (17).
4
buckle. [*1] Flower plate: 35 kg
11. Disconnect parking brake lever linkage (19).
7. Remove the mounting bolts of lower plate (16).
8. Remove the mounting bolts of floor plate (17).
9. Lift off operator's seat assembly (18).

a Remove the operator's seat assembly and
lower plate (16) together.
4 Operator's seat assembly: 100 kg
18 D275A-5R
12. Remove cover (20) and duct hose (21). [*2] 16. Disconnect 5 blade PPC hoses (37), 5 ripper
PPC hoses (38), and accumulator hose (39).
13. Disconnect receiver tank hose (23) and air con- [*4]
ditioner compressor hose (24). [*3]
a Discharge the refrigerant (gas) from the air
conditioner curcuit before disconnecting the
air conditioner hoses.
14. Disconnect heater hoses (25) and (26).

a Close the heater hose valve on the engine
side.
a Plug the disconnected hoses.
17. Disconnect floor front support ground wire (40)

on the right side of the machine body.
18. Disconnect 2 front mount bolts (41).
19. Remove 5 rear mount bolts (42) from each side.
15. Disconnect intermediate wiring connectors

PWR (28), USB (29), PL4 (30), PL5 (31), PL1
(32), PL2 (33), and F01 (34).
D275A-5R 19
20. Lift off floor frame (43). Installation

4 Floor frame: 550 kg q Carry out installation in the reverse order to re-
moval.
[*1]
ing lever".
[*2]
3 Hose (21) clamp:
6.8 ± 0.49 Nm {69 ± 5 kgcm}
[*3]
a Install each hose so that it will not be twisted.
a When installing the air conditioner hoses, take
care that dirt, dust, and water will not enter
them.
a When installing each air conditioner hose, check
that O-ring (70) is fitted to it.
a Check O-ring (70) for a flaw and deterioration.
a When connecting each refrigerant pipe, apply
compressor oil for new refrigerant (R134a)
(DENSO: ND-OIL8 or ZEXEL ZXL100PT
(equivalent to PAG46) to O-ring (70)).
3 Tightening torque for refrigerant gas pipes

Tightening torque
screw flats
11.8 – 14.7 Nm
M16 x 1.5 19 mm
{1.2 – 1.5 kgm}
19.8 – 24.5 Nm
M22 x 1.5 24 mm
{2.0 – 2.5 kgm}
29.4 – 34.3 Nm
M24 x 1.5 27 mm
{3.0 – 3.5 kgm}
M6 bolt of 3.9 – 6.9 Nm

10 mm
M6 bolt of 7.8 – 11.8 Nm

10 mm
20 D275A-5R
[*4]
a Since the connecting positions of the PPC hos-
es are indicated by their clamp colors, check the
clamp colors when connecting those hoses.
q Blade PPC hose clamp colors
(Dual tilt machine)
Green (44): Solenoid valve hose (Outside of
machine body)
Yellow (45): Solenoid valve hose (Inside of ma-
chine body)
Not colored (46): Work equipment control valve
hose (port PA2)
Black (47): Work equipment control valve hose
(port PB2) a Hose clamp colors seen from the right of the
Blue (48): Drain centralized block hose (Rear machine body are shown.
side of machine body)
q Ripper PPC hose clamp colors q Blade PPC hose clamp colors
(Dual tilt machine) (Single tilt machine)
Brown (49): Work equipment control valve hose Not colored (46): Work equipment control valve
(port PA5) hose
Black (50): Work equipment control valve hose Black (47): Work equipment control valve hose
(port PA4) Green (58): Work equipment control valve hose
White (51): Work equipment control valve hose Yellow (59): Work equipment control valve hose
(port PB5) q Ripper PPC hose clamp colors
Not colored (52): Work equipment control valve (Single tilt machine)
hose (port PB4) Brown (49): Work equipment control valve hose
Blue (53): Drain centralized block hose (Front Black (50): Work equipment control valve hose
side of machine body) White (51): Work equipment control valve hose
q Clamp colors between block and work equip- Not colored (52): Work equipment control valve
ment control valve (Dual tilt machine) hose
Yellow (54): Work equipment control valve hose
Brown (55): Work equipment control valve hose
Green (56): Work equipment control valve hose
White (57): Work equipment control valve hose
a Hose clamp colors seen from the right of the

machine body are shown.
q Filling of air conditioner gas

Fill the air conditioner circuit with refrigerant
(R134a).
D275A-5R 21
D275A-5R Bulldozer
© 2008 KOMATSU
All Rights Reserved
22 D275A-5R
SEN03249-01
D275A-5R

D275A-5R 35001 and up

Electrical system
Removal and installation of transmission controller assembly........................................................................ 2
Removal and installation of steering controller assembly ............................................................................... 3
Removal and installation of engine controller assembly ................................................................................. 4
Removal and installation of monitor panel assembly ...................................................................................... 5
D275A-5R 1

transmission controller assembly1
Removal
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). [*1]
Installation
moval.
[*1]
3 Screw: 2.83 ± 0.28 Nm {0.29 ± 0.03 kgm}
2 D275A-5R

steering controller assembly 1
Removal
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 con-

troller assembly (2). [*1]
Installation
moval.
[*1]
3 Screw: 2.83 ± 0.28 Nm {0.29 ± 0.03 kgm}
D275A-5R 3
Removal and installation of 5. Disconnect connectors EGC3 (6), EGC1 (7) and
EGC2 (8) and remove cover (9). [*1]
engine controller assembly 1
Removal
1. Open the left engine side cover (1) and lift off
side cover assembly (2).
4 Side cover assembly: 25 kg
6. Remove the mounting bolts (remaining 2 ones),

ground wire (10) and engine controller assembly
(11).
2. Remove oil filter (3).
Installation
moval.
[*1]
3 Connector mounting screw:
2.83 ± 0.28 Nm {0.29 ± 0.03 kgm}
4. Remove the 2 mounting bolts of cover (5).

a Cover (5) is tightened together with the en-
gine controller.
4 D275A-5R

monitor panel assembly 1 • Carry out installation in the reverse order to re-
moval.
Removal
1. Remove mounting bolts, then open monitor pan-

el assembly (1).
Serial No.: 35001 – 35004
2. Disconnect connectors (CN-S01, CN-S02, CN-

S03, CN-S04) (2).
3. Remove monitor panel assembly.
D275A-5R 5
D275A-5R Bulldozer
© 2008 KOMATSU
All Rights Reserved
6 D275A-5R
SEN02180-00
BULLDOZER
D275A-5R

D275A-5R 35001 and up
90 Diagrams and drawings 1

Hydraulic circuit diagram
Hydraulic circuit diagram................................................................................................................................. 3
Power train hydraulic circuit diagram .............................................................................................................. 5
D275A-5R 1
SEN02180-00 90 Diagrams and drawings
2 D275A-5R
Hydraulic circuit diagram Hydraulic circuit diagram 1
D275A-5R
SEN02180-00
D275A-5R 3
Power train hydraulic circuit diagram Power train hydraulic circuit diagram
D275A-5R
D275A-5R 5
D275A-5R 7
D275A-5R Bulldozer
© 2007 KOMATSU
All Rights Reserved
8 D275A-5R
SEN02181-01
BULLDOZER
D275A-5R

D275A-5R 35001 and up
90 Diagrams and drawings 1

Electrical diagrams and drawings
Electrical circuit diagram (1/13)....................................................................................................................... 3
Electrical circuit diagram (5/13)......................................................................................................................11
Electrical circuit diagram (6/13)..................................................................................................................... 13
Electrical circuit diagram (10/13)................................................................................................................... 21
Electrical circuit diagram (11/13) ................................................................................................................... 23
Electrical circuit diagram for inside cab ........................................................................................................ 29
Air conditioner unit electrical circuit diagram................................................................................................. 31
Connectors table and arrangement drawing................................................................................................. 33
D275A-5R 1
2 D275A-5R
Electrical circuit diagram (1/13) Electrical circuit diagram (1/13) 1
D275A-5R
SEN02181-01
D275A-5R 3
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D275A-5R 27
Electrical circuit diagram for inside cab Electrical circuit diagram for inside cab
D275A-5R
D275A-5R 29
Air conditioner unit electrical circuit diagram 1

1
D275A-5R 31
32 D275A-5R
Connectors table and arrangement drawing D275A-5R Connectors table and arrangement drawing
D275A-5R
Type of Number Type of Number Type of Number

Connector No. connector of pin Location Address Connector No. connector of pin Location Address Connector No. connector of pin Location Address
1 DT 6 Intermediate connector H-9 DPNL — 2 Diode AJ-8 PA DT 2 Dual sellect solenoid D-8
2 Terminal 1 Rear speaker RH H-9 DS1 DT-B 12 Intermediate connector Q-3 PAMB FRAMATOME 3 Ambient pressure sensor AG-7
3 Terminal 1 Rear speaker RH H-9 DS2 DT-C 12 Intermediate connector Q-2 PB DT 2 Pitch sellect solenoid D-8
4 YAZAKI 4 Rear wiper motor G-9 DS3 DT-A 12 Intermediate connector Q-2 PCV1 SUMITOMO 2 Supply pump#1 AE-5
5 Terminal 1 Rear speaker LH G-9 DS4 DT-D 12 Intermediate connector Q-3 PCV2 SUMITOMO 2 Supply pump#2 AE-6
6 Terminal 1 Rear speaker LH G-9 DS5 DT-D 12 Intermediate connector Q-1 PFUEL AMP 3 Common rail pressure sensor AG-6
9 KES1 6 Front wiper motor D-8 E22 DT 2 Intermediate connector AF-6 PHR Relay 5 Pre-heater relay AA-7
10 — 9 Radio H-9 EG1 DTP 2 Intermediate connector AH-8 PIM CANNON 4 Boost pressure sensor AG-9
11 KES1 6 L.H Wiper switch E-9 EG2 DT-B 12 Intermediate connector AH-8 PL1 24-23 23 Intermediate connector Y-3
12 KES1 6 Front Wiper switch E-9 EG4 DT-A 12 Intermediate connector C-7 PL1F 24-23 23 Switch harness for emergency AK-8
13 KES1 6 R.H Wiper switch E-9 EG6 DT 2 Intermediate connector AH-8 PL1M 24-23 23 Switch harness for emergency AK-8
14 KES1 6 Rear Wiper switch F-9 EGC1 DRC 60 Engine controller AG-7 PL2 24-31 31 Intermediate connector Y-2
15 M 2 Rear lamp switch F-9 EGC2 DRC 50 Engine controller AH-7 PL2 24-31 31 Switch harness for emergency AK-8
17 YAZAKI 4 Wiper motor for right door E-8 EGC3 DTP 4 Engine controller AG-7 PL4 DT-B 12 Intermediate connector Y-2
18 YAZAKI 4 Wiper motor for left door I-9 EHL Relay 5 Engine hold relay Z-7 PL5 DT-A 12 Intermediate connector X-2
19 DT 4 Intermediate connector J-2 EPP DT 6 Electrical priming pump timer C-7 PNL 24-31 31 Switch for emergency AI-9
20 DTHD 1 ACC power supply V-1 ESD DT 3 Service connector(for engine option) AA-7 POIL FRAMATOME 3 Engine oil pressure sensor AF-6
21 DTHD 1 Battery power supply V-1 F1T DT 2 Transmission 1st clutch ECMV (Fill switch) AM-2 PPL DT 2 Pin puller solenoid J-3
22 — 2 Lighter power supply terminal I-9 F2T DT 2 Transmission 2nd clutch ECMV (Fill switch) AL-1 PRE DT 2 Pre-lubrication connector AB-7
23 M 2 Front lamp switch F-9 F32 Terminal 1 Circuit breaker(30A) K-1 PRS DT 2 Pre-lubrication connector AB-8
25 DT 2 Rotary lamp I-9 F3T DT 2 Transmission 3rd clutch ECMV (Fill switch) AM-2 PRT DT-A 12 Intermediate connector Q-2
26 M 2 Rotary lamp switch F-9 F96 Terminal 1 Circuit breaker(105A) K-1 PRT2 DT 4 Intermediate connector AH-8
81 KES1 2 Room lamp E-9 FAC DT 2 Fan pump AL-2 PT1 DT 3 Pitch angle sensor A-8
217 DT 2 Caution buzzer R-1 FAN1 — 3 Fan clean mode switch Q-5 PWR DTHD 1 Main power X-2
223 DT Intermediate connector K-3 FAN2 — 4 Fan reverse mode switch (If equipped) Q-5 RDG DT-A 12 Intermediate connector B-7
225 DT 2 Rear lamp LH K-3 FAR DT 2 Fan reverse solenoid B-2 RES DT 2 Pull up resister AF-9
226 DT Ripper lamp J-3 FD1 24-31 31 Intermediate connector Y-2 RHT Terminal 1 Ribbon heater AC-9
241 DT-A 12 Intermediate connector AI-7 FD5 DT 6 Intermediate connector W-1 RPD DT 2 Ripper down switch(SSC specification) T-8
242 DT 2 Work lamp RH C-7 FFT DT 2 Transmission F clutch ECMV (Fill switch) AN-1 RPNL — 2 Resister AK-9
245 DT 3 Intermediate connector I-9 FLB DT 2 Brake ECMV LH (Fill switch) AM-8 RPU DT 2 Ripper up switch(SSC specification) U-8
250 Terminal 1 Starting switch terminal B P-5 FLC DT 2 Clutch ECMV LH (Fill switch) AL-8 RSD DT 2 Diode —
255 Terminal 1 Starting switch terminal R1 P-4 FLV DT 2 Fuel gauge J-9 RTI DT 2 Ripper tilt in switch(SSC specification) T-8
260 Terminal 1 Starting switch terminal BR O-4 FRB DT 2 Brake ECMV RH (Fill switch) AN-7 RWL — 4 Rear work lamp switch Q-4
262 DT 2 Horn switch S-7 FRC DT 2 Clutch ECMV RH (Fill switch) AK-7 S01 AMP040 12 Machine monitor R-7
263 DT 2 Pin puller switch T-8 FRT DT 2 Transmission R clutch ECMV (Fill switch) AN-2 S02 M 2 Machine monitor Q-6
265 Terminal 1 Horn switch S-7 FS11 — 5 Fuse box AA-9 S03 AMP070 20 Machine monitor R-7
266 Terminal 1 Horn switch S-7 FS12 — 5 Fuse box AA-9 S04 AMP070 12 Machine monitor R-6
270 Terminal 1 Starting switch terminal ACC O-5 FS21 — 5 Fuse box AB-9 S1T DT 2 Transmission 1st clutch ECMV (Solenoid) AL-1
280 Terminal 1 Starting switch terminal C O-5 FS22 — 5 Fuse box AB-9 S24 — — Service switch R-1
360 DT 6 Washer motor L-2 FS31 — 5 Fuse box AB-8 S2T DT 2 Transmission 2nd clutch ECMV (Solenoid) AM-1
369 DT 6 Washer motor L-2 FS32 — 5 Fuse box AB-8 S3T DT 2 Transmission 3rd clutch ECMV (Solenoid) AM-2
406 DT 2 HSS charge pressure sensor D-8 FSB 24-31 31 Intermediate connector U-1 SDS DT 2 Hydraulic oil temperature sensor D-8
453 DT 2 Torque converter oil Temperature sensor AL-3 FTU — 4 Pivot turn switch Q-5 SFT DT 2 Transmission F clutch ECMV (Solenoid) AM-1
800 Plug 1 Input terminal W-1 FWL — 4 Front work lamp switch Q-4 SFTD — 3 Shift down switch Y-5
connector
G SUMITOMO 3 Bkup sensor AE-5 SFTU — 3 Shift up switch Y-5
801 Plug 1 Input terminal W-1
connector GND08 Terminal 1 Ground(Guard) (If equipped) — SLB DT 2 Brake ECMV LH (Solenoid) AM-7
Plug GND1 Terminal 1 Ground(Floor) Y-3 SLC DT 2 Clutch ECMV LH (Solenoid) AL-8
810 1 Input terminal —
connector GND1 Terminal 1 Ground — SM1 SHINAGAWA 5 Connector for relay —
811 Plug 1 Input terminal — GND11 Terminal 1 Ground(Engine) AF-6 SRB DT 2 Brake ECMV RH (Solenoid) AM-7
connector
GND2 Terminal 1 Ground(Floor) Y-3 SRC DT 2 Clutch ECMV RH (Solenoid) AL-7
12S1 YAZAKI 2 12V Soket1 Y-7
GND2 Terminal 1 Ground — SRT DT 2 Transmission R clutch ECMV (Solenoid) AM-2
12S2 YAZAKI 2 12V Soket2 Y-7
GND3 Terminal 1 Ground Y-3 SRV DT-A 12 Service connector S-1
12V DT 3 12V Power supply terminal V-1
GND3 Terminal 1 Ground(ROPS) — SSA DT 4 Acceleration sensor(SSC specification) A-8
12VS DT 3 12V Power supply J-9
GND5 Terminal 1 Ground(Fender) J-9 ST DT 2 Starting motor terminal R,S AG-1
A/C1 DT 2 Intermediate connector AH-8
GND6 Terminal 1 Ground(Floor) — ST/B Terminal 1 Starting motor terminal B AG-1
A/C2 DT 2 Air conditioner compressor AE-6
GND7 Terminal 1 Ground(Dash board) Q-3 ST8 DT 2 Sudden stop prevent valve AM-8
ACT Relay 5 ACC cut relay Z-7
GND9 Terminal 1 Ground(Fender) — STCN1 DRC26 24 steering controller Y-5
ADH — 4 Heater switch Q-4
H01 Plug 1 Intermediate connector U-9 STCN2 DRC26 40 steering controller Y-7
AF1 DT 2 Air cleaner crogged switch B-7 connector
STCN3 DRC26 40 steering controller X-8
AL/B Terminal 1 Alternator terminal B AH-1 Plug
H02 1 Intermediate connector V-9 STF X 4 Boot program X-8
AL/R Terminal 1 Alternator terminal R AH-2 connector
HDT DT 2 Diode — SW Terminal 1 Battery relay(Coil signal terminal) B-8
AL1 DT 2 Front lamp LH —
HHP DT 2 Work equipment hydraulic pressure sensor C-8 SX8 Terminal 1 Ground(Fender) L-1
AL2 DT 2 Front lamp RH —
HRN Terminal 1 Horn C-2 T0F DT 2 Intermediate connector O-9
AL3 DT 2 Front lamp L.R —
HT Terminal 1 Heater relay(Terminal C) B-9 T0M DT 2 Intermediate connector O-9
AL4 DT 2 Front lamp R.R —
HT/A Terminal 1 Heater relay(Terminal A) B-9 T1F DT 2 Intermediate connector P-7
AL5 DT 2 Rear lamp LH —
HT/B Terminal 1 Heater relay(Terminal B) AG-9 T1M DT 2 Intermediate connector P-7
AL6 DT 2 Rear lamp RH —
INJ DT 12 Intermediate connector AF-6 TFUEL PACKARD 2 Fuel temperature sensor AF-9
ASD — 4 Auto shift down switch Q-5
J1939 DT 3 Service connector AE-9 TIM PACKARD 2 Boost temperature sensor AF-9
ASUS DT 2 Service connector(for suspention seat) X-8
JM01 — 3 Junction wiring harness — TL1 24-23 23 Intermediate connector U-1
B105HL Terminal 1 Circuit breaker(105A) J-1
JM02 — 3 Junction wiring harness — TL2 DT-B 8 Steering/directional/gearshift lever Y-4
B105HS Terminal 1 Circuit breaker(105A) J-2
JM03 — 2 Junction wiring harness — TL3 DT 6 Intermediate connector Y-4
B105S Terminal 1 Circuit breaker(105A) J-2
JM04 — 2 Junction wiring harness — TM1 DT 2 Bevel revolution sensor AN-6
B30S Terminal 1 Circuit breaker(30A) K-2
JM05 — 1 Junction wiring harness — TMCN1 DRC26 24 Transmisson controller W-8
B7L Terminal 1 Circuit breaker(30A) K-1
JM06 — 1 Junction wiring harness — TMCN2 DRC26 40 Transmisson controller W-9
B7S Terminal 1 Circuit breaker(30A) J-2
JM07 — 2 Junction wiring harness — TMCN3 DRC26 40 Transmisson controller V-9
BKA Relay 5 Back alarm relay Z-8
JM08 — 4 Junction wiring harness — TMF X 4 Boot program W-8
BKAL DT 2 Back alarm J-9
KEY DT 6 Starting switch Q-6 TMV 24-23 23 Intermediate connector AN-2
BRB Terminal 1 Battery relay(Contact input terminal) B-9
KOM1 DRC26-40 40 KOMTRAX controller Q-7 TWTR PACKARD 2 Water temperature sensor AF-1
BRC Terminal 1 Battery relay(Contact output terminal) B-9
KOM2 — 1 KOMTRAX controller Q-7 USB DTHD 1 Unswitched power W-1
BRE Terminal 1 Battery relay(Coil ground terminal) C-8
KOM3 — 1 KOMTRAX controller Q-8 WLV DT 2 Coolant level sensor A-4
BRK DT 3 Brake pedal T-1
KOM4 — 1 GPS Antenna — WNBL YAZAKI 3 Pitch sellect switch —
BUZ — 3 Buzzer cancel switch Q-6
KOM5 — 1 Orbcomm Antenna — WNBU YAZAKI 3 Dual tilt sellect switch —
CA1 DT 3 CAN Terminal resistance AH-7
CAN DT-A 12 Intermediate connector P-9 LHD DT 2 Intermediate connector A-5
CB1 — 1 Circuit breaker(20A) Z-9 LHDL DT 2 Front lamp LH B-6
CB2 — 1 Circuit breaker(20A) Z-9 LHDL1 DT 2 Additional front lamp LH (If equipped) —
CB3 — 1 Circuit breaker(20A) Z-9 LHDL2 DT 2 Additional front lamp LH (If equipped) —
CB4 — 1 Circuit breaker(20A) Z-9 LHDR DT 2 Front lamp RH A-6
CB5 — 1 Circuit breaker(20A) Z-8 LHDR1 DT 2 Additional front lamp RH (If equipped) —
CB6 — 1 Circuit breaker(20A) Z-8 LHDR2 DT 2 Additional front lamp RH (If equipped) —
CN1 DT 2 Injector#1 AG-6 LMFL Relay 5 Front lamp relay(LH) Z-8
CN2 DT 2 Injector#2 AF-5 LMFR Relay 5 Front lamp relay(RH) Z-7
CN3 DT 2 Injector#3 AF-5 LMW Relay 5 Work lamp relay Z-7
CN4 DT 2 Injector#4 AE-5 LREL DT 2 Rear lamp LH K-3
CN5 DT 2 Injector#5 AE-5 LRER DT 2 Rear lamp RH G-9
CN6 DT 2 Injector#6 AD-4 LWKL DT 2 Work lamp LH G-1
CONV DT 6 Converter(DC24V-12V) V-1 M26 — 6 Air conditioner controller Q-1
CT1 DT 2 CAN Terminal resistance Q-6 NE FRAMATOME 3 Ne sensor AH-7
CUR — 3 Cursor switch Q-5 NSF Relay 5 Neutral safty relay Z-7
DCL DT 3 Decel pedal T-1 NSW DT 3 Parking switch AA-7
DIAL M 3 Fuel dial Y-4 P03 DT 6 Intermediate connector T-8
SEN02181-01
D275A-5R 33
D275A-5R 35
D275A-5R Bulldozer
© 2007 KOMATSU
All Rights Reserved
36 D275A-5R

Manuelle D'atelier KOMATSU D275A-5R

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SEN02158-04

BULLDOZER D275A -5R

BULLDOZER 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

Composition of shop manual 1

Section Title Form Number

Shop Manual, contents binder, binder label and tabs SEN02158-04

00 Index and foreword SEN02159-04

10 Structure, function and maintenance standard SEN02164-01

20 Standard value table SEN02175-01

30 Testing and adjusting SEN02176-01

Troubleshooting by failure and error codes, Part 4 SEN02761-00

50 Disassembly and assembly SEN02178-01

90 Diagrams and drawings SEN02179-01

Foreword and general information SEN02161-02

10 Structure, function and maintenance standard

Undercarriage and frame SEN02168-00

20 Standard value table

30 Testing and adjusting

Failure code [CA132] Throttle sensor low error........................................................................... 14

Troubleshooting by failure and error codes, Part 4 SEN02761-00

Troubleshooting by failure and error codes, Part 5 SEN02762-00

Failure code [DXH7KB] Reverse clutch ECMV short circuit ....................................................... 38

H-4 Machine travels only in one direction forward or in reverse ................................................. 7

50 Disassembly and assembly

Removal and installation of aftercooler assembly ....................................................................... 41

Electrical system SEN03249-01

90 Diagrams and drawings

BULLDOZER 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

1. General precautions 7) If welding repairs are needed, always

2. Preparations for work 6) When removing a cover which is under

4. Precautions for sling work and making

How to read the shop manual 1

1. Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

2. Revision and distribution

q Revised edition mark

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving stan-

2 Coat Places to be coated with adhesives, etc. during assembly.

Explanation of terms for maintenance standard 1

1. Standard size and tolerance

a The tolerance may be indicated in the text

q Usually, the size of a hole and the size of

2. Standard clearance and standard value 5. Clearance limit

4. Repair limit and allowable value or allow-

Handling of electric equipment and hydraulic component 1

Points to remember when handling electric

2. Main failures occurring in wiring harness

2) Defective crimping or soldering of connec-

4) High-pressure water entering connector

5) Oil or dirt stuck to connector

3. Removing, installing, and drying connec-

2] When removing from clips

q When removing a connector from a