275ax 5eo

SEN00919-02
Shop
Manual
D275AX-5E0
BULLDOZER
SERIAL NUMBERS
D275AX-5E0 30001 and up
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to
make changes or improvements at any time without incurring any obligation to install such changes on products
sold previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
Copyright 2007 Komatsu

Printed in U.S.A.
Komatsu America Corp.
May 2007
SEN00921-02
BULLDOZER
1SHOP MANUAL
D275AX-5E0
Machine model
Serial number
D275AX-5E0
30001 and up
00 Index and foreword
Index
Composition of shop manual .......................................................................................................................... 2
Table of contents ............................................................................................................................................. 4
D275AX-5E0
SEN00921-02
Composition of shop manual
The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
File overview and other materials in sections in the order shown below and utilize them accordingly.
Section Title
Form Number
Shop Manual, contents binder, binder label and tabs
SEN00919-02

Index
Foreword and general information
SEN00920-02
SEN00921-02 q
SEN00922-01 q
01 Specification
Specification and technical data
SEN00923-00
SEN00924-00
10 Structure, function and maintenance standard

Engine and cooling system
Power train system, Part 1
Undercarriage and frame
Hydraulic system, Part 1
Work equipment
Cab and its attachments
Electrical system
SEN00925-00
SEN00926-00
SEN00927-00
SEN00928-00
SEN00929-00
SEN00930-00
SEN00931-00
SEN00932-00
SEN00933-00
SEN00934-00
SEN00935-00
20 Standard value table

Standard service value table
SEN00936-00
SEN01413-00
30 Testing and adjusting

Testing and adjusting, Part 1
SEN00937-00
SEN01414-00
SEN01415-00
SEN01416-00
SEN01417-00
40 Troubleshooting
Failure code table and fuse locations
General information on troubleshooting
Troubleshooting by failure and error codes, Part 1
SEN00938-00
SEN01767-00
SEN01768-00
SEN01655-00
SEN01656-00
SEN01657-00
D275AX-5E0

Troubleshooting of electrical system (E-mode)
Troubleshooting of hydraulic and mechanical system (H-mode)
Troubleshooting of engine (S-mode)
SEN00921-02
SEN01658-00
SEN01659-00
SEN01878-00
SEN01646-00
SEN01647-00
SEN01648-00
50 Disassembly and assembly

General information on disassembly and assembly
Engine
Power train, Part 1
Power train, Part 2
Undercarriage and frame, Part 1
Hydraulic system
Work equipment
Electrical system
SEN00939-00
SEN02340-00
SEN02341-00
SEN02342-00
SEN02343-00
SEN02344-00
SEN02345-00
SEN02346-00
SEN02347-00
SEN02348-00
SEN02349-00
SEN02350-00
90 Diagrams and drawings

Hydraulic diagrams and drawings
Electrical diagrams and drawings
SEN00940-01
SEN00941-00
SEN00942-01 q
D275AX-5E0
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
SEN00921-02
Table of contents

Index
SEN00921-02
Composition of shop manual.......................................................................................................
2
Table of contents .........................................................................................................................
4
SEN00922-01
Safety notice................................................................................................................................
2
How to read the shop manual .....................................................................................................
7
Explanation of terms for maintenance standard..........................................................................
9
Handling electric equipment and hydraulic component............................................................... 11
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
SEN00924-00
Specification and technical data ..................................................................................................
2
Specefication dimension drawings...........................................................................................
2
Specifications...........................................................................................................................
3
Weight table .............................................................................................................................
9
Table of fuel, coolant and lubricants ........................................................................................ 11
SEN00926-00
Engine and cooling system .........................................................................................................
2
Engine mount...........................................................................................................................
2
Cooling system ........................................................................................................................
4
Cooling fan pump.....................................................................................................................
6
Cooling fan motor .................................................................................................................... 14
SEN00927-00
Power train system, Part 1 ..........................................................................................................
2
Power train skeleton ................................................................................................................
2
HSS system .............................................................................................................................
4
Overall drawing of power train unit ..........................................................................................
6
Power train hydraulic piping drawing .......................................................................................
8
Transmission control................................................................................................................
9
Steering, brake control............................................................................................................. 10
Damper, universal joint ............................................................................................................ 12
Torque converter, PTO............................................................................................................. 14
Transmission............................................................................................................................ 28
Tranmission ECMV .................................................................................................................. 40
Main relief valve and torque convertor relif valve .................................................................... 46
Torque converter valve ............................................................................................................ 50
Lubrication relief valve ............................................................................................................. 58
SEN00928-00
Power train system, Part 2 ..........................................................................................................
3
Bevel gear shaft, HSS, brake ..................................................................................................
3
Brake valve .............................................................................................................................. 16
Brake ECMV ............................................................................................................................ 17
Parking brake valve ................................................................................................................. 23
Sudden brake prevention valve ............................................................................................... 24
Final drive ................................................................................................................................ 25
D275AX-5E0
SEN00921-02
Sprocket................................................................................................................................... 30
SEN00929-00
Undercarriage and frame ............................................................................................................
2
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
SEN00930-00
Hydraulic system, Part 1 .............................................................................................................
2
Work equipment hydraulic piping diagram ..............................................................................
2
PPC control piping diagram.....................................................................................................
6
Work equipment control...........................................................................................................
8
Hydraulic tank.......................................................................................................................... 10
Scavenging pump.................................................................................................................... 12
Work equipment pump ............................................................................................................ 14
Power train pump, steering lubrication pump .......................................................................... 30
HSS pump ............................................................................................................................... 31
HSS motor ............................................................................................................................... 47
PPC, HSS charge filter ............................................................................................................ 56
SEN00931-00
2
Control valve............................................................................................................................
2
Self pressure reducing valve ................................................................................................... 31
SEN00932-00
2
HSS charge filter bypass .........................................................................................................
2
HSS oil cooler bypass valve ....................................................................................................
4
PPC valve................................................................................................................................
6
PCCS lever.............................................................................................................................. 18
PPC lock valve ........................................................................................................................ 21
Work equipment cylinder ......................................................................................................... 22
Piston valve ............................................................................................................................. 25
Quick drop valve...................................................................................................................... 26
Pin puller switch....................................................................................................................... 27
Pin puller solenoid valve.......................................................................................................... 28
Blade control knob................................................................................................................... 30
Pitch, dual tilt solenoid valve ................................................................................................... 31
Accumulator............................................................................................................................. 32
Work equipment
SEN00933-00
Work equipment ..........................................................................................................................
2
Cylinder stay ............................................................................................................................
2
Blade .......................................................................................................................................
4
Cutting edge, end bit ...............................................................................................................
8
Ripper ...................................................................................................................................... 10
SEN00934-00
Cab and its attachments..............................................................................................................
2
Cab mount ...............................................................................................................................
2
Cab ..........................................................................................................................................
3
Air conditioner..........................................................................................................................
5
D275AX-5E0
SEN00921-02
Electrical system
SEN00935-00
Electrical system .........................................................................................................................
2
Engine control..........................................................................................................................
2
Engine control system ............................................................................................................
3
Engine controller......................................................................................................................
4
Deceleration potentiometer...................................................................................................... 11
CRI engine control system....................................................................................................... 12
Monitor system ........................................................................................................................ 14
Monitor panel ........................................................................................................................... 16
Sensors.................................................................................................................................... 20
Mode selection system ............................................................................................................ 24
Electrical equipment ................................................................................................................ 30
Palm Command Control System ............................................................................................. 33
KOMTRAX terminal system..................................................................................................... 35
SEN01413-00
Standard value table for engine...................................................................................................
2
Standard value table for machine................................................................................................
3
SEN01414-00
Tools for testing, adjusting, and troubleshooting .........................................................................
3
Testing engine speed ..................................................................................................................
6
Testing intake air pressure (Boost pressure) ...............................................................................
9
Testing exhaust temperature ....................................................................................................... 11
Testing exhaust gas color............................................................................................................ 13
Adjusting valve clearance............................................................................................................ 15
Testing compression pressure..................................................................................................... 17
Testing blow-by pressure............................................................................................................. 19
Testing engine oil pressure.......................................................................................................... 20
Handling of fuel system devices.................................................................................................. 21
Releasing residual pressure from fuel system ............................................................................ 21
Testing fuel pressure ................................................................................................................... 22
Testing fuel return rate and fuel leakage ..................................................................................... 23
Bleeding air from fuel circuit ........................................................................................................ 27
Testing fuel circuit for leakage ..................................................................................................... 29
Testing and adjusting alternator belt tension ............................................................................... 30
Testing and adjusting air conditioner compressor belt ................................................................ 31
Testing fan speed ........................................................................................................................ 32
Testing fan circuit oil pressure ..................................................................................................... 33
Bleeding air from fan pump ......................................................................................................... 34
Adjusting fuel control dial and decelerator pedal......................................................................... 35
SEN01415-00
Testing power train oil pressure...................................................................................................
3
Testing and adjusting HSS oil pressure....................................................................................... 12
Adjusting transmission speed sensor.......................................................................................... 17
Bleeding air from HSS pump ...................................................................................................... 18
Simple method of testing brake performance.............................................................................. 18
Adjusting brake pedal and parking brake lever ........................................................................... 19
Adjusting PCCS lever console position ....................................................................................... 22
Emergency escape method when power train has trouble ......................................................... 23
Adjusting clearance of idler ......................................................................................................... 26
Inspecting wear of sprocket......................................................................................................... 26
Testing and adjusting track shoe tension .................................................................................... 27
Testing and adjusting work equipment oil pressure..................................................................... 28
D275AX-5E0
SEN00921-02
Testing control circuit main pressure........................................................................................... 32

Testing PPC valve output pressure ............................................................................................. 33
Adjusting play of PPC valve ........................................................................................................ 35
Testing outlet pressure of ripper pin puller solenoid valve .......................................................... 36
Testing parts which cause hydraulic drift of blade and ripper...................................................... 37
Testing internal leakage of work equipment cylinder................................................................... 38
Releasing residual pressure from work equipment cylinder........................................................ 39
Bleeding air from work equipment cylinder ................................................................................. 39
Adjusting ripper lever position ..................................................................................................... 40
Adjusting work equipment lock lever........................................................................................... 41
Adjusting blade............................................................................................................................ 42
Testing and adjusting operator's cab........................................................................................... 44
SEN01416-00
Special functions of machine monitor (EMMS) ...........................................................................
2
SEN01417-00
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
40 Troubleshooting
SEN01767-00
Failure codes table ......................................................................................................................
2
Fuse locations ............................................................................................................................. 10
SEN01768-00
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-adapter box and T-adapter table .............................................................................................. 39
SEN01655-00
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 [1800MW] Power train clutch slip ........................................................................... 18
Failure code [2300NR] Brake thermal load ................................................................................. 19
Failure code [2301L1] Right steering brake oil pressure 1.......................................................... 20
Failure code [2301LH] Right steering brake oil pressure 2 ......................................................... 22
Failure code [2301NR] Right steering brake thermal load .......................................................... 24
Failure code [2302L1] Left steering brake oil pressure 1 ............................................................ 26
Failure code [2302LH] Left steering brake oil pressure 2 ........................................................... 28
Failure code [2302NR] Left steering brake thermal load............................................................. 30
Failure code [A000NS] Engine overheat..................................................................................... 30
Failure code [AA10NX] Air cleaner clogging ............................................................................... 32
D275AX-5E0
SEN00921-02
Failure code [AB00MA] Battery charge abnormal ....................................................................... 34

Failure code [B@BAZG] Eng oil press low.................................................................................. 36
Failure code [B@BAZK] Eng oil level low ................................................................................... 37
Failure code [B@BCNS] Eng coolant overheat........................................................................... 38
Failure code [B@BCZK] Radiator coolant level low .................................................................... 38
Failure code [B@BEBF] Water gets mixed with fuel ................................................................... 39
Failure code [B@BFZK] Fuel level abnormal reduction .............................................................. 39
Failure code [B@CENS] Torque converter oil overheat .............................................................. 40
Failure code [B@CHZG] HSS charge oil pressure reduction...................................................... 41
Failure code [B@CHZK] Power train oil oil level reduction ......................................................... 41
Failure code [B@GAZK] Battery electrolyte level reduction........................................................ 42
Failure code [B@HANS] Hyd oil overheat................................................................................... 42
Failure code [B@HAZK] Hydraulic oil level reduction ................................................................. 43
SEN01656-00
Failure code [CA111] EMC critical internal failure .......................................................................
4
Failure code [CA115] Eng Ne and Bkup speed sens error..........................................................
6
Failure code [CA122] Chg air press sensor high error ................................................................
8
Failure code [CA123] Chg air press sensor low error ................................................................. 10
Failure code [CA131] Throttle sensor high error ......................................................................... 12
Failure code [CA132] Throttle sensor low error........................................................................... 14
Failure code [CA135] Eng 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 temp sensor high error................................................................. 24
Failure code [CA154] Chg air 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....................................................................... 39
Failure code [CA271] PCV1 short error....................................................................................... 40
Failure code [CA272] PCV1 open error....................................................................................... 41
Failure code [CA273] PCV2 short error....................................................................................... 42
Failure code [CA274] PCV2 open error....................................................................................... 43
Failure code [CA322] Inj #1 (L#1) open/short error..................................................................... 44
Failure code [CA342] Calibration code incompatibility ................................................................ 50
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] Rail press low error................................................................................... 64
Failure code [CA689] Eng Ne speed sensor error ...................................................................... 68
D275AX-5E0
SEN00921-02

SEN01657-00
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 [CA1228] EGR valve servo error 1.........................................................................
6
Failure code [CA1625] EGR valve servo error 2.........................................................................
7
Failure code [CA1626] BP valve sol current high error ...............................................................
8
Failure code [CA1627] BP valve sol current low error ................................................................ 10
Failure code [CA1628] Bypass valve servo error 1 ..................................................................... 11
Failure code [CA1629] Bypass valve servo error 2 ..................................................................... 12
Failure code [CA1631] BP valve pos sens high error ................................................................. 14
Failure code [CA1632] BP valve pos sens low error................................................................... 16
Failure code [CA1633] KOMNET datalink timeout error ............................................................. 18
Failure code [CA1642] EGR inlet press sens low error............................................................... 20
Failure code [CA1653] EGR inlet press sens high error ............................................................. 22
Failure code [CA2185] Throt sens sup volt high error................................................................. 24
Failure code [CA2186] Throt sens sup volt low error .................................................................. 26
Failure code [CA2249] Rail press very low error......................................................................... 26
Failure code [CA2271] EGR valve pos sens high error .............................................................. 28
Failure code [CA2272] EGR valve pos sens low error................................................................ 30
Failure code [CA2351] EGR valve sol current high error ............................................................ 32
Failure code [CA2352] EGR valve sol current low error ............................................................. 34
Failure code [CA2555] Grid htr relay volt low error ..................................................................... 35
Failure code [CA2556] Grid htr relay volt high error.................................................................... 36
Failure code [D110KA] Battery relay holding disconnection ....................................................... 38
Failure code [D110KB] Battery relay drive short circuit ............................................................... 40
Failure code [D130KA] Neutral safety relay disconnection ......................................................... 42
Failure code [D130KB] Neutral safety relay short circuit............................................................. 44
Failure code [D161KA] Back-up alarm relay disconnection ........................................................ 46
Failure code [D161KB] Back-up alarm relay short circuit............................................................ 48
Failure code [D190KA] Engine controller ACC signal cut relay .................................................. 50
Failure code [D190KB] Engine controller ACC signal cut relay short ......................................... 52
Failure code [D811KR] KOMTRAX controller CAN defective communication ............................ 54
Failure code [DAFRKR] Machine monitor CAN communication defective communication......... 56
SEN01658-00
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
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
D275AX-5E0
SEN00921-02
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 component system)...................................................................... 34
Failure code [DB3SKR] Steering controller S-NET defective communication
(Abnormality in objective component 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
SEN01659-00
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 [DHH3KA] HSS pump oil pressure sensor A disconnection................................... 14
Failure code [DHH3KB] HSS pump oil pressure sensor A short circuit ...................................... 16
Failure code [DHH4KA] HSS pump oil pressure sensor B disconnection................................... 18
Failure code [DHH4KB] HSS pump oil pressure sensor B short circuit ...................................... 20
Failure code [DK10KA] Fuel control dial disconnection .............................................................. 22
Failure code [DK10KB] Fuel control dial short circuit .................................................................. 24
Failure code [DK30KA] Steering potentiometer (1) disconnection .............................................. 26
Failure code [DK30KB] Steering potentiometer (1) short circuit.................................................. 28
Failure code [DK30KX] Steering potentiometer (1) out of input signal range.............................. 30
Failure code [DK30KZ] Steering potentiometer (1) disconnection or short circuit....................... 31
Failure code [DK30L8] Steering potentiometer (1) analog signals do not agree......................... 32
Failure code [DK31KA] Steering potentiometer (2) disconnection .............................................. 34
Failure code [DK31KB] Steering potentiometer (2) short circuit.................................................. 36
Failure code [DK40KA] Brake potentiometer disconnection ....................................................... 38
Failure code [DK40KB] Brake potentiometer short circuit ........................................................... 40
Failure code [DK55KX] Directional potentiometer out of input signal range ............................... 42
Failure code [DK55KZ] Directional potentiometer disconnection or short circuit ........................ 43
Failure code [DK55L8] Directional potentiometer analog signals do not agree .......................... 44
Failure code [DK56KA] F-R potentiometer (1) disconnection ..................................................... 46
Failure code [DK56KB] F-R potentiometer (1) short circuit ......................................................... 48
Failure code [DK57KA] F-R potentiometer (2) disconnection ..................................................... 50
10
D275AX-5E0
SEN00921-02
Failure code [DK57KB] F-R potentiometer (2) short circuit......................................................... 52

Failure code [DK60KA] Acceleration sensor disconnection ........................................................ 54
Failure code [DK60KB] Acceleration sensor short circuit............................................................ 56
Failure code [DKH1KA] Pitch angle sensor disconnection ......................................................... 58
Failure code [DKH1KB] Pitch angle sensor short circuit ............................................................. 60
Failure code [DKH1KX] Pitch angle sensor out of input signal range ......................................... 62
Failure code [DLT3KA] Transmission out-speed sensor disconnection ...................................... 64
Failure code [DLT3KB] Transmission out-speed sensor abnormal ............................................. 66
Failure code [DV00KB] Caution buzzer short circuit ................................................................... 67
Failure code [DW59KA] Blade dual selector solenoid disconnection.......................................... 68
Failure code [DW59KB] Blade dual selector solenoid short circuit ............................................. 70
Failure code [DW59KY] Blade dual selector solenoid hot short.................................................. 72
Failure code [DW5AKA] Blade pitch selector solenoid disconnection ........................................ 73
Failure code [DW5AKB] Blade pitch selector solenoid short circuit ............................................ 74
Failure code [DW5AKY] Blade pitch selection solenoid hot short circuit .................................... 76
SEN01878-00
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 [DWN1KA] HSS pump solenoid right disconnection ..............................................
6
Failure code [DWN1KB] HSS pump solenoid right short circuit..................................................
8
Failure code [DWN1KY] HSS pump solenoid right hot short ...................................................... 10
Failure code [DWN2KA] HSS pump solenoid left disconnection ................................................ 12
Failure code [DWN2KB] HSS pump solenoid left short circuit .................................................... 14
Failure code [DWN2KY] HSS pump solenoid left short circuit .................................................... 16
Failure code [DWN3KA] Sudden stop prevention solenoid disconnection.................................. 18
Failure code [DWN3KB] Sudden stop prevention solenoid short circuit ..................................... 20
Failure code [DWN3KY] Sudden stop prevention solenoid hot short circuit ............................... 22
Failure code [DWN4KA] HSS motor free solenoid disconnection............................................... 23
Failure code [DWN4KB] HSS motor free solenoid short circuit .................................................. 24
Failure code [DWN5KA] Fan pump solenoid disconnection ....................................................... 26
Failure code [DWN5KB] Fan pump solenoid short circuit ........................................................... 28
Failure code [DWN5KY] Fan pump solenoid hot short circuit ..................................................... 30
Failure code [DXH1KA] Lock-up solenoid disconnection............................................................ 32
Failure code [DXH1KB] Lock-up solenoid short circuit ............................................................... 34
Failure code [DXH1KY] Lock-up solenoid hot short.................................................................... 36
Failure code [DXH4KA] 1st clutch ECMV disconnection ............................................................ 38
Failure code [DXH4KB] 1st clutch ECMV short circuit ................................................................ 40
Failure code [DXH4KY] 1st clutch ECMV hot short circuit .......................................................... 42
Failure code [DXH5KA] 2nd clutch ECMV disconnection ........................................................... 44
Failure code [DXH5KB] 2nd clutch ECMV short circuit............................................................... 46
Failure code [DXH5KY] 2nd clutch ECMV hot short circuit......................................................... 48
Failure code [DXH6KA] 3rd clutch ECMV disconnection ............................................................ 50
Failure code [DXH6KB] 3rd clutch ECMV short circuit................................................................ 52
Failure code [DXH6KY] 3rd clutch ECMV hot short circuit.......................................................... 54
Failure code [DXH7KA] Reverse clutch ECMV disconnection.................................................... 56
Failure code [DXH7KB] Reverse clutch ECMV short circuit ....................................................... 58
Failure code [DXH7KY] R clutch ECMV hot short circuit ............................................................ 60
Failure code [DXH8KA] Forward clutch ECMV disconnection .................................................... 62
Failure code [DXH8KB] Forward clutch ECMV short circuit........................................................ 64
Failure code [DXH8KY] F clutch ECMV hot short circuit............................................................. 66
Failure code [DXHBKA] Right brake ECMV disconnection......................................................... 68
Failure code [DXHBKB] Right brake ECMV short circuit ............................................................ 70
Failure code [DXHBKY] Right brake ECMV hot short circuit ...................................................... 72
Failure code [DXHCKA] Left brake ECMV disconnection ........................................................... 74
Failure code [DXHCKB] Left brake ECMV short circuit............................................................... 76
Failure code [DXHCKY] Left brake ECMV hot short circuit......................................................... 78
D275AX-5E0
11
SEN00921-02
Troubleshooting of electrical system (E-mode)

SEN01646-00
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 At the locking-up of the torque converter, the torque converter lock-up display lamp
does not come on................................................................................................................. 26
E-12 The engine coolant temperature gauge does not indicate normally ................................... 26
E-13 Indication of the power train temperature gauge is abnormal............................................. 27
E-14 The hydraulic oil temperature gauge does not indicate normally ....................................... 27
E-15 Indication of the fuel gauge is abnormal ............................................................................. 28
E-16 Indications of gear speed and engine speed are abnormal................................................ 29
E-17 Indication of the shift mode service meter is abnormal....................................................... 29
E-18 The switch module cannot be operated.............................................................................. 30
E-19 The warning lamp does not flash or does not go out.......................................................... 31
E-20 The alarm buzzer does not sound or does not stop ........................................................... 32
E-21 Auto shift down is not possible or is not released............................................................... 33
E-22 Pivot turn is not possible or is not released ........................................................................ 34
E-23 The alarm buzzer cannot be cancelled............................................................................... 35
E-24 The operator mode cannot be operated ............................................................................. 36
E-25 The service mode cannot be operated ............................................................................... 38
E-26 The back-up alarm does not sound .................................................................................... 40
E-27 The night light, the headlamp, the working lamp and the rear lamp on the panel
do not come on .................................................................................................................... 42
E-28 The air conditioner does not operate .................................................................................. 48
E-29 KOMTRAX system does not operate normally ................................................................... 54
Troubleshooting of hydraulic and mechanical system (H-mode)
SEN01647-00
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
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 Machine does not turn (Not turned rightward or leftward) ....................................................
9
H-7 Steering speed or power is low............................................................................................. 10
H-8 Brake does not work............................................................................................................. 11
H-9 Torque converter does not lock-up ....................................................................................... 12
H-10 Overheat of power train oil temperature ............................................................................. 13
H-11 Abnormal sound around HSS pump or HSS motor ............................................................ 14
H-12 All work equipment speeds are slow .................................................................................. 15
H-13 Work equipment does not move......................................................................................... 16
H-14 Blade lift speed is slow or lacks power ............................................................................... 17
H-15 Blade tilt speed is slow or lacks power ............................................................................... 18
H-16 Ripper lift speed is slow or lacks power.............................................................................. 19
H-17 Ripper tilt speed is slow or lacks power.............................................................................. 20
H-18 Excessive hydraulic drift of blade lift................................................................................... 21
H-19 Excessive hydraulic drift of blade tilt................................................................................... 22
H-20 Excessive hydraulic drift of ripper lift .................................................................................. 23
H-21 Ripper pin puller cylinder does not work (Giant ripper attachment machine) ..................... 24
12
D275AX-5E0
SEN00921-02
H-22 Blade pitch does not work (Dual tilt attachment machine) ................................................. 25
H-23 Abnormal sound comes out from around work equipment pump....................................... 26
H-24 Fan speed is abnormal (Sound and/or vibration of fan are/is abnormally large or
engine overheats). ............................................................................................................... 27
SEN01648-00
Method of using troubleshooting chart ........................................................................................
3
S-1 Starting performance of engine is poor.................................................................................
6
S-2 Engine does not start............................................................................................................
8
S-3 Engine does not pick up smoothly........................................................................................ 12
S-4 Engine stops during operation .............................................................................................. 13
S-5 Engine does not rotate smoothly .......................................................................................... 14
S-6 Engine lack output (or lacks power) ..................................................................................... 15
S-7 Exhaust gas is black (incomplete combustion)..................................................................... 16
S-8 Oil consumption is excessive (or exhaust gas is blue) ......................................................... 18
S-9 Oil becomes dirty quickly...................................................................................................... 19
S-10 Fuel consumption is excessive........................................................................................... 20
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................. 21
S-12 Oil pressure drops .............................................................................................................. 22
S-13 Oil level rises (Entry of coolant or fuel)............................................................................... 24
S-14 Coolant temperature becomes too high (Overheating) ...................................................... 26
S-15 Abnormal noise is made ..................................................................................................... 27
S-16 Vibration is excessive ......................................................................................................... 28
General information on disassembly and assembly
SEN02340-00
How to read this manual .............................................................................................................
2
List of adhesives .........................................................................................................................
4
Special tool list ............................................................................................................................
7
Sketchs of special tools............................................................................................................... 15
SEN02341-00
Removal and installation of engine assembly .............................................................................
2
Removal and installation of radiator assembly (including hydraulic oil cooler assembly and
aftercooler assembly) ..................................................................................................................
7
Removal and installation of hydraulic oil cooler assembly .......................................................... 10
Removal and installation of aftercooler assembly ....................................................................... 12
Removal and installation of radiator guard assembly ................................................................. 14
Removal and installation of fuel tank assembly .......................................................................... 19
Removal and installation of engine hood assembly .................................................................... 20
Removal and installation of fan drive assembly .......................................................................... 22
Removal and installation of fan motor assembly......................................................................... 24
Engine
SEN02342-00
Removal and installation of fuel supply pump assembly.............................................................
2
Removal and installation of common rail ....................................................................................
6
Removal and installation of cylinder head assembly ..................................................................
9
Removal and installation of fuel injector assembly ..................................................................... 20
Removal and installation of engine front seal ............................................................................. 24
Removal and installation of engine rear seal .............................................................................. 26
Power train, Part 1
SEN02343-00
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 ...................................................... 15
Disassembly and assembly of PTO assembly ............................................................................ 26
Disassembly and assembly of torque converter assembly ......................................................... 33
Disassembly and assembly of torqflow transmission assembly.................................................. 43
D275AX-5E0
13
SEN00921-02
Power train, Part 2

SEN02344-00
Removal and installation of scavenging pump ............................................................................
2
Disassembly and assembly of HSS case assembly....................................................................
3
Removal and installation of final drive assembly......................................................................... 23
Disassembly and assembly of final drive assembly .................................................................... 26
SEN02345-00
Removal and installation of track frame assembly ......................................................................
2
Removal and installation of recoil spring assembly.....................................................................
7
Disassembly and assembly of recoil spring assembly ................................................................ 11
Removal and installation of idler assembly ................................................................................. 13
Disassembly and assembly of idler assembly............................................................................. 14
Removal and installation of track roller assembly ....................................................................... 18
Disassembly and assembly of track roller assembly................................................................... 21
Removal and installation of carrier roller assembly..................................................................... 25
Disassembly and assembly of carrier roller assembly ................................................................ 26
Removal and installation of 1st bogie assembly ......................................................................... 30
Removal and installation of 2nd, 3rd and 4th bogie assembly .................................................... 36
Disassembly and assembly of bogie assembly........................................................................... 44
SEN02346-00
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 ................................................................. 32
Hydraulic system
SEN02347-00
Removal and installation of HSS pump assembly.......................................................................
2
Removal and installation of work equipment and HSS charge pump assembly .........................
4
Removal and installation of power train and lubricating oil pump assembly ...............................
6
Removal and installation of HSS motor assembly ......................................................................
8
Removal and installation of fan pump assembly .........................................................................
9
Removal and installation of control valve assembly.................................................................... 11
Disassembly and assembly of work equipment control valve assembly ..................................... 15
Disassembly and assembly of hydraulic cylinder assembly........................................................ 16
Work equipment
SEN02348-00
Removal and installation of blade assembly ...............................................................................
2
Disassembly and assembly of ripper assembly ..........................................................................
4
SEN02349-00
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 floor frame assembly ....................................................................... 14
Electrical system
SEN02350-00
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 air conditioner unit assembly...........................................................
5
Removal and installation of monitor panel assembly ..................................................................
8
Hydraulic diagrams and drawings
SEN00941-00
Hydraulic diagrams and drawings ...............................................................................................
3
Hydraulic circuit diagram .........................................................................................................
3
Power train hydraulic circuit diagram.......................................................................................
5
14
D275AX-5E0
SEN00921-02

SEN00942-01
Electrical circuit diagram (1/12)...................................................................................................
3
5
7
9
Electrical circuit diagram (5/12)................................................................................................... 11
Electrical circuit diagram (10/12)................................................................................................. 21
Electrical circuit diagram (11/12) ................................................................................................. 23
Electrical circuit diagram (12/12)................................................................................................. 25
Electrical circuit diagram for inside cab ...................................................................................... 27
Air conditioner unit electrical circuit diagram............................................................................... 29
Connectors table and arrangement drawing ............................................................................... 31
D275AX-5E0
15
SEN00921-02
D275AX-5E0 Bulldozer
Form No. SEN00921-02
16
D275AX-5E0
SEN00922-01
BULLDOZER
1SHOP MANUAL
D275AX-5E0
Machine model
Serial number
D275AX-5E0
30001 and up

Safety notice ................................................................................................................................................... 2
How to read the shop manual ......................................................................................................................... 7
Explanation of terms for maintenance standard ............................................................................................. 9
Handling electric equipment and hydraulic component .................................................................................11
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
D275AX-5E0
SEN00922-01
Safety notice
(Rev. 2007/02)
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 situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1.
General precautions
k Mistakes in operation are extremely
dangerous. Read the Operation and
Maintenance Manual carefully before
operating the machine.
1) Before carrying out any greasing or
repairs, read all the safety plates stuck to
the machine. For the locations of the
safety plates and detailed explanation of
precautions, see the Operation and Maintenance Manual.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always
keep the tools and parts in their correct
places. Always keep the work area clean
and make sure that there is no dirt, water,
or oil on the floor. Smoke only in the areas
provided for smoking. Never smoke while
working.
3) When carrying out any operation, always
wear safety shoes and helmet. Do not
wear loose work clothes, or clothes with
buttons missing.
q
Always wear safety glasses when hitting parts with a hammer.
q
Always wear safety glasses when
grinding parts with a grinder, etc.
4) When carrying out any operation with 2 or
more workers, always agree on the operating procedure before starting. Always
inform your fellow workers before starting
any step of the operation. Before starting
work, hang UNDER REPAIR warning
signs in the operator's compartment.
5) Only qualified workers must carry out work
and operation which require license or
qualification.
6) Keep all tools in good condition, learn the
correct way to use them, and use the
proper ones of them. Before starting work,
thoroughly check the tools, machine, forklift, service car, etc.
7)
8)
If welding repairs are needed, always

have a trained and experienced welder
carry out the work. When carrying out
weld in g wo rk , al way s wear wel din g
gloves, apron, shielding goggles, cap and
other clothes suited for welding work.
Before starting work, warm up your body
thoroughly to start work under good condition.
Safety points
1 Good arrangement
2 Correct work clothes
3 Following work standard
4 Making and checking signs
5
Prohibition of operation and handling by

unlicensed workers
6 Safety check before starting work

7
Wearing protective goggles

(for cleaning or grinding work)
Wearing shielding goggles and protectors

(for welding work)
9 Good physical condition and preparation

10
2.
Precautions against work which you are

not used to or you are used to too much
Preparations for work

1) Before adding oil or making any repairs,
park the machine on hard and level
ground, and apply the parking brake and
block the wheels or tracks to prevent the
machine from moving.
2) Before starting work, lower the work
equipment (blade, ripper, bucket, etc.) to
the ground. If this is not possible, insert
the lock pin or use blocks to prevent the
work equipment from falling. In addition,
be sure to lock all the control levers and
hang warning signs on them.
D275AX-5E0
3)
4)
3.
When disassembling or assembling, support the machine with blocks, jacks, or

stands before starting work.
Remove all mud and oil from the steps or
other places used to get on and off the
machine. Always use the handrails, ladders or steps when getting on or off the
m a c h i n e . N e v e r j u m p o n o r o ff t h e
machine. If it is impossible to use the
handrails, ladders or steps, use a stand to
provide safe footing.
Precautions during work

1) Before disconnecting or removing components of the oil, water, or air circuits, first
release the pressure completely from the
circuit. When removing the oil filler cap, a
drain plug, or an oil pressure pickup plug,
loosen it slowly to prevent the oil from
spurting out.
2) The coolant and oil in the circuits are hot
when the engine is stopped, so be careful
not to get scalded. Wait for the oil and
coolant to cool before carrying out any
work on the oil or water circuits.
3) Before starting work, stop the engine.
When working on or around a rotating
part, in particular, stop the engine. When
checking the machine without stopping
the engine (measuring oil pressure,
revolving speed, temperature, etc.), take
extreme care not to get rolled or caught in
rotating parts or moving parts.
4) Before starting work, remove the leads
from the battery. Always remove the lead
from the negative () terminal first.
5) When raising a heavy component (heavier
than 25 kg), use a hoist or crane. Before
starting work, check that the slings (wire
ropes, chains, and hooks) are free from
damage. Always use slings which have
ample capacity and install them to proper
places. Operate the hoist or crane slowly
to prevent the component from hitting any
other part. Do not work with any part still
raised by the hoist or crane.
6) When removing a cover which is under
internal pressure or under pressure from a
spring, always leave 2 bolts in diagonal
positions. Loosen those bolts gradually
and alternately to release the pressure,
and then remove the cover.
7) When removing components, be careful
not to break or damage the electrical wiring. Damaged wiring may cause electrical
fires.
D275AX-5E0
SEN00922-01
8)
9)
10)
11)
12)
13)
14)
15)
16)
When removing piping, stop the fuel or oil

from spilling out. If any fuel or oil drips
onto the floor, wipe it up immediately. Fuel
or oil on the floor can cause you to slip
and can even start fires.
As a general rule, do not use gasoline to
wash parts. Do not use it to clean electrical parts, in particular.
Be sure to assemble all parts again in their
original places. Replace any damaged
parts and parts which must not be reused
with new parts. When installing hoses and
wires, be sure that they will not be damaged by contact with other parts when the
machine is operated.
When installing high pressure hoses,
make sure that they are not twisted. Damaged tubes are dangerous, so be
extremely careful when installing tubes for
high pressure circuits. In addition, check
t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
installed.
When assembling or installing parts,
always tighten them to the specified
torques. When installing protective parts
such as guards, or parts which vibrate violently or rotate at high speed, be particul 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
installed correctly.
When aligning 2 holes, never insert your
fingers or hand. Be careful not to get your
fingers caught in a hole.
When measuring hydraulic pressure,
check that the measuring tools are correctly assembled.
Take care when removing or installing the
tracks of track-type machines. When
removing the track, the track separates
suddenly, so never let anyone stand at
either end of the track.
If the engine is operated for a long time in
a place which is not ventilated well, you
may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.
SEN00922-01
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 seen well
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q
Do not stand under the load.
q
Do not step on the load.
2) Check the slings before starting sling
work.
3) Keep putting on gloves during sling work.
(Put on leather gloves, if available.)
4) Measure the weight of the load by the eye
and check its center of gravity.
5) Use proper sling according to the weight
of the load and method of slinging. If too
thick wire ropes are used to sling a light
load, the load may slip and fall.
6) Do not sling a load with 1 wire rope alone.
If it is slung so, it may rotate and may slip
out of the rope. Install 2 or more wire
ropes symmetrically.
k Slinging with 1 rope may cause
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original winding position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60, as a rule.
Do not sling a heavy load with ropes forming a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allowable load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes
sling a load vertically, up to 19.6 kN {2,000
kg} of total weight can be suspended.
This weight is reduced to 9.8 kN {1,000
kg} when the 2 ropes make a hanging
angle of 120. If the 2 ropes sling a 19.6
kN {2,000 kg} load at a lifting angle of
150, each of them is subjected to a force
as large as 39.2 kN {4,000 kg}.
8)
When installing wire ropes to an angular

load, apply pads to protect the wire ropes.
If the load is slippery, apply proper material to prevent the wire rope from slipping.
9) Use the specified eyebolts and fix wire
ropes, chains, etc. to them with shackles,
etc.
10) Apply wire ropes to the middle portion of
the hook.
q
Slinging near the tip of the hook may
cause the rope to slip off the hook
during hoisting. The hook has the
maximum strength at the middle portion.
11) Do not use twisted or kinked wire ropes.

12) When lifting up a load, observe the following.
q
Wind in the crane slowly until wire
ropes are stretched. When settling
the wire ropes with the hand, do not
grasp them but press them from
above. If you grasp them, your fingers
may be caught.
q
After the wire ropes are stretched,
stop the crane and check the condition of the slung load, wire ropes, and
pads.
D275AX-5E0
If the load is unstable or the wire rope

or chains are twisted, lower the load
and lift it up again.
q
Do not lift up the load slantingly.
13) When lifting down a load, observe the following.
q
When lifting down a load, stop it temporarily at 30 cm above the floor, and
then lower it slowly.
q
Check that the load is stable, and
then remove the sling.
q
Remove kinks and dirt from the wire
ropes and chains used for the sling
work, and put them in the specified
place.
SEN00922-01
13) If the hoist stops because of a power failure, turn the power switch OFF. When
turning on a switch which was turned OFF
by the electric shock prevention earth
leakage breaker, check that the devices
related to that switch are not in operation
state.
14) If you find an obstacle around the hoist,
stop the operation.
15) After finishing the work, stop the hoist at
the specified position and raise the hook
to at least 2 m above the floor. Do not
leave the sling installed to the hook.
5.
6.
Precautions for using mobile crane

a Read the Operation and Maintenance
Manual of the crane carefully in advance
and operate the crane safely.
Precautions for using overhead hoist crane
k When raising a heavy part (heavier
than 25 kg), use a hoist, etc. In Disassembly and assembly, the weight of a
part heavier than 25 kg is indicated
after the mark of 4.
1) Before starting work, inspect the wire
ropes, brake, clutch, controller, rails, over
wind stop device, electric shock prevention earth leakage breaker, crane collision
prevention device, and power application
warning lamp, and check safety.
2) Observe the signs for sling work.
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east,
west, south, and north) and the directions
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move
the crane while the slung load is swinging.
6) Do not raise or lower a load while the
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immediately in an emergency.
D275AX-5E0
7.
Selecting wire ropes

1) Select adequate ropes depending on the
weight of parts to be hoisted, referring to
the table below.
Wire ropes
(Standard Z twist ropes without galvanizing)
(JIS G3525, No. 6, Type 6X37-A)
Nominal
Allowable load
diameter of rope
mm
kN
ton
10
8.8
0.9
12
12.7
1.3
14
17.3
1.7
16
22.6
2.3
18
28.6
2.9
20
35.3
3.6
25
55.3
5.6
30
79.6
8.1
40
141.6
14.4
50
221.6
22.6
60
318.3
32.4
The allowable load is one-sixth of the

breaking strength of the rope used
(Safety coefficient: 6).
SEN00922-01
8.
Precautions for disconnecting and connecting hoses and tubes in air conditioner
circuit
1) Disconnection
k
2)
Collect the air conditioner refrigerant

(R134a) from the 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 atmosphere.
If the refrigerant gas (R134a) gets in
your eyes, you may lose your sight.
Accordingly, when collecting or filling
it, you must be qualified for handling
the refrigerant and put on protective
goggles.
Connection
1] When installing the air conditioner circuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not damaged or deteriorated.
4] When connecting the refrigerant piping, apply compressor oil for refrigerant (R134a) (DENSO: ND-OIL8,
ZEXEL: ZXL100PG (equivalent to
PAG46)) to its O-rings.
Example of O-ring (Fitted to every joint of

hoses and tubes)
For tightening torque, see the precautions for

installation in each section of "Disassembly
and assembly".
D275AX-5E0
How to read the shop manual

q
q
q
1.
SEN00922-01
Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
Materials and specifications are subject to change without notice.
Shop manuals are divided into the Chassis volume and Engine volume. For the engine unit, see the
engine volume of the engine model mounted on the machine.
Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The S mode of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q
Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q
Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
2.
Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
D275AX-5E0
SEN00922-01
3.
4.
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 )
Revisions
Revised brochures are shown in the shop manual composition table.
Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol
Item
Safety
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing work.
Weight
Weight of parts of component or parts. Caution necessary when

selecting hoisting wire, or when working posture is important, etc.
Tightening
torque
Coat
Oil, coolant
Drain
Remarks
Special safety precautions are necessary when performing work.
Places that require special attention for tightening torque during

assembly.
Places to be coated with adhesives, etc. during assembly.
Places where oil, etc. must be added, and capacity.
Places where oil, etc. must be drained, and quantity to be drained.
5.
Units
In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.
D275AX-5E0
SEN00922-01
Explanation of terms for maintenance standard
The maintenance standard values necessary for judgment of products and parts are described by the following terms.
1.
Standard size and tolerance

To be accurate, the finishing size of parts
is a little different from one to another.
q
To specify a finishing size of a part, a temporary standard size is set and an allowable difference from that size is indicated.
q
The above size set temporarily is called
the standard size and the range of difference from the standard size is called the
tolerance.
q
The tolerance with the symbols of + or is
indicated on the right side of the standard
size.
q
Example:
Standard size
120
Tolerance
0.022
0.126
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)
Usually, the size of a hole and the size of

the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft.
The tightness of fit is decided by the tolerance.
Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Standard size
60
D275AX-5E0
Tolerance
Shaft
Hole
0.030
+0.046
0.076
+0
SEN00922-01
2.
Standard clearance and standard value

The clearance made when new parts are
assembled is called the standard clearance, which is indicated by the range
from the minimum clearance to the maximum clearance.
q
When some parts are repaired, the clearance is generally adjusted to the standard
clearance.
q
A value of performance and function of
new products or equivalent is called the
standard value, which is indicated by a
range or a target value.
q
When some parts are repaired, the value
of performance/function is set to the standard value.
5.
3.
4.
Standard interference
q
When the diameter of a hole of a part
shown in the given standard size and tolerance table is smaller than that of the
mating shaft, the difference between those
diameters is called the interference.
q
The range (A B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the hole to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the standard interference.
q
After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.
Clearance limit
Parts can be used until the clearance
between them is increased to a certain
limit. The limit at which those parts cannot
be used is called the clearance limit.
q
If the clearance between the parts
exceeds the clearance limit, they must be
replaced or repaired.
q
6.
Interference limit
The allowable maximum interference
between the hole of a part and the shaft of
another part to be assembled is called the
interference limit.
q
The interference limit shows the repair
limit of the part of smaller tolerance.
q
If the interference between the parts
exceeds the interference limit, they must
be replaced or repaired.
q
Repair limit and allowable value

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 must be
replaced or repaired.
q
The performance and function of a product lowers while it is used. A value below
which the product can be used without
causing a problem is called the allowable
value.
q
If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from various tests or experiences in most cases,
however, it must be judged after considering the operating condition and customer's
requirement.
q
10
D275AX-5E0
Handling electric equipment and hydraulic component
SEN00922-01
To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must
be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on Handling electric equipment and
Handling hydraulic equipment (particularly gear oil and hydraulic oil).
Points to remember when handling electric
equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, connectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fitted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects
of rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they
are frequently removed and installed again, so
they are likely to suffer deformation or damage.
For this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2.
Main failures occurring in wiring harness

1) Defective contact of connectors (defective contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not
correctly aligned, or because there is corrosion or oxidization of the contact surfaces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connecting and disconnecting the connector about
10 times.
2)
Defective crimping or soldering of connectors

The pins of the male and female connectors are in contact at the crimped terminal
or soldered portion, but if there is excessive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
D275AX-5E0
11
SEN00922-01
12
3)
Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the soldering may be damaged, or the wiring
may be broken.
4)
High-pressure water entering connector

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

If oil or grease are stuck to the connector
and an oil film is formed on the mating surface between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with compressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the compressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air completely before cleaning with compressed air.
D275AX-5E0
3.
SEN00922-01
Removing, installing, and drying connectors and wiring harnesses

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

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

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

After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassembled for a long time, it is particularly easy for improper contact to
occur, so always cover the connector.
D275AX-5E0
13
SEN00922-01
2)
14
Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or damage to the connector pins.
Check that there is no damage or
breakage to the outside of the connector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or breakage, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stopper clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring harness.
For connectors fitted with boots, correct any protrusion of the boot. In
addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position.
a If the connector cannot be corrected easily, remove the clamp
and adjust the position.
q
If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
D275AX-5E0
3)
Heavy duty wire connector (DT 8-pole, 12pole)

Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizontally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
D275AX-5E0
SEN00922-01
Disconnection
Connection (Example of
incomplete setting of (a))
15
SEN00922-01
4)
16
Drying wiring harness

If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do
not use high-pressure water or steam
directly on the wiring harness. If water
gets directly on the connector, do as follows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
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 connector.
After drying, leave the wiring harness
disconnected and carry out a continuity test to check for any short circuits
between pins caused by water.
a After completely drying the conn e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
D275AX-5E0
4.
Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These control all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the controller.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness connectors connected to the controller. Fit an
arc welding ground close to the welding
point.
5.
Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before disconnecting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnecessary abnormality displays will be
generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the reading of the tester.
a If there is any change, there is probably defective contact in that circuit.
D275AX-5E0
SEN00922-01
17
SEN00922-01
Points to remember when handling hydraulic equipment

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

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

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

refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
18
D275AX-5E0
5.
Change hydraulic oil when the temperature

is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.
6.
Flushing operations
After disassembling and assembling the equipment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7.
Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment cannot remove, so it is an extremely effective
device.
D275AX-5E0
SEN00922-01
19
SEN00922-01
Connectors newly used for Tier 3 engines

1.
Slide lock type

(FRAMATOME-3, FRAMATOME-2)
q
107 170, 12V140 engines
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
(107, 114 engines)
Ne speed sensor of flywheel housing:
NE
(107 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)
2.
Pull lock type (PACKARD-2)

107 170, 12V140 engine
q
Various temperature sensors
Example)
Intake air temperature sensor in
intake manifold: TIM
Fuel temperature sensor: TFUEL
Oil temperature sensor: TOIL
Coolant temperature sensor: TWTR,
etc.
Disconnect the connector by pulling lock
(B) (on the wiring harness side) of connector (2) outward.
Disconnect connector (1) according to the following procedure.

1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connector (1) toward you.
a Even if lock (L2) is pressed, connector (1) cannot be pulled out toward
you, if part A does not float. In this
case, float part A with a small screwdriver while press lock (L2), and then
pull out connector (1) toward you.
20
D275AX-5E0
3.
SEN00922-01
Push lock type

q
107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)
Disconnect connector (3) according to the following procedure.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q
114 engine
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.
107 engine
2)
If the lock is on the underside, use

flat-head screwdriver [1] since you
cannot insert your fingers.
While pressing up lock (C) of the connector with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
D275AX-5E0
21
SEN00922-01
4)
125 170, 12V140 engine

While pressing lock (E) of the connector,
pullout connector (5) in the direction of the
arrow.
Example)
Fuel pressure in common rail: PFUEL etc.
(AMP-3)
4.
Turn-housing type (Round green connector)

140 engine
Example)
Intake air pressure sensor in intake manifold (CANNON-04): PIM etc.
1)
Disconnect connector (6) according to the

following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring harness side.
2)
Connect the connector according to the

1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of
the arrow until it clicks.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
22
D275AX-5E0
SEN00922-01
How to read electric wire code

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 symbols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX
0.85
L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.
Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.
Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indicated.)
1.
Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Type
Low-voltage
wire for
automobile
Thin-cover
low-voltage
wire for
automobile
Symbol
AV
AVS
Heat-resistant low-voltAEX
age wire for
automobile
D275AX-5E0
Material
Conductor
Insulator
Conductor
Annealed copper for electric appliance

Soft polyvinyl chloride
Insulator
Soft polyvinyl chloride
Conductor

Heat-resistant crosslinked
polyethylene
Insulator
Using
temperature
range (C)
Example of use
General wiring
(Nominal No. 5 and above)
30 to +60
General wiring
(Nominal No. 3 and below)
General wiring in extremely
50 to +110 cold district, wiring at high-temperature place
23
SEN00922-01
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
CovAV
Standard
4.6
er D
AEX
Standard
2.0
2.2
2.7
3.0
3.1
3.8
4.6
Nominal No.
Number of
strands/Diameter of strand
Conductor
Sectional
area (mm2)
d (approx.)
AVS
Standard
CovAV
Standard
er D
AEX
Standard
15
20
30
40
50
60
85
100
50/0.45
84/0.45
41/0.80
70/0.80
85/0.80
7.95
13.36
20.61
35.19
42.73
54.29
63.84
84.96
109.1
3.7
5.5
5.3
4.8
7.0
7.0
6.0
8.2
8.2
8.0
10.8
10.8
8.6
11.4
11.4
9.8
13.0
13.0
10.4
13.6
13.6
12.0
16.0
16.0
13.6
17.6
17.6
108/0.80 127/0.80 169/0.80 217/0.80
f of nominal No. denotes flexible.
24
D275AX-5E0
3.
SEN00922-01
Color codes table
(Table 3)
Color Code
B
Br
BrB
BrR
BrW
BrY
Ch
Dg
G
GB
GL
Gr
GR
GW
GY
L
LB
Lg
LgB
LgR
Color of wire
Color Code
LgW
LgY
LR
LW
LY
O
P
R
RB
RG
RL
RW
RY
Sb
Y
YB
YG
YL
YR
YW
Black
Brown
Brown & Black
Brown & Red
Brown & White
Brown & Yellow
Charcoal
Dark green
Green
Green & Black
Green & Blue
Gray
Green & Red
Green & White
Green & Yellow
Blue
Blue & Black
Light green
Light green & Black
Light green & Red
Color of wire
Light green & White
Light green & Yellow
Blue & Red
Blue & White
Blue & Yellow
Orange
Pink
Red
Red & Black
Red & Green
Red & Blue
Red & White
Red & Yellow
Sky Blue
Yellow
Yellow & Black
Yellow &Green
Yellow & Blue
Yellow & Red
Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: GW means that the background is Green and marking is White.
4.
Types of circuits and color codes
(Table 4)
Type of wire
Charge
Ground
Start
Light
Instrument
Signal
Type of
circuit
Others
D275AX-5E0
AVS or AV
R
B
R
RW
Y
G
L
Br
Lg
O
Gr
P
Sb
Dg
Ch
AEX
R
B
R
D
Y
G
L
WG
RB
YR
GW
LW
BrW
LgR
RY
YB
GR
LR
BrR
LgY
RG
YG
GY
LY
BrY
LgB
RL
YL
GB
LB
BrB
LgW
YW
GL
Gr
Br
25
SEN00922-01
Precautions when carrying out operation
[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
1.
q
q
q
q
q
q
q
q
q
q
Precautions when carrying out removal work

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

Nominal
number
04
05
3)
Plug (nut end)
Flange (hose end)
Sleeve head (tube end)
Split flange
07379-00400
07379-00500
07378-10400
07378-10500
07371-30400
07371-30500
If the part is not under hydraulic pressure, the following corks can be used.
Nominal
number
Part Number
06
08
10
12
14
16
18
20
22
24
07049-00608
07049-00811
07049-01012
07049-01215
07049-01418
07049-01620
07049-01822
07049-02025
07049-02228
07049-02430
Dimensions
D
d
L
6
5
8
8
6.5
11
10
8.5
12
12
10
15
14
11.5
18
16
13.5
20
18
15
22
20
17
25
22
18.5
28
24
20
30
27
07049-02734
27
22.5
34
D275AX-5E0
2.
q
q
q
q
q
q
q
q
q
q
q
q
q
a
3.
SEN00922-01
Precautions when carrying out installation work

Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
Bend the cotter pins and lock plates securely.
When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 3 drops of adhesive.
When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with gasket sealant.
Clean all parts, and correct any damage, dents, burrs, or rust.
Coat rotating parts and sliding parts with engine oil.
When press fitting parts, coat the surface with anti-friction compound (LM-P).
After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
When using the machine for the first time after repair or long storage, follow the same procedure.
Precautions when completing the operation
1) Refilling with coolant, oil and grease
q
If the coolant has been drained, tighten the drain valve, and add coolant to the specified level.
Run the engine to circulate the coolant through the system. Then check the coolant level
again.
q
If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level
again.
q
If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
a For details, see Testing and adjusting, Bleeding air.
q
Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
2) Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q
For the tightening torque, see Disassembly and assembly.
3) Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air
suction and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for
coolant leakage.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
D275AX-5E0
27
SEN00922-01
4)
5)
28
Checking muffler and exhaust pipe for damage and looseness

1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for
looseness.
If any bolt or nut is loosened, retighten it.
Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to Troubleshooting and Disassembly
and assembly.
D275AX-5E0
SEN00922-01
Method of disassembling and connecting push-pull type coupler

k
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.
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.
D275AX-5E0
29
SEN00922-01
Type 2
1.
Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to disconnect it. (Fig. 8)
2.
Connection
q
Hold the tightening portion and push body
contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9)
30
D275AX-5E0
SEN00922-01
Type 3
1.
Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 10)
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal portion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to disconnect it. (Fig. 12)
2.
Connection
q
Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 13)
D275AX-5E0
31
SEN00922-01
Standard tightening torque table

1.
Table of tightening torques for bolts and nuts

a Unless there are special instructions, tighten metric nuts and bolts to the torque below. (When using
torque wrench)
a
The following table corresponds to the bolts in Fig. A.
Thread diameter of bolt

mm
6
8
10
12
14
16
18
20
22
24
27
30
33
36
39
a
a Fig. A
Width across flats

mm
10
13
17
19
22
24
27
30
32
36
41
46
50
55
60
Tightening torque
Nm
kgm
11.8 14.7
1.2 1.5
27 34
2.8 3.5
59 74
6.0 7.5
98 123
10.0 12.5
153 190
15.5 19.5
235 285
23.5 29.5
320 400
33.0 41.0
455 565
46.5 58.0
610 765
62.5 78.0
785 980
80.0 100.0
1,150 1,440
118 147
1,520 1,910
155 195
1,960 2,450
200 250
2,450 3,040
250 310
2,890 3,630
295 370
The following table corresponds to the bolts in Fig. B.

mm
6
8
10
12
32
Width across flats

mm
10
13
14
27
Tightening torque
Nm
5.9 9.8
13.7 23.5
34.3 46.1
74.5 90.2
kgm
0.6 1.0
1.4 2.4
3.5 4.7
7.6 9.2
a Fig. B
D275AX-5E0
2.
Table of tightening torques for split flange bolts

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

mm
10
12
16
3.
Width across flats

mm
14
17
22
Tightening torque
Nm
kgm
59 74
6.0 7.5
98 123
10.0 12.5
235 285
23.5 29.5
Table of tightening torques for O-ring boss piping joints

a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.
Nominal No.
02
03,04
05,06
10,12
14
4.
SEN00922-01
Thread diameter
mm
14
20
24
33
42
Width across flats

mm
Tightening torque Nm {kgm}

Range
Target
35 63 { 3.5 6.5}
44 { 4.5}
84 132 { 8.5 13.5}
103 {10.5}
Varies depending
on type of connec- 128 186 {13.0 19.0}
157 {16.0}
tor.
363 480 {37.0 49.0}
422 {43.0}
746 1,010 {76.0 103}
883 {90.0}
Table of tightening torques for O-ring boss plugs

a Unless there are special instructions, tighten O-ring boss plugs to the torque below.
Nominal
No.
08
10
12
14
16
18
20
24
30
33
36
42
52
D275AX-5E0
Thread diameter
mm
8
10
12
14
16
18
20
24
30
33
36
42
52
Width across flats

mm
14
17
19
22
24
27
30
32
32
36

Range
Target
5.88 8.82 {0.6 0.9}
7.35 {0.75}
9.81 12.74 {1.0 1.3}
11.27 {1.15}
14.7 19.6 {1.5 2.0}
17.64 {1.8}
19.6 24.5 {2.0 2.5}
22.54 {2.3}
24.5 34.3 {2.5 3.5}
29.4 {3.0}
34.3 44.1 {3.5 4.5}
39.2 {4.0}
44.1 53.9 {4.5 5.5}
49.0 {5.0}
58.8 78.4 {6.0 8.0}
68.6 {7.0}
93.1 122.5 { 9.5 12.5}
107.8 {11.0}
107.8 147.0 {11.0 15.0}
127.4 {13.0}
127.4 176.4 {13.0 18.0}
151.9 {15.5}
181.3 240.1 {18.5 24.5}
210.7 {21.5}
274.4 367.5 {28.0 37.5}
323.4 {33.0}
33
SEN00922-01
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.
Nominal
No. of
hose
Width
across
flats
02
19
03
04
05
06
(10)
(12)
(14)
6.
22
24
27
32
36
41
46
55
Range
34 54 { 3.5 5.5}
34 63 { 3.5 6.5}
54 93 { 5.5 9.5}
59 98 { 6.0 10.0}
84 132 { 8.5 13.5}
128 186 {13.0 19.0}
177 245 {18.0 25.0}
177 245 {18.0 25.0}
197 294 {20.0 30.0}
246 343 {25.0 35.0}
Target
44 { 4.5}
74 { 7.5}
78 { 8.0}
103 {10.5}
157 {16.0}
216 {22.0}
216 {22.0}
245 {25.0}
294 {30.0}
mm
6
8
10
12
14
14
18
22
24
30
33
36
42
Tightening torque
Bolts and nuts
Nm
10 2
24 4
43 6
77 12
kgm
1.02 0.20
2.45 0.41
4.38 0.61
7.85 1.22
Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
Thread size
mm
6
8
10
12
14
34
Thread size
(mm)
Face seal
Nominal No. Thread diameNumber of
ter (mm) (Refthreads, type of
erence)
thread
9/16-18UN
14.3
11/16-16UN
17.5
13/16-16UN
20.6
1-14UNS
25.4
1-3/16-12UN
30.2
Table of tightening torques for 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.
Thread size
7.
Taper seal
Tightening torque
Nm
82
10 2
12 2
24 4
36 5
kgm
0.81 0.20
1.02 0.20
1.22 0.20
2.45 0.41
3.67 0.51
D275AX-5E0
8.
SEN00922-01
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
inch
1/16
1/8
1/4
3/8
1/2
3/4
1
D275AX-5E0
Tightening torque
Nm
31
82
12 2
15 2
24 4
36 5
60 9
kgm
0.31 0.10
0.81 0.20
1.22 0.20
1.53 0.20
2.45 0.41
3.67 0.51
6.12 0.92
35
SEN00922-01
Conversion table
Method of using the conversion table

The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
1.
Convert 55 mm into inches.

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

1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches
(A)
36
(B)
0
10
20
30
40
0
0
0.394
0.787
1.181
1.575
1
0.039
0.433
0.827
1.220
1.614
2
0.079
0.472
0.866
1.260
1.654
3
0.118
0.512
0.906
1.299
1.693
4
0.157
0.551
0.945
1.339
1.732
50
60
70
80
90
1.969
2.362
2.756
3.150
3.543
2.008
2.402
2.795
3.189
3.583
2.047
2.441
2.835
3.228
3.622
2.087
2.480
2.874
3.268
3.661
2.126
2.520
2.913
3.307
3.701
5
0.197
0.591
0.984
1.378
1.772
(C)
2.165
2.559
2.953
3.346
3.740
6
0.236
0.630
1.024
1.417
1.811
7
0.276
0.669
1.063
1.457
1.850
2.205
2.598
2.992
3.386
3.780
2.244
2.638
3.032
3.425
3.819
1 mm = 0.03937 in
8
9
0.315
0.354
0.709
0.748
1.102
1.142
1.496
1.536
1.890
1.929
2.283
2.677
3.071
3.465
3.858
2.323
2.717
3.110
3.504
3.898
D275AX-5E0
SEN00922-01
Millimeters to inches
0
10
20
30
40
0
0
0.394
0.787
1.181
1.575
1
0.039
0.433
0.827
1.220
1.614
2
0.079
0.472
0.866
1.260
1.654
3
0.118
0.512
0.906
1.299
1.693
4
0.157
0.551
0.945
1.339
1.732
5
0.197
0.591
0.984
1.378
1.772
6
0.236
0.630
1.024
1.417
1.811
1 mm = 0.03937 in
7
8
9
0.276
0.315
0.354
0.669
0.709
0.748
1.063
1.102
1.142
1.457
1.496
1.536
1.850
1.890
1.929
50
60
70
80
90
1.969
2.362
2.756
3.150
3.543
2.008
2.402
2.795
3.189
3.583
2.047
2.441
2.835
3.228
3.622
2.087
2.480
2.874
3.268
3.661
2.126
2.520
2.913
3.307
3.701
2.165
2.559
2.953
3.346
3.740
2.205
2.598
2.992
3.386
3.780
2.244
2.638
3.032
3.425
3.819
1 kg = 2.2046 lb
6
7
8
9
13.23
15.43
17.64
19.84
35.27
37.48
39.68
41.89
57.32
59.53
61.73
63.93
79.37
81.57
83.78
85.98
101.41 103.62 105.82 108.03
2.283
2.677
3.071
3.465
3.858
2.323
2.717
3.110
3.504
3.898
Kilogram to pound
0
10
20
30
40
0
0
22.05
44.09
66.14
88.18
1
2.20
24.25
46.30
68.34
90.39
2
4.41
26.46
48.50
70.55
92.59
3
6.61
28.66
50.71
72.75
94.80
4
8.82
30.86
51.91
74.96
97.00
5
11.02
33.07
55.12
77.16
99.21
50
60
70
80
90
110.23
132.28
154.32
176.37
198.42
112.44
134.48
156.53
178.57
200.62
114.64
136.69
158.73
180.78
202.83
116.85
138.89
160.94
182.98
205.03
119.05
141.10
163.14
185.19
207.24
121.25
143.30
165.35
187.39
209.44
123.46
145.51
167.55
189.60
211.64
125.66
147.71
169.76
191.80
213.85
127.87
149.91
171.96
194.01
216.05
130.07
152.12
174.17
196.21
218.26
Liters to U.S. Gallons
0
10
20
30
40
0
1
2
0
0.264
0.528
2.642
2.906
3.170
5.283
5.548
5.812
7.925
8.189
8.454
10.567 10.831 11.095
3
0.793
3.434
6.076
8.718
11.359
4
1.057
3.698
6.340
8.982
11.624
1 l = 0.2642 U.S.Gal
5
6
7
8
9
1.321 1.585
1.849
2.113
2.378
3.963 4.227
4.491
4.755
5.019
6.604 6.869
7.133
7.397
7.661
9.246 9.510
9.774 10.039 10.303
11.888 12.152 12.416 12.680 12.944
50
60
70
80
90
13.209
15.850
18.492
21.134
23.775
14.001
16.643
19.285
21.926
24.568
14.265
16.907
19.549
22.190
24.832
14.529
17.171
19.813
22.455
25.096
D275AX-5E0
13.473
16.115
18.756
21.398
24.040
13.737
16.379
19.020
21.662
24.304
14.795
17.435
20.077
22.719
25.361
15.058
17.700
20.341
22.983
25.625
15.322
17.964
20.605
23.247
25.889
15.586
18.228
20.870
23.511
26.153
37
SEN00922-01
Liters to U.K. Gallons
0
10
20
30
40
0
0
2.200
4.399
6.599
8.799
1
0.220
2.420
4.619
6.819
9.019
2
0.440
2.640
4.839
7.039
9.239
3
0.660
2.860
5.059
7.259
9.459
4
0.880
3.080
5.279
7.479
9.679
5
1.100
3.300
5.499
7.699
9.899
50
60
70
80
90
10.998
13.198
15.398
17.598
19.797
11.281
13.418
15.618
17.818
20.017
11.438
13.638
15.838
18.037
20.237
11.658
13.858
16.058
18.257
20.457
11.878
14.078
16.278
18.477
20.677
12.098
14.298
16.498
18.697
20.897
1 l = 0.21997 U.K.Gal
6
7
8
9
1.320
1.540
1.760
1.980
3.520
3.740
3.950
4.179
5.719
5.939
6.159
6.379
7.919
8.139
8.359
8.579
10.119 10.339 10.559 10.778
12.318
14.518
16.718
18.917
21.117
12.528
14.738
16.938
19.137
21.337
12.758
14.958
17.158
19.357
21.557
12.978
15.178
17.378
19.577
21.777
kgm to ft.lb
0
10
20
30
40
0
0
72.3
144.7
217.0
289.3
1
7.2
79.6
151.9
224.2
296.6
2
14.5
86.8
159.1
231.5
303.8
3
21.7
94.0
166.4
238.7
311.0
4
28.9
101.3
173.6
245.9
318.3
5
36.2
108.5
180.8
253.2
325.5
6
43.4
115.7
188.1
260.4
332.7
1 kgm = 7.233 ft.lb

7
8
9
50.6
57.9
65.1
123.0
130.2
137.4
195.3
202.5
209.8
267.6
274.9
282.1
340.0
347.2
354.4
50
60
70
80
90
361.7
434.0
506.3
578.6
651.0
368.9
441.2
513.5
585.9
658.2
376.1
448.5
520.8
593.1
665.4
383.4
455.7
528.0
600.3
672.7
390.6
462.9
535.2
607.6
679.9
397.8
470.2
542.5
614.8
687.1
405.1
477.4
549.7
622.0
694.4
412.3
484.6
556.9
629.3
701.6
419.5
491.8
564.2
636.5
708.8
426.8
499.1
571.4
643.7
716.1
100
110
120
130
140
723.3
730.5
737.8 745.0
752.2
759.5 766.7
773.9
781.2
788.4
795.6
802.9
810.1 817.3
824.6
831.8 839.0
846.3
853.5
860.7
868.0
875.2
882.4 889.7
896.9
904.1
911.4
918.6
925.8
933.1
940.3
947.5
954.8 962.0
969.2
976.5 983.7
990.9
998.2 1005.4
1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150
160
170
180
190
1084.9
1157.3
1129.6
1301.9
1374.3
38
1092.2
1164.5
1236.8
1309.2
1381.5
1099.4
1171.7
1244.1
1316.4
1388.7
1106.6
1179.0
1251.3
1323.6
1396.0
1113.9
1186.2
1258.5
1330.9
1403.2
1121.1
1193.4
1265.8
1338.1
1410.4
1128.3
1200.7
1273.0
1345.3
1417.7
1135.6
1207.9
1280.1
1352.6
1424.9
1142.8
1215.1
1287.5
1359.8
1432.1
1150.0
1222.4
1294.7
1367.0
1439.4
D275AX-5E0
SEN00922-01
kg/cm2 to lb/in2
0
10
20
30
40
0
0
142.2
284.5
426.7
568.9
1
14.2
156.5
298.7
440.9
583.2
2
28.4
170.7
312.9
455.1
597.4
3
42.7
184.9
327.1
469.4
611.6
4
56.9
199.1
341.4
483.6
625.8
5
71.1
213.4
355.6
497.8
640.1
6
85.3
227.6
369.8
512.0
654.3
1 kg/cm2 = 14.2233 lb/in2

7
8
9
99.6
113.8
128.0
241.8
256.0
270.2
384.0
398.3
412.5
526.3
540.5
554.7
668.5
682.7
696.9
50
60
70
80
90
711.2
853.4
995.6
1,138
1,280
725.4
867.6
1,010
1,152
1,294
739.6
881.8
1,024
1,166
1,309
753.8
896.1
1,038
1,181
1,323
768.1
910.3
1,053
1,195
1,337
782.3
924.5
1,067
1,209
1,351
796.5
938.7
1,081
1,223
1,365
810.7
953.0
1,095
1,237
1,380
825.0
967.2
1,109
1,252
1,394
839.2
981.4
1,124
1,266
1,408
100
110
120
130
140
1,422
1,565
1,707
1,849
1,991
1,437
1,579
1,721
1,863
2,005
1,451
1,593
1,735
1,877
2,020
1,465
1,607
1,749
1,892
2,034
1,479
1,621
1,764
1,906
2,048
1,493
1,636
1,778
1,920
2,062
1,508
1,650
1,792
1,934
2,077
1,522
1,664
1,806
1,949
2,091
1,536
1,678
1,821
1,963
2,105
1,550
1,693
1,835
1,977
2,119
150
160
170
180
190
2,134
2,276
2,418
2,560
2,702
2,148
2,290
2,432
2,574
2,717
2,162
2,304
2,446
2,589
2,731
2,176
2,318
2,460
2,603
2,745
2,190
2,333
2,475
2,617
2,759
2,205
2,347
2,489
2,631
2,773
2,219
2,361
2,503
2,646
2,788
2,233
2,375
2,518
2,660
2,802
2,247
2,389
2,532
2,674
2,816
2,262
2,404
2,546
2,688
2,830
200
210
220
230
240
2,845
2,987
3,129
3,271
3,414
2,859
3,001
3,143
3,286
3,428
2,873
3,015
3,158
3,300
3,442
2,887
3,030
3,172
3,314
3,456
2,901
3,044
3,186
3,328
3,470
2,916
3,058
3,200
3,343
3,485
2,930
3,072
3,214
3,357
3,499
2,944
3,086
3,229
3,371
3,513
2,958
3,101
3,243
3,385
3,527
2,973
3,115
3,257
3,399
3,542
D275AX-5E0
39
SEN00922-01
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1C = 33.8F
F
40.4
37.2
34.4
31.7
28.9
40
35
30
25
20
40.0
31.0
22.0
13.0
4.0
11.7
11.1
10.6
10.0
9.4
11
12
13
14
15
51.8
53.6
55.4
57.2
59.0
7.8
8.3
8.9
9.4
10.0
46
47
48
49
50
114.8
116.6
118.4
120.2
122.0
27.2
27.8
28.3
28.9
29.4
81
82
83
84
85
177.8
179.6
181.4
183.2
185.0
28.3
27.8
27.2
26.7
26.1
19
18
17
16
15
2.2
0.4
1.4
3.2
5.0
8.9
8.3
7.8
7.2
6.7
16
17
18
19
20
60.8
62.6
64.4
66.2
68.0
10.6
11.1
11.7
12.2
12.8
51
52
53
54
55
123.8
125.6
127.4
129.2
131.0
30.0
30.6
31.1
31.7
32.2
86
87
88
89
90
186.8
188.6
190.4
192.2
194.0
25.6
25.0
24.4
23.9
23.3
14
13
12
11
10
6.8
8.6
10.4
12.2
14.0
6.1
5.6
5.0
4.4
3.9
21
22
23
24
25
69.8
71.6
73.4
75.2
77.0
13.3
13.9
14.4
15.0
15.6
56
57
58
59
60
132.8
134.6
136.4
138.2
140.0
32.8
33.3
33.9
34.4
35.0
91
92
93
94
95
195.8
197.6
199.4
201.2
203.0
22.8
22.2
21.7
21.1
20.6
9
8
7
6
5
15.8
17.6
19.4
21.2
23.0
3.3
2.8
2.2
1.7
1.1
26
27
28
29
30
78.8
80.6
82.4
84.2
86.0
16.1
16.7
17.2
17.8
18.3
61
62
63
64
65
141.8
143.6
145.4
147.2
149.0
35.6
36.1
36.7
37.2
37.8
96
97
98
99
100
204.8
206.6
208.4
210.2
212.0
20.0
19.4
18.9
18.3
17.8
4
3
2
1
0
24.8
26.6
28.4
30.2
32.0
0.6
0
0.6
1.1
1.7
31
32
33
34
35
87.8
89.6
91.4
93.2
95.0
18.9
19.4
20.0
20.6
21.1
66
67
68
69
70
150.8
152.6
154.4
156.2
158.0
40.6
43.3
46.1
48.9
51.7
105
110
115
120
125
221.0
230.0
239.0
248.0
257.0
17.2
16.7
16.1
15.6
15.0
1
2
3
4
5
33.8
35.6
37.4
39.2
41.0
2.2
2.8
3.3
3.9
4.4
36
37
38
39
40
96.8
98.6
100.4
102.2
104.0
21.7
22.2
22.8
23.3
23.9
71
72
73
74
75
159.8
161.6
163.4
165.2
167.0
54.4
57.2
60.0
62.7
65.6
130
135
140
145
150
266.0
275.0
284.0
293.0
302.0
14.4
13.9
13.3
12.8
12.2
6
7
8
9
10
42.8
44.6
46.4
48.2
50.0
5.0
5.6
6.1
6.7
7.2
41
42
43
44
45
105.8
107.6
109.4
111.2
113.0
24.4
25.0
25.6
26.1
26.7
76
77
78
79
80
168.8
170.6
172.4
174.2
176.0
68.3
71.1
73.9
76.7
79.4
155
160
165
170
175
311.0
320.0
329.0
338.0
347.0
40
D275AX-5E0
D275AX-5E0
SEN00922-01
41
SEN00922-01
42
D275AX-5E0
SEN00924-00
BULLDOZER
1SHOP MANUAL
D275AX-5E0
Machine model
Serial number
D275AX-5E0
30001 and up
01 Specification

Specification and technical data...................................................................................................................... 2
Specefication dimension drawings........................................................................................................ 2
Specifications........................................................................................................................................ 3
Weight table .......................................................................................................................................... 9
Table of fuel, coolant and lubricants ....................................................................................................11
D275AX-5E0
SEN00924-00
01 Specification

Specefication dimension drawings
Item
Unit
Semi U-tilt dozer +

Giant ripper
U-tilt dozer +
Giant ripper
Semi U-tilt dozer +

Multi-shank ripper
U-tilt dozer+
Multi-shank ripper
Overall
length
mm
9,260
9,595
8,905
9,245
Overall
height
(with ROPS)
mm
3,915
(3,990)
3,915
(3,990)
3,915
(3,990)
3,915
(3,990)
Overall
width
mm
4,300
4,615
4,300
4,615
D275AX-5E0
01 Specification
SEN00924-00
Machine model
D275AX-5E0
Serial number
30001 and up
Machine weight
Bare tractor
Transmission speed ranges

Overall height Overall width Overall length
Dimensions
Ground pressure
Performance
Min. turning radius

Gradeability
Stability (front, rear, left, right)
kg
50,800
m
deg.
deg.
3,9 (Pivot turn)

30
35
Forward
Above with semi U-dozer + variable multishank ripper + ROPS + cab + air conditioner + side cover
38,430
1st speed
2nd speed
3rd speed
km/h
3.6
6.7
11.2
Reverse
Weight
Specifications
1st speed
2nd speed
3rd speed
km/h
4.7
8.7
14.9
Bare tractor
With semi U-dozer + variable multishank ripper
With ROPS + cab + air conditioner +
side cover
With U-dozer + variable multi-shank
ripper + ROPS + cab + air conditioner
+ side cover
Bare tractor (To top of lift cylinder)
With Semi U-dozer + variable multishank ripper
ripper
88.26 {0.90}
kPa {kg/cm2}
119.63 {1.22}
5,570
8,905
mm
9,245
Bare tractor (To top of lift cylinder)

With Semi U-dozer + variable multishank ripper
ripper
mm
To top of exhaust pipe

To top of air intake duct
(To top of control lever)
mm
D275AX-5E0
117.67 {1.20}
2,925
4,300
4,615
3,915
3,153
Overall height
Dimensions
SEN00924-00
01 Specification
Machine model
D275AX-5E0
Serial number
30001 and up
With cab
With ROPS canopy
With canopy
Track gauge
Length of track on ground
Track shoe width (Standard)
Minimum ground clearance
(To the bottom of under cover)
mm
mm
Name
Performance
Engine
Flywheel horsepower
Max. torque
Max. speed at no load
Min. speed at no load
Min. fuel consumption ratio
Starting motor
Alternator
Battery
Power train system
Radiator core type
Torque converter
Transmission
2,260
3,480
610
510
SAA6D140E-5
Type of engine
Number of cylinders = Bore Stroke

Piston displacement
3,915
3,990
3,985
4-cycle, water-cooled, in-line vertical type,

direct injection type with turbocharger and aftercooler
mm
l {cc}
6140 x 165
15.24 {15,240}
kw{HP}/rpm
Nm{kgm}/rpm
rpm
rpm
g/kwh {g/HPh}
306{410}/2,000
1,989{203}/1,400
2,150
700
215 {160}
24V, 11kW
24V, 75A
12V, 170Ah x 2
Rectangle wave fin
3-element, 1-stage, 1-phase
Planetary gear type, multiple disc clutch type,
hydraulically actuated type (electric),
force-feed lubrication gear pump type,
forward 3-speed, reverse 3-speed,
electrically operated type
D275AX-5E0
01 Specification
SEN00924-00
Machine model
D275AX-5E0
Serial number
30001 and up
HSS pump
Variable swash plate type (HPV180)

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

Max. allowable working pressure: 41.2 {420}
Spiral bevel gear type, force-feed lubrication
gear pump type
Bevel gear shaft
HSS steering system
Differential planetary gear type, hydraulic motor actuated type, electric motorized type, hydraulically actuated type
Master brake
Wet type, multiple disc clutch type, spring-boosted

type, hydraulically actuated type, pedal operated type
HSS
Power train system
HSS motor
MPa
{kg/cm2}
Spur gear 1-stage, planetary gear 1-stage type,

splash type lubrication
Undercarriage
Final drive
Suspension
Rigid, balancing beam type
Carrier roller
2 on each side
Track roller
7 on each side
Assembly type, single grouser, 39 each side Pitch:
260.6 mm
Track shoe (610 mm)

Power train + lubrication pump (tandem)
Gear type (BAR(3)100+50)
Variable in-line pump type
Work equipment
hydraulic system
Scavenging pump
Work equipment pump
Cooling fan pump
Cooling fan motor
D275AX-5E0
Gear type (BAR(3)160)

MPa
{kg/cm2}
Variable swash plate type (HPV112)

l/min/rpm
MPa
{kg/cm2}
Variable swash plate type: (LPV64)

l/min/rpm
MPa
{kg/cm2}
Fixed swash plate type (LMF110)

Max. allowable working pressure: 18.6 {190}
Main control
valve
SEN00924-00
01 Specification
Machine model
D275AX-5E0
Serial number
30001 and up
Type
For blade lift
For blade tilt
For ripper lift
For ripper tilt
Double + single + single type, spool type,

hydraulic assisted type Ripper tilt + ripper lift +
blade lift + blade tilt
Dimension of riper Dimension of ripper Dimension of blade Dimension of blade Dimension of blade
tilt cylinder
lift cylinder
tilt + pitch cylinder
tilt cylinder
lift cylinder
Hydraulic cylinder
Work equipment hydraulic system
Type
Double acting piston type

Cylinder bore
Piston rod outside diameter
Piston stroke (Max.)
Max. distance between pins
Min. distance between pins
mm
mm
mm
mm
mm
120
80
1,495
2,470
985
Cylinder bore
mm
mm
mm
mm
mm
180
100
190
1,555
1,365
Cylinder bore
mm
mm
mm
mm
mm
180
100
190
1,555
1,365
Cylinder bore
mm
mm
mm
mm
mm
180
100
465
1,565
1,100
Cylinder bore
mm
mm
mm
mm
mm
160
90
455
1,570
1,115
Hydraulic tank
Box type(Control valve externally installed type)
D275AX-5E0
01 Specification
SEN00924-00
Machine model
D275AX-5E0
Serial number
30001 and up
Type
Hydraulic semi U-tilt dozer,Hydraulic U-tilt dozer
mm
1,450
Performance
mm
640
mm
deg.
m3
1,000
6
13.7
Dimensions
Blade width
Blade height
Blade cutting angle
mm
mm
deg.
4,300
1,960
52
Max. lifting blade height

(from ground level)
Max. lowering blade depth
(from ground level)
Max. tilt
Blade cutting angle variation
Blade capacity (SAE)
mm
1,450
Performance
Brace type (Right-side tilt cylinder)
Max. lifting blade height

(from ground level)
Max. lowering blade depth
(from ground level)
Max. tilt
Blade cutting angle variation
Blade capacity (SAE)
mm
640
mm
deg.
m3
1,070
6
16.6
Blade width
Blade height
Blade cutting angle
mm
mm
deg.
4,615
1,973
52
Max. tilt
Max. pitch angle
Max. pitch-back angle
mm
deg.
deg.
1,140
6
6
Max. tilt
Max. pitch angle
Max. pitch-back angle
mm
deg.
deg.
1,220
6
6
Dimensions Performance Dimensions
U-dozer
U-dozer
Semi U-dozer
Work equipment
Semi U-dozer
Blade support method
D275AX-5E0
01 Specification
Machine model
D275AX-5E0
Serial number
30001 and up
Type
Weight
Beam length
Number of shanks
kg
mm
unit
deg.
Cutting depth
Max. digging depth
Max. lifting height
mm
mm
Type
Weight
Beam length
Number of shanks
Cutting angle (Standard)
kg
mm
unit
deg.
Cutting depth
Max. digging depth
Max. lifting height
mm
mm
Performance
Cutting angle (Standard)
Performance
Variable multi-shank ripper

Variable giant ripper
Work equipment
SEN00924-00
Variable cutting angle type,parallelogram type

4,490
2,495
3
51.7 (Stepless adjustment is possible between 38.9
and 61.2 deg.)
Two Switch-Selectable
900
955
Variable cutting angle type, parallelogram type
3,640
1,252
1
52.7 (Stepless adjustment is possible between 38.7
and 62.2)
Three Switch-Selectable
1,300
870
D275AX-5E0
01 Specification
SEN00924-00
Weight table
a
This weight table is for reference in handling or transporting components.

Unit: kg
Machine model
D275AX-5E0
Serial number
30001 and up
Engine
Engine assembly
Damper assembly
Universal joint
Engine mounting parts (Wiring)
1,850
135
25
5
Radiator assembly
(Including built-in oil cooler)
Aftercooler assembly
Hydraulic cooler
Fuel tank assembly (When empty)
Fuel tank assembly (When full)
49
25
385
1,090
Power train unit assembly (Including HSS pump, motor)

Torque converter, PTO assembly
Transmission assembly
HSS assembly
Brake valve assembly
HSS charging filter assembly
HSS cooler bypass valve assembly
Power train filter assembly
Scavenging pump
Power train, lubricating pump
Work equipment pump + HSS charging pump
HSS motor
HSS pump
Cooling fan pump
Cooling fan motor
2,615
534
645
996
14
25
5
23 x 2
19
27
78
64
103
40
25
Final drive assembly

Sprocket teeth
Hull frame assembly
Track group assembly (each side)
Track frame
Idler assembly
Recoil spring assembly
First bogie and track roller assembly
Second-fourth bogies and track roller assembly
Track roller assembly (Single flange x 1)
Track roller assembly (Double flange x 1)
Carrier roller assembly
D275AX-5E0
451
1,720 x 2
(25 x 5) x 2
4,054
5,021
1,396
333
352
231
527 x 3
149 x 2
161 x 5
58 x 2
SEN00924-00
01 Specification
Unit: kg
Machine model
D275AX-5E0
Serial number
30001 and up
Track shoe assembly (610mm width, wet type)

Pivot shaft assembly
Equalizer bar
3,405 x 2
142 x 2
273
Hydraulic tank assembly

Main control valve
(Blade lift + blade tilt + ripper lift + ripper tilt)
166
Engine underguard
Transmission underguard
Operator seat
250
312
41
Semi U-tilt dozer assembly

Blade
Straight frame
Tilt brace
Center brace
Tilt cylinder assembly
6,750
4,150
967 x 2
153 x 1
141 x 2
230
Semi U-tilt + pitch dozer assembly

Blade
Straight frame
Center brace
Pitch cylinder assembly
6,827
4,150
967 x 2
141 x 2
230 x 2
Radiator guard assembly (Including cylinder yoke + lattice mask)

Blade lift cylinder assembly
1,336
235 x 2
Multi-shank ripper assembly

Shank
Lift cylinder assembly
4,462
350 x 3
184 x 2
155 x 2
Giant ripper assembly

Shank
Lift cylinder assembly
Pin puller cylinder assembly
3,600
500 x 1
184 x 2
155 x 2
7
ROPS assembly (Specification with cab)

Cab assembly
ROPS canopy
Dash board
Floor frame assembly
Air conditioner assembly (Including air conditioner unit assembly)
Operator seat assembly
10
99
605
455
650
83
591
87
64
D275AX-5E0
01 Specification
SEN00924-00
Table of fuel, coolant and lubricants

a
For details of the notes (Note 1, Note 2 - - -) in the table, see Operation and Maintenance Manual.
D275AX-5E0
11
SEN00924-00
01 Specification
Unit: l
Refilling points
D275AX-5E0
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
(with blade, without ripper)
270
130
Cooling system
(including reservoir tank)
110
Fuel tank
840
12
D275AX-5E0
SEN00924-00
01 Specification
14
D275AX-5E0
SEN00926-00
BULLDOZER
1SHOP MANUAL
D275AX-5E0
Machine model
Serial number
D275AX-5E0
30001 and up
10 Structure, function and

maintenance standard

Engine and cooling system ............................................................................................................................. 2
Engine mount ....................................................................................................................................... 2
Cooling system..................................................................................................................................... 4
Cooling fan pump ................................................................................................................................. 6
Cooling fan motor............................................................................................................................... 14
D275AX-5E0
SEN00926-00
Engine mount
Unit: mm
No.
Check item
Clearance between bracket
and cushion
Free height of mount rubber
Criteria
Standard
size
60
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
0.100
0.300
+0.046
+0.046
0.100
0.346
0.4
Standard clearance
Repair limit
90
84
Replace
D275AX-5E0
SEN00926-00
Cooling system
D275AX-5E0
A:
B:
C:
D:
Power train oil cooler inlet

Power train oil cooler outlet
Hydraulic oil cooler inlet
Hydraulic oil cooler outlet
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Hydraulic oil cooler

Radiator cap
Aftercooler outlet hose
Radiator inlet hose
Aftercooler inlet hose
Radiator
Aftercooler
Power train oil cooler
Radiator outlet hose
Drain plug
Cooling fan motor
Cooling fan
Reservoir tank
SEN00926-00
Specifications
Radiator
Power train
oil cooler
Hydraulic oil cooler
Aftercooler
Rectangle wave fin
PTO-OL
J4
Rectangle straight fin
8.0/2
4.0
8.0/2
Total heat dissipation surface (m2)
41.99 x 3
3.741
8.52
25.82
Cracking pressure of pressure valve (kPa{kg/cm2})
88.3 14.7
{0.9 0.15}
Cracking pressure of vacuum valve (kPa {kg/cm2})
0 4.9
{0 0.05}
Core type
Fin pitch (mm)
D275AX-5E0
SEN00926-00
Cooling fan pump
LPV64
P1:
PS:
PA:
PE:
Pump discharge port

Pump suction port
Pump control basic pressure
Pump control pressure
P1C: Pump pressure detection port

PEN: Pump control pressure detection port
PD: Pump drain port
PD2: Pump drain port
D275AX-5E0
1.
2.
3.
4.
5.
6.
Shaft
Oil seal
Case
Rocker cam
Shoe
Piston
D275AX-5E0
SEN00926-00
7.
8.
9.
10.
11.
12.
Cylinder block
Valve plate
Spring
Servo piston
Ball
End cap
SEN00926-00
Function
q
The rotation and torque of the engine are
transmitted to the shaft of this pump and converted into hydraulic energy in this pump. This
pump discharges the pressurized oil according
to the load.
q
The discharge of this pump can be changed by
changing the swash plate angle in it.
Structure
q
Cylinder block (7) is supported on shaft (1)
through spline (B). Shaft (1) is supported by
the front and rear bearings.
q
The end of piston (6) has a spherical hollow
which is combined with shoe (5). Piston (6)
and shoe (5) form a spherical bearing.
q
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).
D275AX-5E0
SEN00926-00
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.
D275AX-5E0
SEN00926-00
2.
q
10
Control of discharge
If swash plate angle (a) is increased, the difference between volumes (E) and (F) is
increased, and so discharge (Q) is increased.
Swash plate angle (a) is changed with servo
piston (10).
Servo piston (10) reciprocates straight according to the signal pressure of the servo valve.
This straight motion is transmitted to rocker
cam (4).
Then, rocker cam (4) supported on ball (11)
slides around ball (11).
D275AX-5E0
SEN00926-00
Servo valve
P:
T:
PE:
PH:
EPC valve basic pressure

Drain
Control piston pressure
Pump discharge pressure
1.
2.
3.
4.
5.
6.
7.
Plug
Lever
Retainer
Seat
Spool
Piston
Sleeve
D275AX-5E0
11
SEN00926-00
Function
q
The servo valve controls the current (i) input to
the EPC valve and the swash plate angle (a) of
the pump so that they will be related as shown
in the figure below.
12
The relationship between the input current (i)

to the EPC valve and the output pressure of
EPC valve (F) is as follows.
D275AX-5E0
SEN00926-00
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 balanced with the spring.
q
Then, the land (PE) of the servo piston pressure passage is connected to the pump discharge passages by the cut of spool (5) and
the discharge pressure is led to the servo piston.
q
The servo piston is raised by the rocker cam.
The position feedback is applied and the lever
moves to compress the spring.
q
If spool (5) is pushed back, the pump discharge circuit and the servo piston circuit are
shut off.
q
The pressure in the servo piston chamber lowers and the rocker cam returns toward the
maximum swash plate angle.
q
These processes are repeated until the swash
plate is fixed to a position where the EPC output pressure is balanced with the spring force.
q
Accordingly as the EPC output pressure is
heightened, the swash plate angle is
decreased.
As the EPC output pressure is lowered, the
swash plate angle is increased.
D275AX-5E0
13
SEN00926-00
Cooling fan motor
Type: LMF110(65)
P: From fan pump

T: From cooler to tank
TC: To tank
14
Specifications
Type: LMF110(65)
Capacity: 65.1 cc/rev
Rated speed: 1,250 rpm
Rated flow: 81.4 l/mm
Check valve crack pressure: 78.5 kPa {0.8 kg/cm2}
D275AX-5E0
1.
2.
3.
4.
5.
6.
Output shaft
Case
Thrust plate
Piston assembly
Cylinder block
Valve plate
SEN00926-00
7.
8.
9.
10.
11.
12.
End cover
Center spring
Check valve
Pilot valve
Spool for reversible valve
Safety valve
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
13 Spool return spring
14 Check valve spring
D275AX-5E0
Free length x Installation

outer diameter
length
Repair limit
Installation
load
Free
length
62.66 x 19.8
53.5
146 N
{14.9 kg}
16.4 x 8.9
11.5
13.7 N
{1.4 kg}
Installation
load
Replace spring
if damaged or
117 N
{11.9 kg} deformed.
11.0 N
{1.12 kg}
15
SEN00926-00
1. Hydraulic motor
Function
q
This hydraulic motor is called a swash platetype axial piston motor. It converts the energy
of the pressurized oil sent from the hydraulic
pump into rotary motion.
Principle of operation
The oil sent from the hydraulic pump flows
through valve plate (7) into cylinder block (5).
This oil can flow on only 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 generates 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 cylinder block (5) through the piston.
q
Since this cylinder block (5) is splined to the
output shaft, the output shaft revolves to transmit the torque.
q
16
D275AX-5E0
2. Suction valve
Function
q
If the fan pump stops, the pressurized oil does
not flow into the motor. Since the motor continues revolution because of the force of inertia,
however, the pressure on the outlet side of the
motor rises.
q
When the oil stops flowing in from inlet port (P),
suction valve (1) sucks in the oil on the outlet
side and supplies it to port (MA) where there is
not sufficient oil to prevent cavitation.
SEN00926-00
2)
q
When the pump is stopped

If the engine is stopped and the input revolution of the fan pump lowers to 0 rpm, the pressurized oil from the pump is not supplied to
port (P) any more. As the pressurized oil is not
supplied to the (MA) side of the motor, the
motor speed lowers gradually to stop.
If the motor shaft is revolved by the force of
inertia while the oil flow in the port (P) is reducing, the oil in port (T) on the outlet side is sent
by the suction valve (1) to the (MA) side to prevent 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.
D275AX-5E0
17
SEN00926-00
3. Operation of reversible valve

1)
q
q
q
18
When the ON-OFF solenoid is de-energized.

If ON-OFF solenoid (1) is de-energized, the
pressurized oil from the pump is blocked by
ON-OFF selector valve (2), and port (C) opens
for the tank circuit.
Spool (3) is pushed to the right by spring (4).
Motor port (MA) opens and pressurized oil
flows in to revolve the motor in forward (clockwise).
2)
q
q
q
When the ON-OFF solenoid is energized.

If ON-OFF solenoid (1) is energized, ONOFF selector valve (2) changes to let the pressurized oil from the pump flow through port (C)
into spool chamber (D).
The pressurized oil in chamber (D) pushes
valve spool (3) to the left against spring (4).
Motor port (MB) opens and pressurized oil
flows in to revolve the motor in reverse (counterclockwise).
D275AX-5E0
SEN00926-00
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
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 pressurized oil into port (T).
q
By this operation, generation of abnormal pressure in port (P) is prevented.
q
D275AX-5E0
19
SEN00926-00
20
D275AX-5E0
SEN00927-00
BULLDOZER
1SHOP MANUAL
D275AX-5E0
Machine model
Serial number
D275AX-5E0
30001 and up


Power train system, Part 1.............................................................................................................................. 2
Power train skeleton............................................................................................................................. 2
HSS system ......................................................................................................................................... 4
Overall drawing of power train unit....................................................................................................... 6
Power train hydraulic piping drawing ................................................................................................... 8
Transmission control ............................................................................................................................ 9
Steering, brake control ....................................................................................................................... 10
Damper, universal joint....................................................................................................................... 12
Torque converter, PTO ....................................................................................................................... 14
Transmission ...................................................................................................................................... 28
Tranmission ECMV ............................................................................................................................ 40
Main relief valve and torque convertor relif valve............................................................................... 46
Torque converter valve....................................................................................................................... 50
Lubrication relief valve ....................................................................................................................... 58
D275AX-5E0
SEN00927-00

Power train skeleton
1
1
Outline
q
The power generated by engine (1) has its torsional vibration dampened by damper (2), and
then passes through universal joint (3), and is
transmitted to torque converter (10).
q
The power from the engine is transmitted
through the oil by torque converter (10) to the
transmission input shaft (turbine shaft) in
accordance with the change in load.
q
Transmission (11) uses a combination of a
planetary gear system and hydraulic clutches
to reduce the speed and shift the gears (3 forward gears and 3 reverse gears). It connects
2 sets of clutches selected according to the
change in load, and transmits the power to
bevel gear (12) from the bevel pinion at the
rear end of the transmission.
q
The power transmitted to the bevel gear shaft
is transmitted to HSS (Hydrostatic Steering
System) (13). HSS pump (10) is driven by
PTO (7), and output oil of the HSS pump drives
HSS motor (14). The rotation of the pair of the
HSS gears on the right and left is controlled by
HSS motor (14). The steering is carried out by
generating a difference in speed on the right
and left.
It is also possible to use the HSS mechanism

to rotate the right and left sides in opposite
directions to carry out pivot turns.
Brake (15) of the HSS is used for braking the
machine. Brake (15) is a wet, multiple disc
clutch, spring boosted type. If brake (15) on
only 1 side is applied, the machine can carry
out pivot turns. The power sent from brake
(15) is transmitted to final drive (16).
Final drive (16) consists of a single-stage spur
gear and a single-stage planetary gear system.
It reduces the speed and rotates sprocket (17)
to drive track shoe (18) and move the machine.
It also rotates fan motor (21) with the oil discharged from fan pump (19) driven with PTO
(7).
D275AX-5E0
1.
2.
3.
4.
5.
6.
7.
Engine (SAA6D140E-5)
Damper
Universal joint
Scavenging pump
[BAR(3)-160]
HSS charge pump [SAL(3)-72]
Work equipment pump (HPV112)
PTO
D275AX-5E0
8.
9.
10.
11.
12.
13.
14.
Power train pump

[SAR(3)-100]
Steering lubricating oil pump
[SAR(3)-50]
Torque converter
Transmission
Bevel gear
HSS unit
HSS motor (HMF180)
SEN00927-00
15.
16.
17.
18.
19.
20.
21.
Brake
Final drive
Sprocket
Track shoe
Cooling fan pump (LPV64)
HSS pump (HPV180)
Cooling fan motor (LMF110)
SEN00927-00
HSS system
D275AX-5E0
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
PCCS lever
HSS controller
Servo valve
HSS pump
Engine
Hydraulic pump
Hydraulic valve
Sproket
Final drive
HSS motor
HSS closed circuit
Motor free solenoid
SEN00927-00
A:
B:
C:
D:
E:
F:
G:
Travel REVERSE signal 2

Travel; REVERSE signal 1
Steering signal 1,2
Engine speed signal
Hydraulic pressure signal
Steering circuit pressure signal A
Steering circuit pressure signal B
Outline
q
The HSS system is a hydraulic system; HSS
stands for hydraulic Steering System.
q
The HSS system consists of a set of piston
pump and piston motor as shown in the diagram. With this system, it is possible to turn
continuously by generating a difference in
speed between the left and right tracks.
There is no need to reduce speed.
q
The HSS controller controls the angle of the
swash plate in the HSS pump according to the
angle of operation of the monolever, and controls the speed and directional of rotation of the
HSS motor.
The HSS motor uses the planetary gear system of the bevel gear shaft to create a differe n c e i n t h e s p e e d o f t h e l e ft a n d r i g h t
sprockets, and this turns the machine.
q
The HSS controller detects the speed of the
engine and the hydraulic pressure at all parts,
and controls the swash plate angle of the HSS
pump to ptevent the engine from stalling.
q
If the pivot turn mode is selected and the steering lever is operated to the stroke end, the
motor-free solenoid operates to open the HSS
circuit and the steering brake on one side operates.
As a result, the machine makes a pivot turn.
D275AX-5E0
SEN00927-00
Overall drawing of power train unit
D275AX-5E0
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.

Torque converter, PTO
Power train pump [SAR(3)-100]
Steering lubricating oil pump [SAR(3)-50]
Transmission
Parking brake valve
Left brake ECMV
Right brake ECMV
Sudden brake prevention valve
Cooling fan pump (LPV64)
HSS pump (HPV180)
HSS motor (HMF180)
HSS unit
Main relief valve
Power train oil strainer
Scavenging pump [BAR(3)-160]
D275AX-5E0
SEN00927-00
Outline
q
The power train unit consists of the main components of torque converter (3), transmission
(6), and HSS unit (14). Accordingly, after the
power train unit is removed, it can be divided
into the torque converter, transmission unit,
and HSS unit.
q
The HSS unit consists of the bevel pinion unit,
bevel gear shaft, HSS motor, planetary gear
system, and brake.
SEN00927-00
Power train hydraulic piping drawing
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Scavenging pump [BAR(3)-160]

Power train oil filter
Power train lubrication oil filter
Centralized pressure pick-up ports
Power train pump [SAR(3)-100]
Steering lubricating oil pump [SAR(3)-50]
HSS charge filter
Brake control valve
HSS motor (HMF180)
Main relief valve
HSS pump (HPV180)
Power train oil cooler
(built in radiator lower tank)
15. Transmission ECMV
A:
B:
Left brake oil pressure pick-up port (LB)

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: Torque converter stator clutch pressure pick-up
port (SC)
K: Torque converter lock-up clutch pressure pickup port (LU)
L: Torque converter outlet pressure pick-up port
(OUT)
M: Torque converter inlet pressure pick-up port (IN)
D275AX-5E0
SEN00927-00
Transmission control
For steering operation concerned to operation

of PCCS lever, see "Steering and brake control".
1.
2.
3.
Brake pedal
Lock lever
PCCS lever (Forward-Reverse,
Gear shift)
UP switch
(Gear is shifted up each time this
switch is pressed.)
DOWN switch
(Gear is shifted down each time
this switch is pressed.)
Transmission neutral safety
switch
Cable
Transmission control valve
4.
5.
6.
7.
8.
D275AX-5E0
Lever positions
(A): Neutral
(B): Forward
(C): Reverse
(D): OFF
(E): Shift UP
(F): Shift DOWN
(G): Free
(H): Lock
PCCS: Abbreviation for Palm Command Control System.
Outline
q
The transmission is controlled with PCCS
lever (3).
The PCCS lever is used to select the travel
direction and shift the gear.
q
Since the safety mechanism is employed,
transmission neutral safety switch (6) does
not work and the engine does not start
unless lock lever (2) is in the LOCK position.
SEN00927-00
Steering, brake control

q
10
Regarding the transmission-related description

of the operation of the PCCS lever, refer to the
transmission control.
PCCS: Palm Command Control System
D275AX-5E0
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Brake pedal
Lock lever
PCCS lever (Steering)
Steering controller
Limit switch
Steering ECMV
Brake valve
Parking brake lever (From lock lever)
Cable
Rod (From brake pedal)
Potentiometer
Outline
q
PCCS lever (3) sends electric signals to steering controller (4). Upon receiving those signals, steering controller (4) sends signals to
HSS Pump servo to changes the discharge of
the pump to operate the starting motor.
q
Brake pedal (1) sends electric signals through
potentiometer (11) to steering controller (4).
Upon receiving this signal, steering controller
(4) sends proportional current to ECMV (6) to
operate the brake. Rod (10), as a redundant
device, operates the brake through brake valve
(7) (only in the complete braking mode).
D275AX-5E0
SEN00927-00
Positions of levers and pedals

A: Neutral
B: Forward straight
C: Reverse straight
D: Left clutch OFF
E: Left clutch OFF
Left brake ON
F: Right clutch OFF
G: Right clutch OFF
Right brake ON
H: Brake OFF
J: Brake ON
K: Free
L: Lock
Lock lever (2) is connected to parking brake

lever (8) and used as the parking brake lever,
too.
11
SEN00927-00
Damper, universal joint
12
D275AX-5E0
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
SEN00927-00
Breather
Oil level gauge
Drain plug
Output shaft
Flywheel
Outer body
Coupling
Universal joint
Cover
Rubber coupling
Inner body
Outline
The damper dampens the torsional vibration
caused by the change in engine torque and the
impact torque generated when accelerating suddenly or when carrying out heavy-duty digging. In
this way it acts to protect the torque converter,
transmission, and other parts of the power train.
This damper has few component parts: it uses a
rubber coupling, so the vibration is absorbed 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 transmitted to inner body (11). It
passes through universal joint (8), and is then
transmitted to the torque converter and transmission.
Unit: mm
No.
Check item
Clearance between flywheel

12
housing and cover
13
Clearance between flywheel

and damper
14
Outer circumference of coupling oil seal contact surface
D275AX-5E0
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
511.18
0.022
0.092
+ 0.070
+ 0.070
0.022
0.162
0.2
466.72
0.020
0.083
+ 0.063
+ 0.063
0.020
0.146
0.2
Standard size
Tolerance
Repair limit
90
0.087
0.087
89.8
Replace
13
SEN00927-00
Torque converter, PTO
14
D275AX-5E0
D275AX-5E0
SEN00927-00
15
SEN00927-00
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
16
Work equipment pump, HSS charge pump

mounting port
HSS pump mounting port
Scavenging pump mounting port
Fan pump mounting port
PTO lubrication tube
Power train, Steering lubricating oil pump
mounting port
Coupling
Input shaft [PTO drive gear (56 teeth)]
Idler gear (77 teeth)
Idler gear shaft
Torque converter case
Drive case
Turbine
Stator
Stator boss
Pump
Retainer
Shaft
Stator clutch rear housing
Stator clutch front housing
Stator shaft
Stator shaft boss (90 teeth)
Return spring
Stator clutch plate
Stator clutch disc
Stator clutch piston
Transmission input shaft
Turbine boss (90 teeth)
Lock-up clutch plate
Lock-up clutch disc
Lock-up clutch piston
Lock-up clutch housing
Pump drive gear (49 teeth)
(Work equipment, HSS charge pump, power
train, and steering lubricating oil pump)
HSS, Fan pump drive gear (49 teeth)
Scavenging pump drive gear (57 teeth)
A:
B:
C:
D:
E:
F:
From power train pump (to torque converter

valve, transmission ECMV, and steering brake
ECMV)
To oil cooler
Torque converter oil inlet
To transmission case (From torque converter
case)
To transmission case (To scavenging pump)
From steering case and transmission case
(Oil pan pass)
D275AX-5E0
Outline
q
The torque converter is the 3-element, 1-stage,
and 1-phase type, which is combined with the
transmission into 1 unit. It is equipped with a
torque converter lock-up device of the wet and
multiple disc type and a stator clutch to reduce
the fuel consumption and increase the operability and reduce the horsepower consumption
by the engine.
q
For higher efficiency of continuous dozing and
leveling work, the engine power should be
transmitted directly to the input shaft of the
transmission. For this reason, the hydraulic
lock-up clutch is built in the torque converter.
When the torque converter is locked up (the
pump and turbine is combined into 1 unit), the
oil supplied from the torque converter relief
valve does not stop. Accordingly, the oil flowing from the pump through the turbine is given
an unnecessary directional property and
resists the revolution of the pump and turbine
(agitates the oil).
To avoid this, a stator clutch similar to the lockup clutch is installed so that the stator can
rotate freely together with the pump and turbine when the torque converter is locked up.
As a result, the oil discharged from the pump
and turbine is returned to the pump against
less resistance.
a
The torque converter is set in the lock-up

range and torque converter range under the
following conditions.
SEN00927-00
Structure
q
Pump (17) is combined with coupling (8), shaft
(9), clutch housing (33), and drive case (13)
into 1 unit and rotated by the engine power.
q
Turbine (14) is combined with turbine boss (29)
and transmission input shaft (turbine shaft)
(28) into 1 unit and rotated by the engine
power.
q
Stator (15) is combined with stator boss (16),
stator shaft (22), and stator shaft boss (23) into
1 unit and fixed to front housing (21) and rear
housing (20) through the stator clutch unit.
q
The lock-up clutch unit consists of clutch plate
(30) meshed with drive case (13), clutch disc
(31) meshed with turbine boss (29), and clutch
piston (32) which slides inside housing (33)
combined with the drive case into 1 unit.
q
The stator clutch unit consists of clutch disc
(26) meshed with boss (23) coupled with stator
shaft (22) by the spline, clutch plate (25) supported by the pins on front housing (21) and
rear housing (20) of the clutch, and clutch piston (27) which slides inside the front housing.
The front hosing and rear housing of the stator
clutch are bolted to the front housing of the
transmission R clutch.
q
The PTO unit consists of input shaft (9), idler
gear (10), scavenging pump drive gear (36),
work equipment pump and power train pump
drive gear (34), and HSS pump and fan pump
drive gear (35).
Unit: rpm
Lock-up range
Torque converter range
F1
Min. 1,471
Max. 1,433
F2
Min. 1,440
Max. 1,419
F3
Min. 1,420
Max. 1,407
R1
Min. 1,419
Max. 1,392
R2
Min. 1,420
Max. 1,404
R3
Min. 1,417
Max. 1,408
While the transmission gear is being shifted,

the torque converter is set in the torque converter range.
D275AX-5E0
17
SEN00927-00
18
D275AX-5E0
SEN00927-00
Unit: mm
No.
Check item
Criteria
Tolerance
Repair limit
120
0.054
0.054
119.8
150.5
90.5
Outside diameter of coupling

oil seal contact surface
Inside diameter of retainer seal

ring contact surface
150
+ 0.040
+ 0.040
Inside diameter of sleeve seal

ring contact surface
90
+ 0.035
+ 0.035
Backlash between PTO drive

gear and scavenging pump
drive gear
Backlash between PTO drive

gear and driven gear
Wear of stator shaft seal ring
Stator clutch Lock-up clutch
Standard clearance
Clearance limit
0.204 0.512
0.204 0.512
Standard size
Repair limit
Width: 4.5
Height: 5.5
Width: 4.05
Height: 4.95
Thickness of disk
5.0
4.5
Thickness of plate
5.0
4.5
Thickness of
overall assembly
15.0
13.9
Thickness of disk
5.0
4.5
Thickness of plate
5.0
4.5
15.0
13.9
Thickness of
overall assembly
Standard size
9
Remedy
Standard size
Stator clutch spring
D275AX-5E0
Repair hard
chrome plating or
replace
Replace
Repair limit
Free length
Installed
length
Installed
load
Free length
Installed
load
35
27.2
83.5 N
{8.5 kg}
34.0
79.3 N
{8.1 kg}
19
SEN00927-00
Power train route

1.
When lock-up clutch is OFF

and stator clutch is ON
If the lock-up clutch is OFF,
drive case (13) and turbine (14)
are disconnected from each
other. If stator clutch is ON at
this time, rear housing (20) and
stator shaft (22) are connected
to each other to fix stator (15)
and the lock-up torque converter works as an ordinary
torque converter. The engine
power is transmitted through
the damper and universal joint
to coupling (8) and rotates input
shaft (9), clutch housing (33),
drive case (13), and pump (17)
as 1 unit. The power of the
p u m p r o ta t e s t u r b i n e ( 1 4 )
through oil and is transmitted to
transmission input shaft (28)
combined with the turbine into 1
unit.
2.
When lock-up clutch is ON

and stator clutch is OFF
If the lock-up clutch is ON, drive
case (13) and turbine (14) are
connected to each other. If stator clutch is OFF at this time,
rear housing (20) and stator
shaft (22) are disconnected
from each other and stator (15)
is dragged and rotated by pump
(17) and tur bine ( 14) . T he
engine power is transmitted
through the damper and universal joint to coupling (8) and
rotates input shaft (9), clutch
housing (33), drive case (13),
and pump (17) as 1 unit. Since
drive case and turbine (14) are
connected by the clutch, the
power is transmitted directly to
transmission input shaft (28)
without using the oil.
20
D275AX-5E0
SEN00927-00
Flow of oil
q
The oil pressure is regulated to

below 1.0 MPa {10.2 kg/cm2} by the
torque converter relief valve and the
oil flows through port (C) and oil hole
of stator clutch front housing (21) into
p u m p ( 1 7 ) . S i n c e th e p u m p i s
rotated constantly by the engine
power, the oil in the pump is given a
centrifugal force and put in turbine
(14), then the turbine is rotated by
the centrifugal force of the oil. Since
the turbine is combined with transmission input shaft (28), the power
received by the turbine is transmitted
the transmission. The oil discharged
from the turbine is sent to stator (15)
and put in the pump again, but some
of it is sent from the stator through
port (B) to the oil cooler.
D275AX-5E0
21
SEN00927-00
Torque converter lock-up control system

System diagram
Operation
q
The torque converter lock-up control system
controls the lock-up operation of the torque
converter automatically with a sensor signal
and the controller in it according to the load on
the machine. When the torque converter is
locked up, the pilot lamp on the monitor panel
lights up.
q
The signal of the transmission outlet speed
sensor is input to the transmission controller.
q
The lock-up mode is set with the mode selection panel.
q
The machine controller receives the transmission outlet speed sensor signal etc. and turns
ON and OFF the lockup system by controlling
the lockup solenoid and pilot lamp according to
the machine condition.
22
D275AX-5E0
1.
SEN00927-00
When traveling in torque converter range
While the machine is in the "torque converter

range", the solenoid valve is deactivated and
plunger (29) is returned up by the oil pressure
and the seats of valve (22) and ball (23) are
separated and ports (P) and (N) are opened.
Since the drain circuit of port (N) is open, oil in
port (M) is also drained.
Since lock-up changeover valve (20) is pushed
to the right by spring (19), the passages
between ports (Q) and (L) and between (S)
and (T) are closed and the passages between
(Q) and (S) and between (L) and (R) are
opened. Then, the oil from the pump flows
through port (Q) into port (S) and applies back
pressure to the stator clutch piston and excited
the stator clutch when the circuit oil pressure
rises. At the same time, the oil which has been
applying back pressure to the lock-up clutch
piston is drained through port (L) into (R) and
the lock-up clutch is deactivated. The oil from
the pump flows in port (P), too. It is drained
through throttle (A), however, since the solenoid is deactivated. The oil pressure in port
D275AX-5E0
(Q) is secured by throttle (A) and regulated by

modulating valve (5).
23
SEN00927-00
2.
When traveling in direct range
While the machine is in the "direct range", the solenoid valve is excited and plunger (29) is pushed
back down and the seats of valve (22) is closed and
ports (P) and (M) are opened and the drain circuit
of port (N) is closed. The oil from (M) moves piston
(21) and lock-up changeover valve (20) to the left to
close the passages between ports (Q) and (S) and
between ports (L) and (R) and open the passages
between ports (Q) and (L) and between ports (S)
and (T). Then, the oil from the pump flows through
port (Q) into port (L) and applies back pressure to
the lock-up clutch piston and excited the lock-up
clutch when the circuit oil pressure rises. At the
same time, the oil which has been applying back
pressure to the stator clutch piston is drained
through port (S) into (T) and the stator clutch is
deactivated. The oil pressure in port (L) is regulated by modulating valve (10).
24
D275AX-5E0
SEN00927-00
Operation of modulation valves of stator clutch and lock-up clutch

q
1.
The modulating valves are in the circuits

between the lock-up changeover valve and the
inlet of the 2 clutches. When each clutch is
turned ON, the modulating valve in its circuit
heightens the oil pressure applied to the piston
gradually to the specified level to excited the
clutch smoothly and reduce the impacts given
to the torque converter and transmission.
The following is the explanation of the modulating valve for the stator clutch. Although the
modulating valve for the lock-up clutch operates similarly to that for the stator clutch, the oil
flow into the clutches in the direct range and
torque converter range is reversed, however.
When traveling in direct range
While the machine is in the "direct range", the
solenoid valve is excited and the oil in port (M)
of lock-up changeover valve (24) pushes piston (21) and valve (20) to the left. Lock-up
changeover valve (20) is pushed to the left by
the oil pressure higher than the tension of
spring (19) and the passage between ports (Q)
and (S) is closed and the passage between
ports (S) and (T) is opened to drain the oil from
port (S) through port (T). If the oil pressure in
port (S) is lost, modulating valve (5) is returned
to the right by the tension of spring (2) to open
part (B) of port (S) fully. At this time, the operating oil of the stator clutch is drained from port
(S) to port (T) and the clutch is deactivated.
The oil from the pump flows through port (Q) to
port (L) and the lock-up clutch is turned ON.
D275AX-5E0
25
SEN00927-00
2.
When traveling in torque converter range

While the machine is in the "torque converter
range", the solenoid valve is deactivated and
the oil from the pump and in port (M) is
drained.
Valve (22) is moved to the right by the tension
of spring (19) and the passages between ports
(Q) and (L) and between ports (S) and (T) are
closed and the passage between port (Q) and
(S) is opened. As a result, the circuit is connected from port (Q) through modulating valve
(5) to the stator clutch.
The oil from the pump flows through port (Q) to
the stator clutch and the oil pressure in the circuit starts rising.
If the circuit pressure rises, the oil flowing
through orifice (d) of modulating valve (5)
pushes piston (7). The reaction force of piston
(7) moves the modulating valve to the left to
narrow part (B) of port (S).
Port (S) is connected to port (U) to apply back
pressure to load piston (3). Load piston (3) is
moved to the right to compress spring (2) and
the tension of the spring opens part (B) of port
(S). This operation is repeated intermittently to
increase the load on spring (2). During this
operation, the oil pressure rises gradually until
part (B) of port (S) is closed. Then, rise of the
oil pressure is completed.
At this time, the stator clutch pressure is 2.65
0.1 MPa {27.0 1 kg/cm2}
The lock-up clutch pressure is 1.3 +0.1
MPa
0
{13 +10 kg/cm2}.
26
D275AX-5E0
SEN00927-00
Transmission
28
D275AX-5E0
A:
B:
C:
D:
E:
F:
G:
H:
J:
K:
To forward clutch
To reverse clutch
To 3rd clutch
To 2nd clutch
To 1st clutch
To torque converter case
From torque converter case
To scavenging pump
To torque converter case
From scavenging pump
D275AX-5E0
SEN00927-00
L:
M:
N:
P:
Q:
R:
S:
T:
U:
V:
From power train pump

To steering valve
To steering case
From steering case
Transmission lubrication oil inlet
Transmission 1st clutch pressure pick-up port
Transmission 3rd clutch pressure pick-up port
Transmission R clutch pressure pick-up port
Transmission 2nd clutch pressure pick-up port
Transmission F clutch pressure pick-up port
29
SEN00927-00
30
D275AX-5E0
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
Main relief valve

Transmission case
Transmission control valve and valve cover
assembly
Lubricating oil relief valve
Input shaft
Reverse clutch sungear (34 teeth)
Pinion shaft
Ring gear of reverse travel (86 teeth)
Planetary pinion for reverse travel (26 teeth)
Disc
Plate
Piston
Planetary pinion for forward travel (27 teeth)
Planetary pinion for 3rd gear speed (36 teeth)
Ring gear for 3rd gear speed (Number of internal teeth: 91, Number of external teeth: 109)
Sun gear for 2nd gear speed (39 teeth)
Planetary pinion for 1st gear speed (21 teeth)
Sun gear for 1st gear speed (49 teeth)
Output shaft (Number of teeth of sun gear for
3rd gear speed: 20)
Ring gear for 1st gear speed (Number of internal teeth: 91, Number of external teeth: 105)
1st clutch carrier (90 teeth)
Clutch housing for 1st gear speed
Clutch housing for 2nd gear speed
Planetary pinion for 2nd gear speed (26 teeth)
Ring gear for 2nd gear speed (Number of internal teeth: 90, Number of external teeth: 105)
Clutch housing for 3rd gear speed
Carrier for 2nd and 3rd gear speeds
Clutch housing for forward travel
Sun gear for forward travel (37 teeth)
Ring gear for forward travel (Number of internal teeth: 91, Number of external teeth: 105)
Carrier for forward travel (86 teeth)
Clutch housing for reverse travel
Return spring
Ring gear for reverse travel (Number of internal teeth: 90, Number of external teeth: 105)
Pin
Carrier for reverse travel (90 teeth)
D275AX-5E0
SEN00927-00
Outline
q
The transmission consists of planetary gear
systems and disc clutches and has "3 forward
gear speeds and 3 reverse gear speeds".
q
Among the 5 sets of planetary gear system
and disc clutch of the transmission, 2 clutches
are fixed hydraulically with control valves to
select 1 rotating direction and rotating speed.
q
Clutches No. 1, No. 2, No. 3, No. 4, and No. 5
are fixed respectively when the reverse, forward, 3rd, 2nd, and 1st gears are selected.
Number of plates and discs
Clutch No.
No.1
No.2
No.3
No.4
No.5
Number of discs Number of plates

6
8
4
4
3
6
7
5
5
4
Gear speeds and operated clutches

Gear speed
Operated clutches (Turned ON)
Forward 1st
Forward 2nd
Forward 3rd
Neutral
Reverse 1st
Reverse 2nd
Reverse 3rd
No.2No.5
No.2No.4
No.2No.3
*1. No.5
No.1No.5
No.1No.4
No.1No.3
*1: While the transmission is in neutral, the 1st

clutch is filled with low-pressure oil and
engaged so that the machine can start without
a time lag.
31
SEN00927-00
32
D275AX-5E0
SEN00927-00
Unit: mm
No.
Check item
Criteria
Standard size
No. 1 clutch spring (12 pcs.)
Remedy
Repair limit
Free length
Installed
length
Installed
load
Free length
Installed
load
91
71.2
174.6 N
{17.8 kg}
88.3
165.7N
{16.9 kg}
84
79.8
53.0 N
{5.4 kg}
81.5
50.0 N
{5.1 kg}
68
59.5
95.1 N
{9.7 kg}
66.0
90.2 N
{9.2 kg}
70
51
93.2 N
{9.5 kg}
67.9
88.3 N
{9.0 kg}
70
53
83.4 N
{8.5 kg}
67.9
79.4 N
{8.1 kg}
Thickness of clutch disc

(No. 1, 2 clutches)
Standard size
Tolerance
Repair limit
5.4
0.1
4.9
Thickness of clutch disc

(No. 3 - 5 clutches)
5.4
0.1
4.6
Thickness of clutch plate

(No. 1 - 5 clutches)
3.2
0.1
2.9
Total thickness of No. 1 clutch
51.6
0.3
48.8
10 Total thickness of No. 2 clutch
65.6
0.4
58.2
37.6
0.3
35.6
37.6
0.3
35.6
29.0
0.3
27.3
Standard clearance
Clearance limit
0.14 0.35
Backlash between each planetary gear and internal teeth of

15
ring gear (Forward, reverse,
1st and 2nd gear speeds)
0.15 0.38
Backlash between planetary

16 pinion and internal teeth of ring
gear (3rd gear speed)
0.16 0.41
Backlash between carrier and

17 internal teeth of ring gear
(Reverse)
0.18 0.54
Backlash between each carrier

18 and internal teeth of ring gear
(Forward, 1st gear speed)
0.18 0.48
Backlash between each sun

gear and planetary pinion
14
(Forward, reverse, 1st - 3rd
gear speeds)
D275AX-5E0
Replace
33
SEN00927-00
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)

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.
q
Clutch disengaged (free)

When the supply of pressure oil from the control 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.
34
D275AX-5E0
SEN00927-00
Oil circuit of 1st clutch

Since the 1st clutch is the farthest from the control
valve and has the longest circuit to the cylinder, it
takes the longest time to fill the circuit.
To solve this problem, the oil is supplied to the 1st
clutch even if the gear shift lever is in the NEUTRAL position,
Accordingly, when the gear shift lever is shifted
from the NEUTRAL position to the F1 position, the
pump is required to supply oil of only quantity to fill
the 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.
D275AX-5E0
35
SEN00927-00
2.
q
36
Forward 1st
When the transmission is set to FORWARD
1st, the No. 2 clutch and No. 5 clutch are
engaged. The motive force from the torque
converter transmitted to input shaft (5) is then
transmitted to output shaft (19).
No. 2 clutch is actuated by the hydraulic pressure applied to the clutch piston, and holds ring
gear (30) in position. No. 5 clutch is actuated
by the hydraulic pressure applied to the clutch
piston, and engages ring gear (20).
The motive force from the torque converter is
transmitted to input shaft (5), and the rotation
of the input shaft passes through sun gear (29)
and is transmitted to planet pinion (13).
Ring gear (30) is held in position by No. 2
clutch, so the rotation of planet pinion (13)
rotates carrier (31), which is on the inside of
ring gear (30).
Carrier (31) and carrier (27) are joined by a
spline, and rotate as one unit, so the rotation of
carrier (31) passes through planet pinion (24)
and is transmitted to ring gear (25).
Carrier (21) is meshed with ring gear (25), and

rotates as one unit, so the rotation is transmitted to planet pinion (17).
Ring gear (20) is being held in position by No.
5 clutch, so the rotation of planet pinion (17)
rotates sun gear (18), and this rotates output
shaft (19).
D275AX-5E0
3.
q
Forward 2nd
2nd the No. 2 clutch and No. 4 clutch are
ring gear (30).
D275AX-5E0
SEN00927-00

spline, and rotate as one unit, so the rotation is
transmitted to planet pinion (24).
shaft (19).
37
SEN00927-00
4.
q
38
Forward 3rd
3rd the No. 2 clutch and No. 3 clutch are
ring gear (30).

spline, and rotate as one unit, so the rotation is
transmitted to planet pinion (14).
rotates output shaft (19).
D275AX-5E0
5.
q
Reverse 1st
When the transmission is set to REVERSE 1st,
the No. 1 clutch and No. 5 clutch are engaged.
The motive force from the torque converter
transmitted to input shaft (5) is then transmitted to output shaft (19).
No. 1 clutch is actuated by the hydraulic pressure applied to the clutch piston, and holds
carrier (36) in position. No. 5 clutch is actuated
Carrier (36) is held in position by No. 1 clutch,
so the rotation of planet pinion (9) rotates ring
gear (8).
Ring gear (8) rotates in the opposite direction
from the input shaft, and rotates carrier (31).
spline, and rotate as one unit, so the rotation of
carrier (31) passes through planet pinion (24)
and is transmitted to ring gear (25).
D275AX-5E0
SEN00927-00
Carrier (21) is meshed with ring gear (25), and

rotates as one unit, so the rotation is transmitted to planet pinion (17).
shaft (19).
39
SEN00927-00
Tranmission ECMV
(Electronic Control Modulation Valve)
40
D275AX-5E0
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
Proportional solenoid valve for 3rd clutch ECMV

Proportional solenoid valve for 1st clutch ECMV
Proportional solenoid valve for R clutch ECMV
Proportional solenoid valve for 2nd clutch ECMV
Proportional solenoid valve for F clutch ECMV
Fill switch for 3rd clutch
Fill switch for 2nd clutch
Fill switch for 1st clutch
Fill switch for R clutch
Fill switch for F clutch
Connector for 1st proportional solenoid valve
Connector for 3rd proportional solenoid valve
Connector for R proportional solenoid valve
Connector for 2nd proportional solenoid valve
Connector for F proportional solenoid valve
Connector for 3rd fill switch
Connector for 2nd fill switch
Connector for 1st fill switch
Connector for R fill switch
Connector for F fill switch
Filter
Pressure control valve
Oil pressure detection valve
Pressure control valve spring
A:
B:
C:
D:
E:
F:
P:
T:
1st clutch operating pressure pick-up port

3rd clutch operating pressure pick-up port
R clutch operating pressure pick-up port
2nd clutch operating pressure pick-up port
F clutch operating pressure pick-up port
To clutch
From pump
Drain
D275AX-5E0
SEN00927-00
41
SEN00927-00
Outline of ECMV
q
The ECMV (Electronic Control Modulation

Valve) consists of the following two units, a
pressure control valve and fill switch.
Converts a current sent from the transmission
controller to the proportional solenoid valve, to
an oil pressure.
Fill switch
Detects that the clutch is filled with oil. It has
the functions below.
1) It outputs a signal (fill signal) to the controller as soon as the clutch is filled with oil
to report the completion of filling.
2) It outputs a signal (fill signal) to the controller while an oil pressure is applied to
the clutch to report the presence/absence
of oil 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
42
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.
D275AX-5E0
SEN00927-00
Operation of ECMV
q
The ECMV is controlled by the command current 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
The clutch is crimped by the piston when shifting the gear with the gear shift switch. If a high
oil pressure is applied suddenly, however, the
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 proportional solenoid (1), the pressure control valve
(2) is draining the oil at the clutch port (A)
through the drain port (dr).
Since, at that time, no oil pressure acts on the
oil pressure detection valve (3), the fill switch
(4) is OFF.
D275AX-5E0
43
SEN00927-00
2.
44
When filling (When inputting the trigger

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

If you flow a current to the proportional solenoid (1), the solenoid produces thrust proportional to the current. Pressure is regulated by
striking a balance among the thrust of the solenoid, the thrust of the oil pressure of the clutch
port, and reaction force of the pressure control
spring (5).
D275AX-5E0
SEN00927-00
Main relief valve and torque convertor relif valve
1.
2.
3.
4.
5.
6.
7.
8.
9.
Body
Torque converter relief valve
Valve spring
Piston
Piston spring
Main relief valve
Valve spring
Piston spring
Piston
A:
B:
C:
D:
E:
P1:
P8:
Drain port (for torque converter relief)

Drain port
From pump
Drain port
To torque converter
Main relief oil pressure detection port
Torque converter relief oil pressure detection
port
46
Outline
1. Main relief valve
Main relief valve (6) sets the set pressure of
the oil pressure for the transmission, steering
clutch, and brake.
2. Torque converter relief valve
Torque converter relief valve (2) acts to protect
the torque converter from abnormally high
pressure by relieving the circuit if the torque
converter inlet port pressure rises above the
set pressure.
Unit: MPa {kg/cm2}
Set pressure
Main relief pressure
3.2 0.1 {32.7 1.0}
Torque converter relief

pressure
0.98 0.05 {10.2 0.5}
D275AX-5E0
SEN00927-00
Unit: mm
No.
Check item
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
28
0.035
0.045
+ 0.013
+ 0.013
0.035
0.058
0.08
Clearance between main relief

valve and piston
19
0.020
0.030
+ 0.018
+ 0.018
0.020
0.048
0.07
Clearance between torque

12 converter relief valve and valve
body
22
0.035
0.045
+ 0.013
+ 0.013
0.035
0.068
0.08
Clearance between torque

converter relief valve and piston
15
0.020
0.030
+ 0.021
+ 0.021
0.020
0.051
0.07
Clearance between main relief

10
valve and valve body
11
13
Standard size
14
15
Main relief valve spring

(outside)
Main relief valve spring

(inside)
16 Main relief valve piston spring
Repair limit
Free length
Installed
length
Installed
load
Free length
Installed
load
122
78
481 N
{49 kg}
118.3
457 N
{46.6 kg}
108
78
368 N
{37.5 kg}
104.8
349 N
{35.6 kg}
30
25
7.32 N
{0.746 kg}
29.1
6.96 N
{0.71 kg}
17

spring
50
41.5
182 N
{18.6 kg}
48.5
174 N
{17.7 kg}
18

piston spring
26
20
4.87 N
{0.497 kg}
25.2
4.61 N
{0.47 kg}
D275AX-5E0
Replace
47
SEN00927-00
Operation of main relief valve

q
The oil from power train pump passes through
the filter, enters port (A) of the main relief
valve, then passes through orifice (a) and
enters port (B). When the oil from the pump
fills the circuit, the oil pressure starts to rise.
q
As the oil pressure in the circuit rises, the oil
entering port (B) pushes piston (4). The reaction compresses spring (7), moves main relief
valve (6) to the left in the arrow direction, and
opens ports (A) and (C).
Then, the oil from the pump is relieved from
port (A) to port (C), then flows from port (C) to
the torque converter.
The oil pressure at port (A) at this point is 3.2
0.1 MPa {32.7 1.0 kg/cm2}.
48
Operation of torque converter relief valve

q
The oil relieved by the main relief valve flows
from port (C) to the torque converter, and at
the same time, passes through orifice (b) and
enters port (D).
When the passage to the torque converter is
filled with oil, the oil pressure starts to rise.
q
As the oil pressure to the torque converter
rises, the oil entering port (D) pushes piston
(9). The reaction compresses spring (3),
moves relief valve (2) to the right in the arrow
direction, and opens ports (C) and (E).
Then, the oil from port (C) is relieved to port (E)
and is drained to the oil tank.
The oil pressure at port (C) at this point is 1.0
0.05 MPa {10.2 0.5 kg/cm2}.
D275AX-5E0
SEN00927-00
Torque converter valve
50
D275AX-5E0
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
Cover
Valve spring
Load piston
Valve body
Stator clutch modulating valve
Piston
Piston
Piston spring (small)
Cover
Lock-up clutch modulating valve
Valve spring (inside)
Valve spring (outside)
Shaft
Stopper
Load piston
Cover
Plug
Valve body
Valve spring
Lock-up changeover valve
Piston
Valve
Ball
Valve
Coil
Base
Case
Cap
Plunger
Shaft
D275AX-5E0
SEN00927-00
A:
P:
P3:
P8:
From pump
Stator clutch pressure pick-up port
Lock-up clutch pressure pick-up port
Main relief pressure pick-up port
51
SEN00927-00
Outline
q
The torque converter valve is installed to the
top of the torque converter case and consists
of valves of the following 4 types.
1. Torque converter lock-up valve
Lock-up changeover valve (20) turns ON and
OFF the lock-up clutch and stator clutch.
2. Torque converter lock-up solenoid valve
The solenoid valve receives electric signals
from the controller and changes the pilot pressure for lock-up changeover valve (20) to turn
ON and OFF the 2 clutches.
52
3.
4.
Stator clutch modulating valve

Modulating valve (5) regulates the clutch pressure to 2.55 2.75 MPa {26 28 kg/cm2} to
protect the stator clutch from abnormally high
pressure and heightens the pressure of the oil
from lock-up changeover valve (20) gradually
to the specified level.
Lock-up clutch modulating valve
Modulating valve (10) regulates the clutch
pressure to 1.27 1.37 MPa {13 14 kg/cm2}
similarly to stator clutch modulating valve (5).
D275AX-5E0
SEN00927-00
54
D275AX-5E0
SEN00927-00
Unit: mm
No.
Check item
Clearance between stator
clutch modulating valve and
valve body
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
25
0.035
0.045
+ 0.013
+ 0.013
0.035
0.058
0.08
Clearance between lock-up

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

valve and valve body
25
0.035
0.045
+ 0.013
+ 0.013
0.035
0.058
0.08
Standard size
4
Stator clutch modulating

valve spring
Repair limit
Free length
Installed
length
Installed
load
Free length
Installed
load
103.5
92.7
197.0 N
{20.10 kg}
100.4
187.2 N
{19.10 kg}
Lock-up clutch modulating

valve spring (outside)
141.4
88.7
158.6 N
{16.18 kg}
137.16
150.7 N
{15.37 kg}
Lock-up clutch modulating

valve spring (inside)
80.5
80.5
78.09
Lock-up valve spring
66
54.0
55.9 N
{5.7 kg}
64.0
53.1 N
{5.42 kg}
D275AX-5E0
Replace
55
SEN00927-00
Operation of torque converter lock-up

valve and solenoid valve
q
56
The torque converter lock-up valve supplies oil

for turning ON and OFF the lock-up clutch and
stator clutch installed in the torque converter.
The lock-up valve is operated by the pilot oil
pressure of the solenoid valve which operates
according to the electric signals from the lockup controller.
If the electricity flows in the solenoid valve, the
drain circuit is closed to raise the pilot pressure
in the lock-up valve and operate the valve to
lock up the torque converter.
If the lock-up valve operates, the oil in the stator clutch is drained and the stator clutch
becomes free.
D275AX-5E0
SEN00927-00
Lubrication relief valve
1.
2.
3.
Forward clutch housing

Spring
Piston
A:
B:
C:
From oil cooler

Drain
Drain
Outline
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.
58
The lubrication relief valve is installed to the

right side face of the forward clutch housing.
And prevents any abnormal pressure in the
lubrication oil.
Unit: MPa {kg/cm2}
Set pressure
Pressure when normal
0.14 0.05 {1.4 0.5}
Cracking pressure
0.30 0.03 {3.0 0.3}
D275AX-5E0
SEN00927-00
Unit: mm
No.
Check item
Criteria
Standard size
Lubrication relief valve spring
D275AX-5E0
Remedy
Repair limit
Free length
Installed
length
Installed
load
Free length
Installed
load
26
23.6
12.5 N
{1.27 kg}
25.2
11.9 N
{1.21 kg}
Replace
59
SEN00927-00
60
D275AX-5E0
SEN00928-00
BULLDOZER
1SHOP MANUAL
D275AX-5E0
Machine model
Serial number
D275AX-5E0
30001 and up


Power train system, Part 2.............................................................................................................................. 3
Bevel gear shaft, HSS, brake............................................................................................................... 3
Brake valve ........................................................................................................................................ 16
Brake ECMV ...................................................................................................................................... 17
Parking brake valve............................................................................................................................ 23
Sudden brake prevention valve.......................................................................................................... 24
Final drive........................................................................................................................................... 25
Sprocket ............................................................................................................................................. 30
D275AX-5E0

Bevel gear shaft, HSS, brake
D275AX-5E0
SEN00928-00
1
1
SEN00928-00
D275AX-5E0
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
Cover
Output shaft
Bearing cage
Spring
Brake piston (140 teeth)
Return spring
Brake plate (6 pcs. on each side)
Brake disc (7 pcs. on each side)
Brake outer drum (140 teeth)
Brake inner drum
Bearing cage
Shim (For adjustment of bevel gear)
Bearing A
Bevel gear shaft
Bevel gear (40 teeth)
Bearing B
Carrier
Ring gear (111 teeth)
Planetary pinion (35 teeth)
Hub (111 teeth)
Sun gear (41 teeth)
Shim (For adjustment of bevel pinion)
Bearing cage
Bearing
Nut (For adjustment of preload on bearing)
Bevel pinion (21 teeth)
Gear E (For driving right sun gear) (50 teeth)
Gear D (16 teeth)
Shaft
HSS motor
Pinion (20 teeth)
Gear A (34 teeth)
Gear C (16 teeth)
Gear B (For driving left sun gear) (50 teeth)
D275AX-5E0
SEN00928-00
A:
B:
C:
D:
E:
F:
G:
To transmission case (power train pump)

From transmission case (scavenging pump)
To pin puller solenoid valve
From pin puller solenoid valve
Drain plug
Left brake oil pressure pick-up port
Right brake oil pressure pick-up port
SEN00928-00
D275AX-5E0
SEN00928-00
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
2.9
2.6
Tolerance
Repair limit
Max. 0.3
0.4
Standard size
Repair limit
4.5
4.0
Tolerance
Repair limit
Max. 0.3
0.4
Total thickness of brake plates

and discs
Standard size
Repair limit
48.9
45.3
38
Backlash between brake disc

and brake inner drum
Standard clearance
Clearance limit
0.42 0.72
1.0
39
Backlash between sun gear

and planetary pinion
0.14 0.39
0.60
Backlash between planetary

40
pinion and ring gear
0.16 0.40
Thickness of brake plate

35
Strain of brake plate
Thickness of brake disc
36
Strain of brake disc
37
41
42
Sealing fitting face of small end

of brake piston
Backlash between gear A and
pinion
Repair or replace
Replace
Repair or replace
Replace
Standard
size
220
0.70
Tolerance
Shaft
Hole
Standard
clearance
0.100
0.172
+ 0.072
+ 0.072
0.100
0.244
Clearance
limit
Standard clearance
Clearance limit
0.20 0.48
0.70

43
gear C
0.08 0.72
0.70
44
Backlash between gear D and

gear E
0.19 0.46
0.80
45

gear B
0.10 0.58
0.80
46
Backlash between bevel gear

and pinion
0.25 0.33
0.50
D275AX-5E0
Replace
Replace
Adjust or replace
SEN00928-00
Outline
Bevel gear shaft
q
The bevel gear shaft device changes the output power of the transmission by a right angle
to the lateral directions and reduce the output
speed by using a bevel pinion and a bevel
gear.
q
The bevel gear shaft device has a spiral bevel
pinion and spiral bevel gear and is lubricated
forcibly with pressurized oil.
q
The bevel gear shaft device consists of bevel
pinion (26) meshed with bevel gear (15), bevel
gear shaft (14), and bearings (13) and (16) to
support the bevel gear shaft.
HSS
q
The HSS (Hydrostatic Steering System) consists of the transfer unit which reverses the
rotating direction of HSS motor (30) and transmits it to sun gear (21) and the planetary unit
whic h adjusts and outputs the input. It
changes the turning direction of the machine
by stopping or reversing the rotation of the
HSS motor.
q
The transfer unit has a spur gear speed reducing mechanism.
q
The transfer unit is lubricated forcibly with the
oil sent from the steering lubricating oil pump.
q
The planetary unit is lubricated forcibly with the
oil sent from the steering lubricating oil pump.
q
The transfer unit consists of HSS motor pinion
(31), gear A (32), gear C (33), shaft (29), gear
D (28), gear E (27), gear B (34), and cover (1)
to support those parts.
q
The planetary unit consists of sun gear (21),
planetary pinion (19), and hub (20), carrier (17)
[connected to brake inner drum (10)].
Brake
q
The brake is installed specially to stop the
machine and connected to brake inner drum
(10).
q
The brake is the wet, multiple disc clutch, and
spring boosted type, which is operated hydraulically with the oil from the brake valve connected to the brake pedal.
q
The brake is lubricated forcibly with oil sent
from the steering lubricating oil pump through
the housing, cage, discs, and plates.
q
The brake consists of inner drum (10) [connected to brake outer drum (9) and carrier
(17)], discs (8), plates (7), brake outer drum
(9), piston (5), spring (4), bearing cage (3) to
support those parts, brake cover (1), and output shaft (2).
Brake outer drum (9) and brake cover (1) are
fixed to the HSS case.
Output shaft (2) is connected to brake inner
drum (10) by spline.
q
If the engine is stopped, the back pressure on
the brake piston lowers and the brake is turned
ON automatically. If the engine is started
again, the oil pressure in the circuit rises and
the brake is deactivated. Since this is dangerous, be sure to set the parking brake lever to
the LOCK position.
D275AX-5E0
SEN00928-00
Mechanical power
Hydraulic power
Conbined power
Flow of power for HSS
The power from the transmission passes

through bevel pinion (26) and bevel gear (15),
and is transmitted to bevel gear shaft (14). It
then goes from bevel gear shaft (14) through
hub (20), ring gear (18), carrier (17), and brake
inner drum (10), and is transmitted to left and
right output shafts (2).
When the steering is operated, HSS motor (30)
rotates and the power is transmitted from pinion (31) to gear A (32), where it is divided to
the left and right. The power sent to the left is
transmitted from gear A (32) to gear B (34),
sun gear (21), and planet pinion (19). It is combined with the power from the transmission at
the planetary gear portion, and is transmitted
from carrier (17) to output shaft (2). The power
sent to the right is transmitted from gear A (32)
through gear C (33), gear D (28), and gear E
(27) to right sun gear (21) in order to reverse
the rotation of the power from the HSS motor.
(The flow of power beyond this point is the
same as on the left side.)
D275AX-5E0
The braking force is applied by braking the

rotation of inner drum (10) (which is interconnected with carrier (17)) at brake outer drum
(9), which is fixed to the HSS case.
SEN00928-00
Operation of HSS
1. When PCCS lever is at NEUTRAL (Traveling straight forward)
a
The direction of rotation of the HSS motor and gears is as seen from the left side of the machine.
Traveling straight forward

When the PCCS lever is at the NEUTRAL position,
HST motor (30), and transfer gear (33) and left and
right sun gears (21) of the planetary gear portion,
which are interconnected with the HSS motor, are
stopped.
In this condition, the power from bevel gear shaft
(14) is input to hub (20), passes through ring gear
(18) and planet pinion (19), and is transmitted to
carrier (17). It then passes through brake inner
drum (10), which forms one unit with the carrier,
and is transmitted to output shaft (2).
Therefore, the left and right output speeds are the
same and the machine travels in a straight line.
q
Direction of rotation of HSS motor.
PCCS lever steering position
PCCS lever directional position
Neutral
Any
Rotation direction seen from left

Stopped
of machine
[1]
[2]
[3]
[4]
Transmission output speed

Left bevel gear shaft output speed
Transmission output speed
Right bevel gear shaft output speed
: Transmission power
Right turn
Left turn
*Neutral Forward Reverse *Neutral Forward Reverse
CW
CW
CCW
CCW
CCW
CW
* Counter rotation turn
10
D275AX-5E0
SEN00928-00
2. PCCS lever operated to RIGHT TURN
[1] Transmission output speed

[2] Acceleration from HSS motor
[3] Left bevel gear shaft output
speed ([1] + [2])

[5] Deceleration from HSS speed
[6] Right bevel gear shaft output
speed ([4] [5])
Forward
When the machine is traveling forward, bevel gear
shaft (14) and hub (20), which is connected to it,
rotate clockwise.
If the PCCS lever is operated to the RIGHT TURN
position when the machine is traveling forward,
HSS motor (30) rotates clockwise, the rotation
passes through gear A (32), and gear B (34) on the
left side of the machine rotates clockwise, while
gear E (27) in the right side of the machine is
rotated counterclockwise by gear C (33).
In other words, the rotation of the HSS motor is
transmitted to sun gears (21) as rotation in opposite
directions on the left and right by the transfer portion.
D275AX-5E0
: HSS motor power
: Combined power
This rotation acts on the left and right planetary

gear mechanisms. The speed of carrier (17) on the
left is accelerated from the speed when traveling in
a straight line by the amount of the power from the
HSS motor.
On the other hand, the speed of carrier (17) on the
right is decelerated from the speed when traveling
in a straight line, so a difference in rotation is generated in the output on the left and right. The output
speed in the right is lower, so as a result, the
machine travels forward and turns to the right.
11
SEN00928-00

[2] Acceleration from HSS motor
speed ([1] + [2])

[5] Deceleration from HSS speed
speed ([4] [5])
Reverse
When the machine is traveling in reverse, bevel
gear shaft (14) and hub (20), which is connected to
it, rotate counterclockwise.
If the PCCS lever is operated to the RIGHT TURN
position when the machine is traveling in reverse,
HSS motor (30) is rotated counterclockwise in the
opposite direction from when traveling forward by
the function of the HSS controller.
The rotation passes through gear A (32), and gear
B (34) on the left side of the machine rotates
counter-clockwise, while gear E (27) on the right
side of the machine is rotated clockwise by gear C
(33).
12
: HSS motor power
: Combined power

gear mechanisms. The speed of carrier (17) on the
left is accelerated from the speed when traveling in
a straight line by the amount of the power from the
HSS motor. On the other hand, the speed of carrier
(17) on the right is decelerated from the speed
when traveling in a straight line, so a difference in
rotation is generated in the output on the left and
right. The output speed in the right is lower, so as a
result, the machine travels in reverse and turns to
the right.
D275AX-5E0
SEN00928-00
3. PCCS lever operated to LEFT TURN

[2] Deceleration from HSS motor
speed ([1] [2])

[5] Acceleration from HSS speed
speed ([4] + [5])
Forward
When the machine is traveling forward, bevel gear
shaft (14) and hub (20), which is connected to it,
rotate clockwise.
If the PCCS lever is operated to the LEFT TURN
position when the machine is traveling forward,
HSS motor (30) rotates counterclockwise, the rotation passes through gear A (32), and gear B (34) on
the left side of the machine rotates counterclockwise, while gear E (27) on the right side of the
machine is rotated clockwise by gear C (33).
gear mechanisms.
D275AX-5E0
: HSS motor power
: Combined power
The speed of carrier (17) on the right is accelerated

from the speed when traveling in a straight line by
the amount of the power from the HSS motor. On
the other hand, the speed of carrier (17) on the left
is decelerated from the speed when traveling in a
straight line, so a difference in rotation is generated
in the output on the left and right. The output speed
in the left is lower, so as a result, the machine travels forward and turns to the left.
13
SEN00928-00

[2] Deceleration from HSS motor
speed ([1] [2])

[5] Acceleration from HSS speed
speed ([4] + [5])
Reverse
When the machine is traveling in reverse, bevel
gear shaft (14) and hub (20), which is connected to
it, rotate counterclockwise.
If the PCCS lever is operated to the TURN LEFT
position when the machine is traveling in reverse,
HSS motor (30) is rotates clockwise in the opposite
direction from when traveling forward by the function of the HSS controller. The rotation passes
through gear A (32), and gear B (34) on the left side
of the machine rotates clockwise, while gear E (27)
on the right side of the machine is rotated counterclockwise by gear C (33).
gear mechanisms.
14
: HSS motor power
: Combined power
The speed of carrier (17) on the right is accelerated

from the speed when traveling in a straight line by
the amount of the power from the HSS motor. On
the other hand, the speed of carrier (17) on the left
is decelerated from the speed when traveling in a
straight line, so a difference in rotation is generated
in the output on the left and right. The output speed
in the left is lower, so as a result, the machine travels in reverse and turns to the left.
D275AX-5E0
Operation of brake
1.
Brake released
When the brake pedal is at the RELEASED
position, the brake valve is also at the NEUTRAL position, so oil flows to back pressure
port (A) of brake piston (5).
When the oil pressure rises, the piston is
pushed to the left in the direction of the arrow,
compresses spring (4), and releases the pressure pushing disc (8) and plate (7) into tight
contact. When this happens, the power transmitted from bevel gear shaft (14) through the
HSS to brake inner drum (10) is transmitted to
output shaft (2), and is then transmitted to the
final drive.
D275AX-5E0
SEN00928-00
2.
Brake applied (brake pedal depressed)

When the brake pedal is depressed, the brake
valve is switched, and the oil at port (A), which
was applying back pressure to piston (5), is
connected to the drain circuit.
In this condition, piston (5) is pushed to the
right in the direction of the arrow by the tension
of spring (4), so disc (8) and plate (7) are
brought into tight contact with the stopper of
brake outer drum (9). The brake outer drum is
joined to the HSS case and is locked in position.
Therefore, the rotation of brake inner drum
(10) (in other words, output shaft (2)) is braked
when the disc and plate are brought into tight
contact.
By adjusting the amount the brake pedal is
depressed, it is possible to adjust the hydraulic
pressure applied to piston (5), thereby adjusting the braking force.
15
SEN00928-00
Brake valve
1.
2.
3.
4.
5.
6.
Parking brake valve

Right brake ECMV
Left brake ECMV
Filter
Sudden brake prevention
valve
Valve seat
A:
B:
C:
D:
E:
Left brake operating pressure

pick-up port
Right brake operating pressure
pick-up port
To right brake
To left lubrication
To right lubrication
Outline
q
The brake valve is installed through the main
relief valve between the power train pump and
the brake piston in the HSS unit. It consists of
2 sets of brake ECMV (Right and left), parking
brake valve, and sudden brake prevention
valve.
Each valve is installed as an assembly on the
valve seat.
q
If the brake pedal is pressed, the oil pressure
applied to the brake piston is shut off and the
brake piston fits the discs and plates with the
spring force to excited the brake. Since the
brake is used to only stop the machine in the
HSS, both brakes are applied simultaneously.
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.
16
F: To right brake
G: From steering lubricating oil
pump
H: To transmission lubrication
J: From power train pump
K: To pin puller solenoid valve
When the parking brake lever is set to the

LOCK position, the port of the parking brake
valve is changed to drain the oil between the
ECMV for both brakes and the brakes and
excited the brakes. The parking brake valve is
connected to the brake pedal by the linkage.
The steering ECMV operates to excited the
brake so that the machine can make a pivot
turn when the turning operation stroke of the
PCCS lever is 80 100%.
D275AX-5E0
Brake ECMV
SEN00928-00
(Electronic control modulation valve)
A:
T:
Dr:
P:
P1:
To brake
Drain
Drain
From pump
Brake oil pressure pick-up port
D275AX-5E0
1.
2.
3.
4.
5.
6.
Connector for fill switch

Connector for proportional solenoid
Oil pressure detection valve
Fill switch
Proportional solenoid
17
SEN00928-00
Outline of ECMV
q
The ECMV (Electronic Control Modulating valve)

consists of a pressure control valve and a fill
switch.
This valve allows a proportional solenoid to
receive a current sent from a steering controller and converts it to oil pressure.
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 termination.
2) While oil pressure is applied to the clutch,
the signal (fill signal) is output to the controller and transmits the presence of oil
pressure.
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 pressure and switches a circuit to the clutch chamber and the brake chamber.
ECMV and proportional solenoid

q
18
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 solenoid is actuated on a pressure control valve
spool and generates oil pressure. Accordingly,
by controlling an amount of the command current, the thrust changes and the pressure control valve is actuated, then a flow of oil and the
oil pressure is controlled.
D275AX-5E0
SEN00928-00
Operation
1.
When PCCS lever is in NEUTRAL and brake pedal is RELEASED (During straight travel and
when PCCS lever is moved from NEUTRAL to 80% of stroke)
When brake pedal is RELEASED (During gradual turn: Both brakes are OFF and parking brake is
OFF)
If the PCCS lever is in NEUTRAL and the

brake pedal is OFF, proportional solenoid valve
(1) of the brake ECMV is excited and pushes
ball (2) to the left to close the seal. The oil in
pump port (Pb) flows in port (A) and pushes
valve (3) to the left to open the passage
between ports (Pb) and (B) and close the passage between ports (B) and (Dr).
The oil in port (Pb) flows through port (B) to the
back pressure port of the brake piston. If the
circuit pressure rises, the brake piston moves
to the left to compress the brake spring and
RELEASE the brake.
If the parking brake is deactivated, the parking
brake valve is closed and the oil in the brake
circuit is not drained.
D275AX-5E0
19
SEN00928-00
2.
When PCCS lever is moved to left more than 80% of stroke (Pivot turn: Left brake is turned "ON",
right brake is deactivated, and parking brake is deactivated)
If the PCCS lever is moved to the left more

than 80% of the stroke in the state in 1 above,
the proportional solenoid valve (1) of the left
brake ECMV is deactivated and ball (2)
becomes free and the seal is opened. Since
oil in port (A) is drained through the seal, valve
(3) is moved to the right by the tension of
spring (4).
At this time, the passage between ports (Pb)
and (B) is closed and the passage between
ports (B) and drain port (Dr) is opened.
The oil from the power train pump is drained
through port (Pb), throttle (a), and the seal of
ball (2).
The oil which has been flowing in the brake
piston port to apply back pressure is drained
through port (B) to (Dr).
20
q
q
The left brake is turned "ON" by the tension of

the brake spring.
If the parking brake is turned "OFF", the parking brake valve is closed and the oil in the
brake circuit is not drained.
D275AX-5E0
3.
When brake pedal is PRESSED

(Brake is "ON" and parking brake is "OFF")
If the brake pedal is pressed, proportional solenoid valves (1) of both brake ECMV's are
deactivated.
The controller outputs a command current to
proportional solenoid valves (1) according to
the pressing stroke of the brake pedal. If a current flows in proportional solenoid valves (1),
the solenoid generates trust in proportion to
the current. The oil pressure, or the braking
force, is regulated by this trust of the solenoids,
oil pressure in the brake port, and reaction
force of pressure control valve spring (4).
D275AX-5E0
SEN00928-00
If the brake pedal is pressed, the parking brake

valve connected by the linkage operates and
drains the oil from the brake circuit.
21
SEN00928-00
4.
When parking brake is turned ON

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

"LOCK" position, parking brake valve (1)
moves to the left and the ports (A) and (B) are
connected to between port (C). The oil which
has been flowing in the brake piston port to
apply back pressure is drained through ports
(A), (B), and (C). As a result, the back pressure in the brake piston port keeps lowering
and the brake is turned "ON" completely and
kept as it is.
When the engine is started again, ports (A)
and (B) are kept connected to drain port (C).
Accordingly, the brake is kept turned "ON".
If the parking brake is turned "OFF", parking
brake valve (1) moves to the right. Ports (A)
and (B) are disconnected from between drain
port (C) and the brake is turned "RELEASED"
by the oil pressure.
22
D275AX-5E0
Parking brake valve
SEN00928-00
Unit: mm
No.
Check item
Clearance between parking
brake valve spool and valve
body
Outside diameter of sliding
parts fitting to dust seal and
V-packing (Spool)
Criteria
Standard
size
14
Tolerance
Shaft
Hole
Standard
clearance
0.020
0.030
+ 0.011
0
0.020
0.041
Parking brake valve spool

spring
Free length
65
D275AX-5E0
Clearance
limit
0.05
Tolerance
Clearance limit
0.020
0.030
13.9
14
Standard size
3
Remedy
Using
length
47.7
Replace
Repair by hard
chromium plating
or replace
Repair limit
Using load Free length Using load
38.2 N
{3.9 kg}
63.1
Replace
36.3 N
{3.71 kg}
23
SEN00928-00
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 drain circuit. If brake
ECMV solenoid valve (2) is deactivated, the oil
is drained from the brake circuit and the brake
is applied suddenly. To prevent this, if solenoid
valve (3) of sudden brake prevention valve (1)
is deactivated, the circuit of throttle (a) is
formed. As a result, pilot pressure drain circuit
( D) i s c h o k e d a n d t h e b r a k e i s " S E M I RELEASED".
24
D275AX-5E0
Final drive
SEN00928-00
Outline
q
The final drive is a single stage spur gear, single stage planetary gear reduction type. The
lubrication is of splash type using the rotation
of the gears. The final drive can be removed
and installed as a single unit.
q
Floating seal (1) is installed to the rotating sliding portion of the sprocket to prevent the entry
of dirt or sand and to prevent leakage of lubricating oil.
D275AX-5E0
25
SEN00928-00
26
D275AX-5E0
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Floating seal
Sun gear
Carrier
Hub
Cover
Sprocket boss
Sprocket teeth
Floating seal guard
Cover
Planetary gear
Ring gear
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
SEN00928-00
Cover
No.1 pinion
Final drive case
Bearing cage
No.1 gear
No.1 gear hub
Boss
Shaft
Wear guard
Pivot shaft
Unit: mm
No.
Check item
Criteria
Remedy
Standard clearance
Clearance limit
0.28 0.93
0.93
22
Backlash between No.1 pinion

and No.1 gear
23
Backlash between sun gear

and planet pinion
0.22 0.81
0.81
24
Backlash between planet pinion and ring gear
0.25 0.90
0.90
25
Outside diameter of No.1 pinion oil seal contact surface
26
Thickness of thrust collar of

roller bearing
Clearance between outer diameter of planet gear shaft and in27

ner diameter of carrier hole.
(Small diameter)
Clearance between outer diameter of planet gear shaft and in28
ner diameter of carrier hole.
(Large diameter)
29
Standard size
Tolerance
30
Standard
size
D275AX-5E0
94.913
Repair or
replace
29.95
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
85
0.036
0.058
0.024
0.059
0.023
0.034
0.034
105
0.036
0.058
0.072
0.107
0.071
0.014
0.014
Standard shim thickness for

No.1 pinion bearing cage
30 Wear of wear guard
Repair limit
0
0.087
95
Replace
Replace
Adjust
Standard size
Repair limit
72
18
Repair or
replace
27
SEN00928-00
Path of power transmission
28
D275AX-5E0
SEN00928-00
The power from the bevel gear shaft and steering 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).
D275AX-5E0
29
SEN00928-00
Sprocket
Unit: mm
No.
Check item
Wear of tooth tip
Thickness of tooth root
30
Criteria
Remedy
Standard clearance
Repair limit
402.4
386
23.2
17
Repair or
replace
D275AX-5E0
SEN00928-00
Sprocket tooth shape of real dimension
The above drawing is reduced to 35%. Enlarge it to 280% to return it to the full scale and make a copy
on an OHP sheet.
D275AX-5E0
31
SEN00928-00
32
D275AX-5E0
SEN00929-00
BULLDOZER
1SHOP MANUAL
D275AX-5E0
Machine model
Serial number
D275AX-5E0
30001 and up


Undercarriage and frame ................................................................................................................................ 2
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
D275AX-5E0
SEN00929-00

Track frame
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Idler
Carrier roller
Track frame
Sprocket
Sprocket cover guard
Track roller bogie
Track roller
Track roller support guard
Pivot shaft
Cylinder
Guide
1
1
Outline
q
The track roller uses an K-shape bogie mount
to increase the ground contact area between
the track shoe and ground surface on rough
surfaces, thereby increasing the drawbar pull.
q
The K-shape bogie is fitted with rubber pads to
absorb the shock from the ground surface.
Track roller, bogie
Track roller flange type and bogie arrangement
1st
2nd
3rd
4th
5th
6th
7th
D275AX-5E0
SEN00929-00
Unit: mm
No.
Check item
Criteria
Item
12
Clearance between idler bogie

and guide
13 Press-fitting force for cartridge
D275AX-5E0
Repair limit
Curvature
7 (for length of 3,000)
Twisting
3 (for level length of 300)
Dents (pipe portion)
12
Deformation of track frame outer pipe
Clearance between inner pipe

11 and adjustment cylinder protrusion
Remedy
Standard
size
50
Tolerance
Shaft
Hole
0.15
0.35
+ 0.1
+ 0.1
Standard
clearance
Clearance
limit
0.15 0.45
2.0
Standard clearance
Clearance limit
0 0.5
3.0
275 530 kN {28 54 ton}
Repair or replace
Replace
Adjust
SEN00929-00
Recoil spring
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Yoke
Nut
Retainer
Recoil spring
Rod
Spring cylinder
Retainer
Holder
Piston
Lubricator (for pumping in and releasing grease)
Grease chamber cylinder
Outline
q
Recoil spring (4) is used to adjust the track tension by pumping in or releasing grease from
lubricator (10) to move rod (5) forward or backward. The recoil spring (4) also acts to dampen
any sudden shock brought to bear on the idler.
D275AX-5E0
SEN00929-00
Unit: mm
No.
Check item
Criteria
Standard size
12 Recoil spring
Clearance between inner cylin13 der and outer cylinder of outer

cylinder bushing
14
Clearance between adjustment

cylinder and bushing
Remedy
Repair limit
Free length
Installed
length
Installed
load
Free length
Installed
load
1,231
1,045
372.7 kN
{38,000 kg}
1.415
345.1 kN
{35,185 kg}
Standard
size
Shaft
Hole
Standard
clearance
340
0.055
0.228
+ 0.317
+ 0.060
0.115
0.545
0.8
110
0.100
1.350
+ 0.054
+ 0.054
0.100
0.404
Tolerance
Press-fitting force for outer cyl15 inder bushing (outer cylinder

side)
42.1 96.1 kN {4.3 9.8 ton}
Press-fitting force for outer cyl16 inder bushing (inner cylinder

side)
44.1 228.6 kN {4.5 23.3 ton}
17
Clearance between recoil

spring mount nut and lock plate
D275AX-5E0
Clearance Replace
limit
Adjust
0 1.0
SEN00929-00
Idler
D275AX-5E0
SEN00929-00
Unit: mm
No.
Check item
Outside diameter of protruding

part
Outside diameter of tread surface
Width of protruding part
Criteria
Remedy
Standard size
Repair limit
822
780
755
121
Width of tread
77
85.5
Overall tread
275
Thickness of tread
25.5
13
Width of shaft flange
242
Clearance between shaft and

bushing
Interference between shaft and

seal guard
Standard
size
147
Standard
size
84
10 Play in axial direction of shaft
D275AX-5E0
Tolerance
Rebuild or
replace
Shaft
Hole
Standard
clearance
Clearance
limit
0.350
0.413
+ 0.170
0.010
0.340
0.583
Interference limit
Tolerance
Shaft
Hole
Standard
interference
+ 0.046
+ 0.046
0.150
0.200
0.150
0.246
Standard clearance
Clearance limit
0.5 1.0
Replace bushing
Replace
SEN00929-00
Track roller
D275AX-5E0
SEN00929-00
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
291
277
single flange
255
185
double flange
255
195
single flange
65
30
double flange
65
35
Outside diameter of flange

(outside of single flange)

(inside of double flange)
Outside diameter
Thickness of
tread
Overall width
336
Width of tread (single flange)
80
Width of tread (double flange)
80
Width of flange (double flange

of outside)
27.5
12.5
Width of flange (double flange

of inside)
24
28.5
10 Width of shaft flange
11
12

bushing

seal guard
Standard
size
115
Standard
size
65
13 Play in axial direction of shaft
D275AX-5E0
Tolerance
Rebuild or
replace
Replace
Shaft
Hole
Standard
clearance
0.350
0.413
+ 0.225
+ 0.007
0.343
0.038
Interference limit
Tolerance
Shaft
Hole
Standard
interference
+ 0.046
+ 0.046
0.150
0.200
0.150
0.246
Clearance
limit
Standard clearance
Clearance limit
0.44 0.91
Replace bushing
Replace
SEN00929-00
Track roller bogie
1.
2.
3.
4.
5.
6.
7.
8.
9.
10
Guide
Cap
Track roller assembly (double)
Large bogie
Rubber mount
Small bogie
Track roller assembly
Cover
Cartridge pin
Outline
q
The track roller are installed to small bogie (6).
The track rollers and track shoes are always in
contact.
q
The vibration of the machine from the ground
surface is absorbed by rubber mount (5).
D275AX-5E0
SEN00929-00
Carrier roller
12
D275AX-5E0
SEN00929-00
Unit: mm
No.
Check item
Outside diameter of carrier roller tread
Thickness of tread
Width of carrier roller tread
Width of flange

support

seal guard
Criteria
Play in axial direction of shaft
D275AX-5E0
Standard size
Repair limit
232
200
175
40
27.5
Standard
size
76
Standard
size
77
Remedy
76.5
23
12
Tolerance
Shaft
Hole
0
0.2
+ 0.35
0
Tolerance
Shaft
+ 0.210
+ 0.150
Hole
+ 0.030
0
Rebuild or
replace
Standard
clearance
Clearance
limit
0
0.550
Standard
interference
Interference limit
0.120
0.210
Standard clearance
Clearance limit
0 0.22
Replace bushing
Replace
13
SEN00929-00
Track shoe
14
Portion P shows the link on the side where the bushing is pressed fitted.
D275AX-5E0
SEN00929-00
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
260.6
263.6
88
30
Thickness of plate
20
Link height
166
148
Thickness of link metal
51.7
33.7
Link pitch
Height of grouser
Reverse or
replace
Lug welding
rebuild or replace
Rebuild or
replace
Bushing outside diameter
90.5
82 (Standard ground)
84.5 (Heavy duty ground)
Thickness of bushing metal
17.1
8.6 (Standard ground)

11.1 (Heavy duty ground)
Shaft
Hole
Standard
interference
90
+ 0.602
+ 0.372
+ 0.087
+ 0.087
0.285
0.602
Interference between pin and

link (without wedge ring)
55.5
+ 0.296
+ 0.236
0.206
0.280
0.442
0.576
Interference between pin and

link (with wedge ring)
55.5
+ 0.296
+ 0.236
0.034
0.096
0.270
0.392
Interference between bushing

and link
Clearance between link and

10
link
11
Tightening torque for regular

bolt
12
Tightening torque for master

bolt
D275AX-5E0
Tolerance
Standard
size
Standard clearance
Each side
Both sides
1.4
2.8
Interference limit Reverse or

replace
0.10
Clearance limit
Both sides
Tightening torque
Additional tightening
784 78 Nm {80 8 kgm}
120 10
490 49 Nm {50 5 kgm}
180 10
Replace
15
SEN00929-00
Main frame
16
D275AX-5E0
1.
2.
3.
4.
5.
6.
7.
8.
SEN00929-00
Main frame
Cage
Clamp
Cover
Seal
Clamp
Cap
Plate
Unit: mm
No.
Check item
Clearance between radiator

guard mounting pin and bushing
Clearance between radiator

10 guard mounting pin and bushing
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
80
0.030
0.076
+ 0.257
+ 0.170
0.410
0.555
0 more than
80
0.030
0.076
+ 0.257
+ 0.170
0.343
0.405
1.0
Replace
11
Clearance between ripper

beam mount pin and bushing
110
0.036
0.090
+ 0.267
+ 0.180
0.098
0.254
1.5
12
Clearance between ripper cylinder mounting pin and bushing
90
0.036
0.090
+ 0.257
+ 0.170
0.064
0.256
1.5
13
Clearance between equalizer

bar shaft and bushing
120
0.036
0.090
0.109
0.260
1.5
14
Press-fitting force for radiator

guard mount bushing
6.08 138.3 kN {6.2 14.1 ton}
15
Press-fitting force for radiator

guard mount bushing
68.7 155.0 kN {7.0 15.8 ton}
16
Press-fitting force for ripper

beam mount bushing
69.7 37.3 kN {7.1 14.0 ton}
17
Press-fitting force for ripper cylinder mount bushing
57.9 114.8 kN {5.9 11.7 ton}
18
Press-fitting force for equalizer

bar shaft bushing
31.4 105.9 kN {2 13 ton}
D275AX-5E0
Adjust
17
SEN00929-00
Suspension
1.
2.
3.
4.
5.
6.
7.
18
Equalizer bar
Cover
Thrust plate
Thrust plate
Pivot shaft
Seal cage
8.
9.
10.
11.
12.
Seal
Bushing
Side pin
Center pin
Bushing
Outline
q
The front of the track frame rocks up and down
using the rear pivot shafts (6) as a fulcrum.
Equalizer bar (1) rocks using center pin (11) as
a fulcrum. The left and right track frames are
connected by side pin (10).
D275AX-5E0
SEN00929-00
Unit: mm
No.
Check item
Clearance between center pin

13
and bushing
14
15
Clearance between side pin

and bushing
Interference between side pin

boss and bushing
Criteria
Standard
size
Shaft
Hole
Standard
clearance
Clearance
limit
105
0.030
0.060
+ 0.247
0.166
0.196
0.307
1.0
75
0.030
0.060
+ 0.046
+ 0.046
0.030
0.106
1.0
Interference
limit
Standard
size
140
16
Press-fitting force for center pin

bushing
Press-fitting force for side pin

17
bushing
D275AX-5E0
Tolerance
Remedy
Tolerance
Shaft
Hole
Standard
interference
0.018
0.018
0.088
0.098
0.098
0.106
Replace bushing
32.4 225.6 kN {3.3 23 ton}
34.3 68.7 kN {3.5 7.0 ton}
19
SEN00929-00
*1. Indicates the left of the blade single tilt specifications.

*2. Indicates the right of the blade single tilt specifications.
No.
Check item
Interference between
18
thrust washer and seal
Criteria
Standard
size
Tolerance
Remedy
Standard Interference
interference
limit
Shaft
Hole
210
+ 0.213
+ 0.098
0.180
0.226
0.278
0.439
Replace
19
Interference between thrust

washer and seal
140
+ 0.140
+ 0.100
0.061
0.124
0.161
0.264
20
Interference between pivot

shaft and seal
194
+ 0.096
+ 0.050
0.075
0.147
0.125
0.243
Clearance between pivot

21
shaft and bushing
22
20
Clearance between pivot

shaft and bushing
Standard
size
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
155
0.145
0.208
+ 0.132
+ 0.059
0.204
0.340
1.0
190
0.170
0.242
+ 0.144
+ 0.059
0.229
0.386
1.0
Replacing
bushing
D275AX-5E0
SEN00929-00
22
D275AX-5E0
SEN00930-00
BULLDOZER
1SHOP MANUAL
D275AX-5E0
Machine model
Serial number
D275AX-5E0
30001 and up


Hydraulic system, Part 1 ................................................................................................................................. 2
Work equipment hydraulic piping diagram............................................................................................ 2
PPC control piping diagram .................................................................................................................. 6
Work equipment control........................................................................................................................ 8
Hydraulic tank ..................................................................................................................................... 10
Scavenging pump ............................................................................................................................... 12
Work equipment pump........................................................................................................................ 14
Power train pump, steering lubrication pump ..................................................................................... 30
HSS pump .......................................................................................................................................... 31
HSS motor .......................................................................................................................................... 47
PPC, HSS charge filter ....................................................................................................................... 56
D275AX-5E0
SEN00930-00
Work equipment hydraulic piping diagram
Semi U-dozer
1.
2.
3.
4.
5.
6.
Blade tilt cylinder

R.H. blade lift cylinder
HSS charge filter bypass valve
HSS charge filter
Control valve
Accumulator
7.
8.
9.
10.
11.
12.
Hydraulic tank
Oil cooler bypass valve
Work equipment pump
HSS charge pump
L.H. blade lift cylinder
Oil cooler
D275AX-5E0
SEN00930-00
U-Dozer + dual tilt
1.
2.
3.
4.
5.
6.
7.
Blade tilt cylinder

R.H. blade lift cylinder
HSS charge filter
Control valve
Accumulator
Dual tilt solenoid valve
D275AX-5E0
8.
9.
10.
11.
12.
13.
14.
Hydraulic tank
Oil cooler bypass valve
Work equipment pump
HSS charge pump
L.H. blade lift cylinder
Blade pitch cylinder
Oil cooler
SEN00930-00
Multi-shank ripper
1.
2.
3.
4.
Control valve
Divider block
Ripper tilt cylinder
Ripper lift cylinder
D275AX-5E0
SEN00930-00
Giant ripper
q
The diagram shows a machine equipped with a pin puller cylinder
1.
2.
3.
4.
5.
Control valve
Divider block
Ripper tilt cylinder (right)
Ripper lift cylinder (right)
Pin puller cylinder
D275AX-5E0
6.
7.
8.
9.
10.
Ripper lift cylinder (left)

Ripper tilt cylinder (left)
Pin puller solenoid valve
Steering case
Brake valve
SEN00930-00
PPC control piping diagram
PPC control piping diagram
1.
2.
3.
4.
5.

HSS charge filter
Blade control PPC valve
Control valve
Accumulator
6.
7.
8.
9.
10.
Ripper control PPC valve

PPC lock valve
Work equipment lock lever
Work equipment pump
HSS charge pump
D275AX-5E0
SEN00930-00
Work equipment control

q
The diagram shows a machine equipped with pitch dozer and pin puller cylinder.
D275AX-5E0
1.
2.
3.
4.
5.
6.
7.
SEN00930-00
Work equipment lock lever

Blade control valve
Pitch button
Tilt switch
Ripper control lever
Pin puller switch
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 interconnected with PPC lock valve (7), and at the
LOCK position, the oil in the PPC circuit is
stopped.
D275AX-5E0
SEN00930-00
Hydraulic tank
1.
2.
3.
4.
5.
6.
10
Oil filler cap

Hydraulic filter element
Spring
Suction valve
Cover
Cover
7.
8.
9.
10.
11.
12.
Hydraulic tank
Strainer
Sight gauge
Pressure valve
Drain valve
Drain plug
D275AX-5E0
SEN00930-00
Specified value
Tank capacity (l)
Hydraulic
Level inside
tank
tank
Breather
cap
200
Hi (l)
149
Center (l)
135
Low (l)
117
Cracking pressure
(KPa {kg/cm2})
16.7 6.9
{0.17 0.07}
Vacuum valve actuating

pressure
(KPa {kg/cm2})
0 0.49
{0 0.005 }
D275AX-5E0
Specified value
102.9 19.6
{1.05 0.2}
Cracking pressure
(KPa {kg/cm2})
Hydraulic Mesh size
filter
Filtering area
Strainer
(m)
30/8
(cm2)
13,600
Filtering oil flow (l/min)
245
Mesh size
105
Filtering area
(m)
(cm2)
1,850
11
SEN00930-00
Scavenging pump
BAR (3) 160
A.
B.
Discharge port
Suction port
Unit: mm
No.
1
Check item
Spline shaft rotation torque
Delivery
12
Criteria
(Oil: EO30 - CD
Oil temperature: 45 50C)
Remedy
Type
Rotating
speed
(rpm)
Discharge
pressure
MPa
({kg/cm2})
Standard
discharge
amount
(l/min)
Permissible
discharge
amount
(l/min)
BAR160
1,250
2.94
{30}
D275AX-5E0
SEN00930-00
Work equipment pump
Type: HPV112 (112-cm3/rev specification)

Outline
This pump consists of a swash plate-type variable-capacity piston pump and an LS valve.
14
D275AX-5E0
1.
2.
3.
SEN00930-00
Piston pump
Control assembly
Gear pump
PA:
PA2:
PD1:
PD2:
PS1:
PS2:
PLS1:
PLS2:
PNC2:
Pump discharge
Gear pump discharge
Pump drain
Pump drain
Pump suction
Gear pump suction
Load pressure input
Load pressure pick-up
Control pressure pick-up
Specifications
Model: HPV112 (112 cm3/rev)
Theoretical displacement: 112 1 cm3/rev
Rated speed: 2,286 rpm
Max. cut-off pressure: 31.9 MPa {325 kg/cm2}
D275AX-5E0
15
SEN00930-00
PA:
Pump discharge
PA1: Pump pressure signal
PD1: Pump drain
16
PD2: Pump drain

PS1: Pump suction
PNC1: Control pressure
D275AX-5E0
1.
2.
3.
4.
5.
6.
7.
Shaft
Case
Cradle
Rocker cam
Shoe
Servo piston
Lod
D275AX-5E0
SEN00930-00
8.
9.
10.
11.
12.
13.
Piston
Cylinder block
Valve plate
End cap
Impeller
Spline
17
SEN00930-00
Outline
q
The engine rotation and torque transmitted to
the pump shaft is converted to hydraulic
energy and pressurized oil is discharged
according to the load.
q
It is possible to change the discharge amount
by changing the swash plate angle.
Structure
Cylinder block (9) is supported to shaft (1) by a
spline (13), and shaft (1) is supported by the
front and rear bearings.
q
The end of piston (8) has a concave ball shape
and shoe (5) is caulked to it to form one unit.
Piston (8) and shoe (5) form a spherical bearing.
q
Rocker cam (4) holds plane (A), and shoe (5)
is always pressed against this surface as it
slides in a circle.
q
18
Rocker cam (4) forms a static bearing sending

high pressure oil at cylindrical surface (B) of
cradle (3), which is fixed to the case, and carries out a sliding movement.
Piston (8) carries out motion relative to the
axial direction inside each cylinder chamber of
cylinder block (9).
The cylinder block (9) carries out rotation relative to valve plate (10) while sealing the pressurized oil, and this surface ensures that the
hydraulic balance is maintained correctly.
The oil inside each cylinder chamber of cylinder block (9) is sucked in and discharged
through valve plate (10).
Impeller (12) is fixed to shaft (1), and rotates
together with the shaft, it makes it easier for
the oil sucked in from the suction port to be
sucked in and sends it into the cylinder chamber by centrifugal force.
D275AX-5E0
OPERATION
1.
q
Operation of pump
(1), and shoe (5) slides on plane (A). When
this happens, rocker cam (4) moves along
cylindrical surface (B), so angle (a) of center
line (X) of rocker cam (4) to the axial direction
of cylinder block (9) changes. This angle (a) is
called the swash plate angle.
SEN00930-00
When center line (X) of rocker cam (4) is the

same as the axial direction of cylinder block (9)
(s wash plate angle = 0) , the differ enc e
between volumes (E') and (F') inside cylinder
block (9) is 0, so pump does not suction and
discharge, and no pumping's carried out. Actually swash plate angle does not become 0.)
The swash plate angle (a) is proportional to
pump discharge volume.
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 generated between volumes (E) and (F) inside the
cylinder block. The amount of suction and discharge is equal to difference (F) (E).
In other words, cylinder block (9) rotates, and
the volume pf chamber (E) becomes smaller,
so oil is discharged during this process. At the
same time, the volume of chamber (F)
becomes larger and oil is sucked in this process.
D275AX-5E0
19
SEN00930-00
1.
q
20
Control of discharge amount

If swash plate angle (a) becomes larger, the
difference between volumes (E) and (F)
becomes larger, and oil discharge (Q) is
increased. Swash plate angle (a) is changed
by servo piston (6).
Servo Piston (6) carries out reciprocal movement in a straight line according to the command from the LS valve single pressure. This
straight line movement is transmitted to rocker
cam (4) through rod (7), and rocker cam (4),
which is supported on the cylindrical surface
by cradle (3) rotates on the cylindrical surface.
The area receiving the pressure is different at
the left and right sides of servo piston (6), and
the receiving pressure at the small diameter
piston end is always connected with main
pump discharge pressure (self pressure) (PP).
Output pressure (PNC) of the LS valve is
applied to the chamber receiving the pressure
at the large diameter piston end (which
receives pressure of the pump).
The movement of servo piston (6) is controlled
by the relationship of the size of pump pressure (PP) and the pressure at the large diameter piston end, and the comparative size of the
ratio of area receiving the pressure at the large
diameter piston end and small diameter piston
end.
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.
The relationship between discharge volume
(Q) and the difference in pressure ( P = PP PLS) (called the LS differential pressure)
between main pump pressure (PP) and LS
pressure (PLS) and is as shown in the diagram
on the right.
D275AX-5E0
SEN00930-00
Control assembly
PP:
Pump pressure signal
PT:
Drain
PLS1: Load pressure signal
PLS2: Load pressure pick-up
PNV1: Control pressure
PNV2: Control pressure pick-up
D275AX-5E0
21
SEN00930-00
1.
2.
3.
4.
5.
6.
7.
22
Valve body
LS valve
Variable throttle valve
Plug
Spool
Spring
Plug
8.
9.
10.
11.
12.
13.
Locknut
Locknut
Plug
Spring
Spool
Plug
D275AX-5E0
SEN00930-00
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.
D275AX-5E0
23
SEN00930-00
2)
Movement in direction to increase pump discharge ( to the right)
Operation
q
When LS differential pressure ( PLS), which
is the difference in pressure between main
pump pressure (PP) and LS pressure (PLS),
becomes smaller (for example, the area of
opening of the control valve becomes larger
and pump pressure (PP) is reduced), spool (4)
is pushed to the right under the combined force
of the LS pressure (PLS) and the force of
spring (3). Main pump pressure (PP) enters
chamber (h). The combined force of spring (3)
and the force of LS pressure (PLS) is greater
than the force of main pump 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).
24
Circuits (c) (f), which are the pressure of (f)

port at the large diameter piston end of servo
piston (1), become the drain pressure, so
servo piston (1) is pushed from the small diameter piston end to the large diameter piston
end.
Rod (2) also moves to the right because of this
movement, and changes the swash plate
angle.
D275AX-5E0
3)
SEN00930-00
Movement in direction to reduce pump discharge (to the left)
Operation
q
The following explains the situation when
servo piston (1) moves to the left (the direction
to make the discharge amount smaller). If LS
differential pressure ( PLS) becomes larger
(for example, the area of opening of the control
valve becomes smaller and pump pressure
(PP) increases), spool (4) is pushed to the left
by pump pressure (PP).
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).
D275AX-5E0
Main pump pressure (PP) also enters the small

diameter piston end, but servo piston (1) is
pushed from the large diameter piston end to
the small diameter piston end because of the
difference in area between the large diameter
piston end and the small diameter piston end.
As a result, rod (2) moves in the direction to
make the swash plate angle smaller (to the
left).
25
SEN00930-00
4)
When servo piston is balanced
Operation
q
In the LS valve, lf main pump pressure (PP) is
balanced with the combined force of LS pressure (PLS) at chamber (g) and force (F) of
spring (3), servo piston (1) stops at the intermediate position for the swash plate angle.
[Force (F) of spring (3) converted to the
hydraulic power: Approx. 1.96 MPa {20kg/
cm2}].
q
If an LS pressure (main pump pressure force
of spring) that fulfills the above conditions for
balancing enters ports (a), main pump pressure (PP) entering from port (d) and combined
force (F) of spring (3) and the force from LS
pressure (PLS) are balanced, and pressure of
a certain size enters port (f) from port (c).
26
When this happens, the force pushing the

small diameter piston and the force pushing
the large diameter piston are balanced, so
servo piston (1) stops. In other words, the following condition is reached.
Pump pressure (PP) x area receiving pressure
at small diameter piston end = hydraulic pressure (PNC) at the large diameter piston end x
area receiving pressure at large diameter piston end.
The difference I area between the large diameter piston and small diameter piston is normally
approx. 2:1, so the pressure at the large diameter piston end is approx. 1/2 of pump pressure (PP).
D275AX-5E0
SEN00930-00
2. Operation of variable throttle valve

1)
q
Properties of variable throttle valve

Because the main pump controls its own pressure, 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 following 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 excessive response.
ii
To prevent cavitation at the suction port
caused by the sudden increase in the suction volume when changing from MIN to
MAX.
The characteristics of the variable throttle
valve are as shown in the diagram below.
It has the function and property of maintaining
the response during operations at low pressure
by making the area (A) of the opening smaller
at high pressure and the area (A) of the opening larger at low pressure, and by preventing
the above problems i and ii at high pressure.
D275AX-5E0
27
SEN00930-00
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 diameters 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.
28
D275AX-5E0
3)
SEN00930-00
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.
D275AX-5E0
29
SEN00930-00
Power train pump, steering lubrication pump
SAR (3) 100 + 50
Unit: mm
No.
Check item
Criteria
Type
Clearance limit
SAR (3) 100
0.13 0.18
0.22
SAR (3) 50
0.10 0.15
0.19
0.060 0.149
0.20
Standard size
Tolerance
14
0
0.5
Side clearance
SAR (3) 100
Clearance between plain

bearing inner diameter and gear
shaft outer diameter
Pin driving depth
SAR (3) 100
SAR (3) 50
Type
SAR (3) 50
Spline shaft rotation torque

Delivery
(Oil: EO10-CD
Oil temperature: 45 50C)
Replace
13.7 73.5Nm{1.4 2.4kgm}

Type
SAR (3) 100
SAR (3) 50
30
Remedy
Standard
clearance
Speed
(rpm)
2,300rpm
Delivery
pressure
MPa
{kg/cm2}
Standard
delivery
(l/min)
Delivery
limit
(l/min)
32.71
188
174
30.3
94
86
D275AX-5E0
SEN00930-00
HSS pump
HPV160
1.
2.
3.
4.
Servo valve connector

Piston pump
Servo piston
Servo valve
5.
6.
7.
Suction safety valve

Charge safety valve
Plug for measuring (PA and PB pump pressure)
Outline
q
The pump is composed of variable displacement piston pump with swash plate, servo
valve, suction safety valve, and charge safety
valve.
D275AX-5E0
31
SEN00930-00
1. Piston pump
a
A figure shows the state where the Servo valve was removed from the HSS pump.
PSVO:Servo valve source pressure

PB:
Pump inlet and outlet port
PA:
Pump inlet and outlet port
PD2: Pump drain port
PR: Charge safety valve relief pressure
32
PSVA: Servo valve output

PSVB: Servo valve output
PSV1: Servo valve source pressure
PC: Charge pressure
D275AX-5E0
1.
2.
3.
4.
5.
6.
7.
Shaft
Case
Cradle
Rocker cam
Servo piston
Slider
Shoe
Outline
q
The rotation torque transmitted to the pump
shaft is converted to hydraulic energy and
pressurized oil is discharged according to the
load.
q
It is possible to charge the delivery amount
(normal delivery i
o0i
o reverse delivery) by
changing the swash plate angle.
Structure
q
spline (13), and shaft (1) is supported by front
and rear bearings (12) and (14).
q
The end of piston (8) has a concave ball
shape, and shoe (7) is caulked to it to form one
unit. Piston (8) and shoe (7) form a spherical
bearing.
SEN00930-00
8.
9.
10.
11.
12.
13.
14.
Piston
Cylinder block
Valve plate
End cap
Bearing
Spline
Bearing
Rocker cam (4) has plane (A), and shoe (7) is

always pressed against this surface as it slides
in a circle.
Rocker cam (4) sends high pressure oil to the
space between cylindrical surface (B) and cradle (3) fixed to the case (2), to form a hydrostatic bearing and carries out a rocking
movement.
cylinder block (9).
Cylinder block (9) carries out rotation relative
to valve plate (10) while sealing the pressurized oil, and this surface ensures that the
hydraulic balance is maintained correctly. The
oil inside each cylinder chamber of cylinder
block (9) is sucked in and discharged through
valve plate (10).
Piston
D275AX-5E0
33
SEN00930-00
Operation
1. Operation of pump
q
(1), and shoe (7) slides on plane (A).
When this happens, angle of center line (X)
of rocker cam (4) to the axial direction of cylinder block (9) changes. This angle (a) is called
the swash plate angle.
1) 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 (7). In
this way, piston (8) slides inside cylinder
block (9), and as a result, a difference is
generated between volumes (E) and (F) inside the cylinder block. The amount of suction and discharge is equal to difference
(F) - (E).
In other words, cylinder block (9) rotates,
and the volume of chamber (F) becomes
smaller, so oil is discharged during this process. At the same time, the volume of
chamber (E) becomes larger and oil is
sucked in as the volume increases.
2)
34
3)
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 (7). In
this way, piston (8) slides inside cylinder
block (9), and as a result, a difference is
generated between volumes (E'') and (F'')
inside the cylinder block. The amount of
suction and discharge is equal to difference (F'') (E'').
In other words, cylinder block (9) rotates,
and the volume of chamber (E'') becomes
smaller, so oil is discharged during this process. At the same time, the volume of
chamber (F'') becomes larger and oil is
sucked in as the volume increases. When
the swash plate angle changes, the suction/discharge action of ports (PA) and
(PB) is reversed.
When center line (X) of rocker cam (4) is

the same as the axial direction of cylinder
block (9) (swash plate angel = 0), the difference between volumes (E') and (F') inside
cylinder block (9) is 0, so no oil flows in or
out, and no pumping is carried out.
D275AX-5E0
2.
SEN00930-00
Control of discharge amount

1) If swash plate angle (a) becomes larger,
the difference between volumes (E) and
(F) becomes large, and oil delivery (Q) is
increased. Swash plate angle ( ) is
changed by servo piston (5).
Servo piston (5) carries out reciprocal
movement in a straight line (i
o) according
to the command from the valve. This
straight-line movement is transmitted to
rocker cam (4) through slider (6), and rocker cam (4), which is supported on the cylindrical surface by cradle (2) slides on the
cylindrical surface (direction).
In the case of the pump, swash plate angle
( ) is a maximum of 19.
D275AX-5E0
35
SEN00930-00
2. Servo valve
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
36
Connector
Solenoid valve B
Connector
Solenoid valve A
Shaft
Coil
Base
Lever 1
Spring
Lever 2
Body
Screw
Arm
Spool
PSV1: Servo valve source pressure

PSVB: Servo valve outlet pressure
PSVA: Servo valve outlet pressure
D275AX-5E0
SEN00930-00
Operation
1) When pressurized oil (servo source pressure) does not enter from the charge
pump or when is no current flowing to
solenoid valve coil (6), the servo valve and
servo piston (15) are not actuated.
D275AX-5E0
37
SEN00930-00
2)
3)
38
When the current flows to solenoid valve

coil (6) and coil is excited, solenoid propulsion force (f1) is generated and shaft (5)
pushes spool (14) to the right in the direction of the arrow. Lever 2 (10), which is
interconnected with spool (14), uses
screw (12) as a fulcrum and rotates clockwise while pulling spring (9).
When spool (14) moves, the passages
between ports (A) and (B) and ports (D)
and (E) open, and pressurized oil from the
charge pump passes through ports (A)
and (B) and flows to port (F) of servo piston (15).
At the same time, the oil at port (G)
passes through ports (D) and (E), and is
drained.
D275AX-5E0
4)
SEN00930-00
Servo piston (15) is moved to the right in

the direction of the arrow by the pressurized oil entering port (F), and the swash
plate angle of the variable pump becomes
larger by an amount equal to stroke (a) of
the servo piston. At the same time, arm
(13), which is connected to servo piston
(15) rotates arm (13) around screw (12) as
a fulcrum, and lever 1 (8) is moved to the
left. Servo piston (15) stops in a position
where solenoid propulsion force (f1) is balanced with spring force (f2).
D275AX-5E0
39
SEN00930-00
5)
40
The stroke of the servo piston, which

changes the delivery amount of the variable pump, is controlled by the servo
valve. The relationship between the stroke
of the servo piston and the current of the
solenoid valve is as shown in the diagram.
D275AX-5E0
SEN00930-00
3. Suction safety valve
1.
2.
3.
4.
5.
Charge pump
HSS pump
Oil cooler
Charge safety valve
5A. Valve
5B. Piston
5C. Sleeve
5D. Poppet
5E. Valve seat
5F. Spring
5G. Pressure adjustment screw: one turn
adjusts pressure by approx. 13.7 MPa
{140kg/cm2}
6. HSS motor
D275AX-5E0
Function
q
There are two suction safety valves installed to
the HSS pump, and they have the following
functions.
1) High pressure relief valve
The valve restricts the maximum pressure
inside the HSS circuit in order to protect
the HSS circuit and to restrict the maximum steering foree of the machine.
2) Suction safety valve
The valve ensures the flow of charge oil to
the HSS circuit and prevents the charge
oil from flowing into the pump high pressure side (delivery side).
41
SEN00930-00
Operation when acting as high pressure relief

valve (Valve at piston pump delivery side)
Port (A) is connected to the piston pump circuit

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

pump circuit and the oil pressure at port (A) and
(C) reaches the pressure set by spring (5F),
poppet (5D) is pushed to the right in the direction of the arrow, and the oil at port (C) is relieved from port (D) to port (B) to reduce the oil
pressure at port (C).
42
When the oil pressure at port (C) goes down, a

differential pressure is generated between port
(A) and port (C) by orifice b in piston (5B). Valve
(5A) is pushed to the right in the direction of the
arrow by the oil pressure at port (A), and the oil
at port (A) is relieved to port (B). In this way, the
piston pump circuit is prevented from reaching
any higher pressure.
D275AX-5E0
Operation when acting as suction safety valve

1. When HSS pump delivery is 0
q
The HSS circuit is closed, and the charge pressure oil does not flow into the HSS circuit.
Therefore, the charge pressure oil from the
charge pump all passes through charge safety
valve (with coin filter) (4) and is drained
through oil cooler (3) to the tank.
D275AX-5E0
SEN00930-00
2.
When HSS pump delivery is discharged

from port PA
1) Valve at piston pump delivery side
q
When pressure oil is discharged from
port (PA) of HSS pump (2), port (PA)
becomes the high pressure side. This
pressure oil at port (PA) passes
through drill hole a in piston (5B) and
flows to port (A). When this happens,
valve (5A) is pushed to the left in the
direction of the arrow against sleeve
(5C) because of the difference in area
(A1>A2). Therefore, the pressure oil
from charge pump (1) is prevented
from flowing into the HSS closed circuit.
43
SEN00930-00
2)
44
Valve at piston pump suction side

q
Port (PB) becomes the suction side,
so it becomes the low pressure side.
Because of the difference in area
(A1>A2), valve (5A) is pushed to the
right in the direction of the arrow by
the charge pressure oil and the seat
of sleeve (5C) opens. As a result, the
charge pressure oil at port (B) passes
through the gap and flows to port
(PB) to carry out the charge function
for the HSS circuit.
D275AX-5E0
SEN00930-00
4. Charge safety valve
1.
2.
3.
4.
Charge pump
HSS pump
Oil cooler
Charge safety valve
4A. Valve
4B. Spring
4C. Valve seat
4D. Poppet
4E. Spring
4F. Pressure adjustment screw
5. Suction safety valve
6. HSS motor
D275AX-5E0
Function
q
The charge safety valve is installed to the HSS
pump between the suction safety valve and the
oil cooler. It acts to restrict the maximum pressure in the charge circuit.
a Set pressure:
3.7 MPa {38kg/cm2} at 204 l/min
45
SEN00930-00
Operation
q
Port (A) is connected to the charge circuit, and
port (B) is connected to the tank drain circuit.
The pressure oil passes through orifice (a) in
valve (4A) and fills (C). Poppet (4D) is in tight
contact with valve seat (4C).
46
When the pressure of the oil at port (C) goes

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

to the HSS pump case, so the back pressure
of drain port (B) is not added to the charge
relief pressure, and the valve always displays
the set relief characteristics.
If abnormal pressure is generated in the circuit

or the shuttle valve of the HSS motor is at neutral, and the pressure oil at ports (A) and (C)
reaches the pressure set by spring (4E), poppet (4D) is pushed to the right in the direction
of the arrow, and the oil at (C) is relieved to
port (D) to reduce the pressure of the oil at (C).
D275AX-5E0
SEN00930-00
HSS motor
HMF180
1. Piston motor
Outline
q
Motor is composed of fixed capacity, fixed swash plate type piston motor, flashing shuttle valve, bypass
valve and charge relief valve.
1.
2.
3.
4.
HSS motor assembly

Flashing shuttle valve
Bypass valve
Charge relief valve
C: From charge pump

T: To hydraulic tank
P: From pivot turn solenoid
CA: Pressure sensor mounting port
CB: Pressure sensor mounting port
CD: To hydraulic tank
MA: From HSS pump PA port
MB: From HSS pump PB port
D275AX-5E0
Specifications
Model
HMF180
Theoretical displacement
(cc/rev)
181
Rated output pressure

MPa{kg/cm2}
41.2{420}
Rated speed
(rpm)
2,078
47
SEN00930-00
1.
2.
3.
4.
5.
6.
7.
8.
9.
Output shaft
Motor case
Swash plate
Piston
Cylinder block
Valve plate
End cover
Cover
Return spring
10.
11.
12.
13.
14.
15.
16.
17.
18.
Flashing shuttle valve

Plug
Spool return spring
Bypass valve
Charge relief valve
Bearing (rear)
Spline
Shoe
Bearing (front)
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
48
Free length
OD
Repair limit
Installed
length
Installed
load
43.5 28.7
48.5 21
Free length
Installed
load
36.0
530N
{54kg}
498N
{50.8kg}
41.0
294N
{30kg}
297N
{38.2kg}
Replace spring
if damaged or
deformed
D275AX-5E0
SEN00930-00
Outline
q
Pressurized oil sent from pump is converted to
rotation energy and is transmitted to output
shaft.
Structure
q
spline (14), and shaft (1) is supported by front
and rear bearings (16) and (13).
q
The end of piston (4) has a concave ball
shape, and shoe (15) is caulked to it to form
one unit.
q
Piston (4) and shoe (15) form a spherical bearing.
q
cylinder block (5).
q
Cylinder block (5) carries out rotation relative
to valve plate (6) while sealing the pressurized
oil, and this surface ensures that the hydraulic
balance is maintained correctly. The oil inside
each cylinder chamber of cylinder block (5) is
sucked in and discharged through valve plate
(6).
D275AX-5E0
49
SEN00930-00
Operation
1. Operation of motor
q
The pressurized oil sent from the pump
enters cylinder block (5) and pushes piston (4) from the back face.
In the case of the motor, the center line of
plate (3) is always at an angle (swash
plate angle a to the axial direction of cylinder block (5). As a result, if we take the
example of one of pistons (4), oil pressure
is applied to the back face of the right, and
piston axial force (FO) is generated.
50
2.
Rotation speed and torque control

q
As flow (Q) from the HSS pump is
increased, motor speed (N) is heightened.
q
Since the swash plate angle of the HSS
motor is fixed (a is constant), torque (T) is
proportional to pressure (P).
q
Swash plate angle ( ) is 19.
Q=qN
(q = E F)
T=
Pq
2x
Q: Total flow
q: Flow per 1 turn
N: Rotation speed
P: Pressure
T: Rotating torque
With shoe (15), which is joined to piston (4)

by the spherical surface, reaction force (FR)
in a direction at right angles to plane (A) is
generated. The combined force of (FO) and
(FR) is (FP), and this becomes the force to
rotate cylinder block (5).
Shaft (1), which is meshed to cylinder block
(5) by spline (14) transmits this rotation
torque to the output side. Cylinder block (5)
rotates, and while the condition changes
from volume (E) to volume (F), pressurized
oil from the pump flows into the cylinder
chamber, and pressure (P) is generated according to the load. On the other hand, when
the condition goes beyond volume (F) and
changes to volume (E), the oil is pushed out
and returned to the pump.
D275AX-5E0
2. Flushing shuttle valve

Function
q
The shuttle valve acts to switch the shuttle
valve spool according to the pressurized oil in
the HSS high-pressure circuit, and to return
the oil in the HSS low-pressure circuit through
the oil cooler to the tank. The shuttle valve is
installed to the HSS motor assembly.
Operation
(1) When HSS pump swash plate angle is at
neutral position
q
The swash plate angle of the pump is at the
neutral position, so the delivery from HSS
pump (2) is 0. When this happens, the same oil
pressure is applied to ports (A) and (B) at both
ends of shuttle valve spool (7), so spool (7)
remains at the neutral position.
q
When this happens, the relationship of the set
pressure of charge relief valve (8) is as follows.
Set pressure of
charge safety valve
(4)
q
SEN00930-00
(2) When HSS pump is discharging oil from

port PA
q
The pressurized oil from HSS pump (2) enters
port (MA) from port (PA), passes through orifice (a) of shuttle valve spool (7), then enters
port (A). Spool (7) is pushed to the right in the
direction of the arrow by the pressurized oil at
port (A), so the passage between ports (MB)
and (D) is opened and the oil is connected to
charge relief valve (8).
q
pressure of charge relief valve is as follows.
Set pressure of
charge safety valve
(4)
q
Set pressure of
charge relief valve
(8)
As a result, the pressurized oil from charge
pump (1) flows from port (D) through charge
relief valve (8), where the set pressure is lower.
It is then relieved and is drained from oil cooler
(3) to the tank.
>
Set pressure of
charge relief valve
(8)
pump (1) flows from port (C) of the motor
through charge relief valve (8), where the set
pressure is lower. It is then relieved and
drained from oil cooler (3) to the tank.
D275AX-5E0
>
51
SEN00930-00
(3) When HSS pump is discharging oil from

port PB
q
The pressurized oil from HSS pump (2) enters
port (MB) from port (PB), passes through orifice (b) of shuttle valve spool (7), then enters
port (B). Spool (7) is pushed to the left in the
direction of the arrow by the pressurized oil at
port (B), so the passage between ports (MA)
and (E) is opened and the oil is connected to
q
pressure of charge relief valve (8) is as follows.
Set pressure of
charge safety valve
(4)
q
52
Set pressure of
charge relief valve
(8)
pump (1) flows from port (E) through charge
relief valve (8), where the set pressure is lower.
It is then relieved and drained from oil cooler
(3) to the tank.
>
D275AX-5E0
3. Bypass valve
Function
q
When the machine carries out a pivot turn, the
HSS motor receives a reverse force from the
steering brake and is rotated at high speed. At
this time, the bypass valve is changed according to the signals from the pivot turn solenoid
to add a passage so that the oil will circulate
inside the motor and the load on the HSS
motor rotating at high speed will be reduced.
SEN00930-00
(2) When the pivot turn solenoid is turned ON

q
Bypass valve spool (1) is pushed to the right
as indicated by the arrow and (MA) and (MB)
are connected to each other and the oil circulates inside the motor. Quantity (Q1) of the oil
circulating in the HSS circuit is the difference
between discharge (Q) of the motor and flow
rate (Q2) of the oil circulating inside the motor.
Q1 = Q Q2
Operation
(1) When the pivot turn solenoid is deactivated
q
Bypass valve spool (1) is in neutral. The quantity of the oil circulating in the HSS circuit is
equivalent to discharge (Q) of the motor.
D275AX-5E0
53
SEN00930-00
4. Charge relief valve
1.
2.
3.
4.
5.
6.
7.
8.
54
Charge pump
HSS pump
Oil cooler
Charge safety valve
HSS motor
Shuttle valve
Charge relief valve
8A: Valve
8B: Spring
8C: Valve seat
8D: Puppet
8E: Spring
8F: Pressure adjustment screw
8G: Filter
Function
q
The charge relief valve is installed to the HSS
motor. It maintains the minimum pressure on
the low pressure side of the circuit to secure
the suction performance of the HSS pump.
a Set pressure:
2.3 MPa {23kg/cm2} (at 120 l/min)
D275AX-5E0
Operation
q
While the HSS pump is discharging oil through
port (PA) or (PB), the oil on the low pressure
side of the HSS circuit flows through port (MA)
or (MB) and shuttle valve (7) to inlet port (A) of
q
SEN00930-00
If the oil pressure in port (C) lowers, differential

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

the drain part of the HSS motor, the back pressure on drain port (B) is not added to the
charge relief pressure and the specified relief
characteristics are maintained.
The oil in port (A) also fills port (C) through orifice (a) of valve (8A). At this time, puppet (8D)
is fitted to valve seat (8C).
If the oil pressure in port (C) rises to the level

set with spring (8E), puppet (8D) is pushed to
the right as indicated by the arrow and the oil in
port (C) is relieved to port (D), thus the oil pressure in port (C) lowers.
D275AX-5E0
55
SEN00930-00
PPC, HSS charge filter
1.
2.
3.
4.
5.
6.
56
Plug
Cover
Spring
Plate
Element
Case
A: To HSS motor
B: To filter bypass valve
C: From charge pump
Performance
Mesh size (mm)
30/8
Filtering area (cm2)
5,400
Oil flow (l/min)
138
D275AX-5E0
SEN00930-00
58
D275AX-5E0
SEN00931-00
BULLDOZER
1SHOP MANUAL
D275AX-5E0
Machine model
Serial number
D275AX-5E0
30001 and up


Control valve ........................................................................................................................................ 2
Self pressure reducing valve.............................................................................................................. 31
D275AX-5E0
SEN00931-00
Control valve
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}
D275AX-5E0
SEN00931-00
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
D275AX-5E0
SEN00931-00
1.
2.
3.
4.
Valve block
Ripper tilt spool
Ripper lift spool
Blade lift spool
5.
6.
7.
8.
Blade tilt spool

Valve body
Load check valve
Pressure compensation valve
Unit: mm
No.
Check item
Criteria
Standard size
Spool return spring

(only for blade lift)
Remedy
Repair limit
Free length
x Outside
diameter
Installed
length
Installed
load
Free length
Installed
load
76.3 x 30
68.5
209.37N
{21.35kg}
167.50N
{17.08kg}
51.7 x 31.3
50
140.1N
{14.3kg}
111.7N
{11.4kg}
173.5N
{17.7kg}
Spool return spring

11
(for blade lift FLOAT)
54.7 x 36.5
32.5
216.6N
{22.1kg}
12 Load check valve spring
20.8 x 10.2
13.5
12.7N
{1.3kg}
9.8N
{1.0kg}
108.3 x 29.5
81
562N
{57.3kg}
449N
{45.8kg}
86.7 x 30
66
192.4N
{19.63kg}
154N
{15.7kg}
13

spring
14 Unload spring
Replace
If damaged or
deformed,
replace spring
D275AX-5E0
1.
2.
3.
LS check valve
Main relief valve
LS relief valve
SEN00931-00
4.
5.
6.
Unload valve
Suction valve
Check valve (built in spool)
Unit: mm
No.
Check item
Criteria
Standard size
Suction valve spring
Remedy
Repair limit
Free length
x Outside
diameter
Installed
length
Installed
load
Free length
Installed
load
64.9 x 12.5
56
6.37N
{0.65kg}
5.1N
{0.52kg}
Check valve spring in spool
27.9 x 6.5
22.5
14.7N
{1.5kg}
11.8N
{1.2kg}
9.4 x 4.6
8.5
0.29N
{0.03kg}
0.20N
{0.02kg}
D275AX-5E0
Replace
If damaged or
deformed,
replace spring
SEN00931-00
1. Suction valve
2. Preset check valve
3. LS bypass valve
Unit: mm
No.
Check item
Criteria
Standard size
Remedy
Repair limit
Free length
x Outside
diameter
Installed
length
Installed
load
Free length
Installed
load
46.8 x 7.5
40.6
5.49N
{0.56kg}
4.4N
{0.45kg}
If damaged or
deformed,
replace spring
D275AX-5E0
SEN00931-00
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}
D275AX-5E0
SEN00931-00
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
P1: From pump
PR: PPC output
TS: Seal drain
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
D275AX-5E0
SEN00931-00
1.
2.
3.
4.
5.
Valve block
Ripper tilt spool
Ripper lift spool
Blade tilt left spool
Blade lift spool
6.
7.
8.
9.
Blade tilt right spool

Valve body
Load check valve
Pressure compensation valve spool
Unit: mm
No.
Check item
Criteria
Standard size
Spool return spring

10
(only for blade lift)
Remedy
Repair limit
Free length
x Outside
diameter
Installed
length
Installed
load
Free length
Installed
load
76.3 x 30
68.5
209.37N
{21.35kg}
167.50N
{17.08kg}
51.7 x 31.3
50
140.1N
{14.3kg}
111.7N
{11.4kg}
173.5N
{17.7kg}
Spool return spring

12
(for blade lift FLOAT)
54.7 x 36.5
33.5
216.6N
{22.1kg}
13 Load check valve spring
20.8 x 10.2
13.5
12.7N
{1.3kg}
9.8N
{1.0kg}
108.3 x 29.5
81
562N
{57.3kg}
449N
{45.8kg}
86.7 x 30
66
192.4N
{19.63kg}
154N
{15.7kg}
14

spring
15 Unload spring
10
Replace
If damaged or
deformed,
replace spring
D275AX-5E0
1.
2.
3.
LS check valve
Main relief valve
LS relief valve
SEN00931-00
4.
5.
6.
Unload valve
Suction valve
Check valve (built in spool)
Unit: mm
No.
Check item
Criteria
Standard size
Remedy
Repair limit
Free length
Outside
diameter
Installed
length
Installed
load
Free length
Installed
load
64.9 x 12.5
56
6.37N
{0.65kg}
5.1N
{0.52kg}
27.9 x 6.5
22.5
14.7N
{1.5kg}
11.8N
{1.2kg}
9.4 x 4.6
8.5
0.29N
{0.03kg}
0.20N
{0.02kg}
D275AX-5E0
Replace
If damaged or
deformed,
replace spring
11
SEN00931-00
1. Suction valve
2. Preset check valve
3. LS bypass valve
Unit: mm
No.
Check item
Criteria
Standard size
12
Remedy
Repair limit
Free length
x Outside
diameter
Installed
length
Installed
load
Free length
Installed
load
46.8 x 7.5
40.6
5.49N
{0.56kg}
4.4N
{0.45kg}
If damaged or
deformed,
replace spring
D275AX-5E0
SEN00931-00
Operation of control valve
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 position, the pump pressure passes from
chamber (A) through oriffice (4) to chamber (D). Chambers (C) and (C') are connected to the drain circuit.
(2) When oil is supplied from the pump, the
pressure in chamber (D) rises, and spool
(1) is pushed to the right by pressure (FO)
which is determined by the cross-sectional
area of piston (3) receiving the pressure.
D275AX-5E0
(3) When (FO) becomes larger than set load

(FS) of spring (2), the spool moves to the
right and connects the passage between
chamber (A) and chamber (B), so the oil
from the pump is drained. Therefore,
spool (1) is balanced at a position that
matches the supply of oil from the pump.
Actually, the amount of oil supplied from
the pump is small, so the pressure in the
circuit is almost the same as the set load
of spring (2).
13
SEN00931-00
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

pump pressure is sent from chamber (A)
through the notch in spool (3) of the pressure
compensation valve, and passes through
chamber (B) to chamber (C). Chamber (G) is
drained through chamber (H) to chamber (F).
When this happens, the pump pressure is acting on the left end of spool (3) of the pressure
14
compensation valve, so it pushes against the

load of spring (4) and moves to the right to the
maximum stroke position. In this condition, the
area of the opening to spool (1) of the blade tilt
valve is at its minimum.
D275AX-5E0
2)
SEN00931-00
At blade right tilt
[1] When the tilt lever is operated to right tilt, pilot

pressure (PB1) acts on the right end of spool
(1) through the PPC valve, and when the pressure becomes greater than the set load of
spring (2), the spool starts to move to the left. It
is balanced at a position corresponding to PPC
output pressure (PB1).
D275AX-5E0
q
q
q
PLS = differential pressure between ports

(K) and (J) = 1.96 MPa {20kg/cm2}
PLS' = differential pressure between ports
(I) and (D)
PLS C PLS'
15
SEN00931-00
[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 differential pressure of spool (1) (chamber (C)
pressure Chamber (D) pressure), and balances with spring (4).
In other words, if the oil flow is too large, the
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 direction 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 differential pressure: ( PLS) remains constant, so
a suitable amount of oil flows to ensure that the
loss of pressure at the control valve ( PLS') is
equal to ( PLS). The loss of pressure in the
control valve is determined by the area of the
opening of the main spool, so the oil flow
matches the opening of the spool.
[5] The return oil flow from the tilt cylinder passes
through chamber (E) and chamber (F), and is
drained.
16
D275AX-5E0
SEN00931-00
3)
18
Meter-out control when blade moves down under its own weight (work equipment lever at LOWER)
D275AX-5E0
In the case where the blade falls owing to the

weight of the blade, the return flow from a cylinder is controlled according to the opening
area of main spool (1).
Oil flows from the suction valve (2) to a cylinder so that it prevents the circuit from being
evacuated.
1)
2)
SEN00931-00
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 openin g ar ea be twee n por ts (A ) a nd ( B)
squeezes the return flow from a lift cylinder in order to control the drop speed.
In the case where the blade falls owing to
the weight of the blade, oil on the cylinder
head side passes through a drain circuit
and the suction valve (2) and then it is
supplied to the cylinder bottom side. At the
same time, the output flow from the pump
passes through ports (A1), (B1), (C1),
(D1) and (E1) and then it is supplied to the
cylinder bottom side.
D275AX-5E0
19
SEN00931-00
4)
20
Meter-out control when blade moves down under its own weight (work equipment lever at FLOAT)
D275AX-5E0
SEN00931-00
When the lift valve is at FLOAT, the cylinder

port and drain port are connected to put the circuit in a no-load condition.
When the lift valve is in the FLOAT condition,
the pump passage and cylinder ports (A3) and
(B3) are separated so that the other control
valves can be operated.
1) When the work equipment control lever is
at the FLOAT position, if pressure (PA3)
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.
D275AX-5E0
21
SEN00931-00
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
q
q
22
P1 = P3 + P4 = Differential pressure
between ports (M) and (P)
P2 = Differential pressure between ports (P)
and (N)
P3 = Differential pressure between ports (M)
and (B)
q
q
P4 = Differential pressure between ports (B)

and (P)
LS = ( P1) + ( P2) = Differential pressure
between ports (M) and (N) = 1.96 MPa {20 kg/
cm2}
D275AX-5E0
SEN00931-00
1) If blade tilt valve (1) is moved, and the pressure 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 throttled and ( P4) will become larger.
3) Because of the pump swash plate control,
the system circuit is balanced at a circuit
pressure which makes the pressure loss
generated by the flow at work equipment LS
relief valve (5) ( P1) + ( P2) equal to LS
differential pressure ( LS). When this happens, pump LS valve (6) detects the differential pressure generated by LS relief valve
(5), and moves the pump swash plate from
the maximum to the minimum position
where the LS differential pressure is 1.96
MPa {20 kg/cm2}.
4) When the pump is at the minimum swash
plate angle (minimum oil flow), if the minimum 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 actuated to relieve the excess oil flow and balance
the circuit.
D275AX-5E0
23
SEN00931-00
(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.
24
D275AX-5E0
SEN00931-00
It consists of a parallel circuit, so when compound 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 pressure (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 priority was given to the oil flow for the tilt
valve.
3)
When pump pressure (P2) = pump pressure (P3)

(P) (P2) C (P) (P3), so an oil flow proportional to the size of the spool opening
is distributed to each spool.
D275AX-5E0
25
SEN00931-00
(3) Unload valve preset system

a The diagram shows the condition with preset check valve (3) open immediately after blade lift valve is
operated.
26
D275AX-5E0
SEN00931-00
This improves the response of the system

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

pressure (P1) (basic pressure of PPC valve) is
sent through preset check valve (3) to the
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 compensation spool (2) moves to the left and the size of
the opening between (A) and (B) becomes the
maximum.
(2) When spool (1) is switched, unload pressure
(P) flows immediately through chamber (A),
(B), (C), (D), and (E) to lift cylinder (8), so the
pressure at the port starts to rise and the time
lag becomes smaller.
(3) At the same time, preset pressure (P2) is supplied to LS circuit (O) by the timing of the spool,
and the pressure in the LS circuit rises. Because of this, unload valve (7) closes, and oil is
sent further to pump LS valve (6) to improve the
response of the pump swash plate angle. This
makes it possible to reduce the response time
for giving the necessary oil flow. Check valve
(5) is built in the spool to prevent preset pressure (P2) from venting in force from the cylinder
port.
(4) When cylinder port pressure (P3) rises and becomes greater than preset pressure (P2), it
pushed up check valve (5), and oil is sent to
chamber (F) of the pressure compensation
valve and pump LS valve (6) to give the basic
( PLS) control.
When this happens, pressure (P3) at the cylinder port is prevented from entering the PPC
pump circuit by preset check valve (3).
D275AX-5E0
27
SEN00931-00
(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
28
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.
D275AX-5E0
2)
When dual tilt operation is carried out
In the dual tilt mode, solenoid valve (1) is

changed as shown in the figure.
At this time, PPC circuit (2) connected to (PB1)
of the control valve is connected to output circuit (4) of the PPC valve.
PPC circuit (3) connected to (PA1) of the control valve is connected to output circuit (5) of
the PPC valve.
Accordingly, both tilt cylinders move in the
opposite directions to carry out the dual tilt
operation.
D275AX-5E0
SEN00931-00
29
SEN00931-00
3)
When pitch operation is carried out
In the pitch mode, solenoid valve (1) is

changed as shown in the figure.
At this time, PPC circuit (2) connected to (PB1)
of the control valve is connected to output circuit (5) of the PPC valve.
PPC circuit (3) connected to (PA1) of the control valve is connected to output circuit (4) of
the PPC valve.
Accordingly, both tilt cylinders move in the
same direction to carry out the pitch operation.
30
D275AX-5E0
Self pressure reducing valve
T:
P1:
P2:
PR:
SEN00931-00
To hydraulic tank
From cooling fan pump
To cooling fan motor
Supply to PPC valve and EPC valve
D275AX-5E0
31
SEN00931-00
1.
2.
3.
4.
5.
32
Valve (sequence valve)

Spring
Screw
Poppet
Spring (pressure reducing valve pilot)
6.
7.
8.
9.
10.
Spring (pressure reducing valve main)

Valve (pressure reducing valve)
Spring (safety valve)
Ball
Filter
D275AX-5E0
SEN00931-00
Unit: mm
No.
11
Check item
Spring
(pressure reduction main)
12
Spring
(pressure reduction valve pilot)
13
Spring
14
Spring (safety valve)
Criteria
Standard size
Free length Installed
Installed
x O.D.
length
load
19.6
19.2 x 7.20
16.1
{2.0 kg}
28 N
17.8 x 7.20
12.7
{2.90 kg}
200 N
71.0 x 18.0
59.0
{20.4 kg}
61.7 N
16.1 x 7.80
13.4
{6.30 kg}
Remedy
Repair limit
Free length Installed
load
17.7 N
{1.80 kg}
25.6 N
{2.60 kg}
186 N
{19.0 kg}
58.8 N
{6.0 kg}
Replace
spring if any
damages or
deformations are
found
Function
The self pressure reducing valves reduces the discharge pressure of the cooling fan pump and supplies it to the PPC valve, the EPC valve, etc. as the
control pressure.
D275AX-5E0
33
SEN00931-00
Operation
1. At engine stop (total low pressure)
34
The spring (6) pushes the poppet (5) the seat,

and the circuit between the ports (PR) and (T)
is closed.
The spring (7) pushes the valve (8) to the left
side, and the circuit between the ports (P1)
and (PR) is open.
The spring (3) pushes the valve (2) to the left
side, and the circuit between the ports (P1)
and (P2) is closed.
D275AX-5E0
SEN00931-00
2.
When the load pressure P2 is lower than the output pressure PR of the self pressure reducing
valve.
The spring (3) and the (PR) pressure (0 MPa

{0 kg/cm2} at the time of engine stop) pushes
the valve (2) in the direction to close the circuit
between the ports (P1) and (P2). When the
hydraulic oil enters the (P1) port, the expression ((P1) pressure
Spring (7) force + ((d)
area x (PR) pressure)) holds, and the self pressure reducing valve will adjust the openings of
the ports (P1) and (P2) so that the (P1) pressure can be maintained higher than the (PR)
pressure.
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 poppet (5) opening to the tank port (T).
D275AX-5E0
Therefore, there will occur a differential pressure around the hold a in the spool (8) and the
spool will move in the direction to close the
port (P1) and the (PR) opening. Then, the (P1)
pressure is reduced and adjusted to a certain
pressure (set pressure) with the opening and is
supplied as the (PR) pressure.
35
SEN00931-00
3.
At raise of load pressure P2
When the load pressure (P2) rises due to digging or other operations, the pump delivery will
increase and the (P1) pressure will rise.
Then, the expression ((P1) pressure > Spring
(7) force + ( (d) area x (PR) pressure)) will
hold, and the valve (2) will move to the right
side till the stroke end. As a result, the opening between the ports (P1) and (P2) will
increase, the passage resistance will become
smaller to reduce engine loss horsepower.
36
When the (PR) pressure rises above the set

pressure, the poppet (5) will open and the
hydraulic oil will flow through the route from the
(PR) port, the hole (a) in the spool (8), the poppet (5) opening to the tank port (T).
Therefore, there will occur a differential pressure around the hold (a) in the spool (8) and
the spool will move in the direction to close the
port (P1) and the (PR) opening. Then, the (P1)
pressure is reduced and adjusted to a certain
pressure (set pressure) with the opening and is
supplied as the (PR) pressure.
D275AX-5E0
4.
At occurrence of abnormal high pressure
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.
D275AX-5E0
SEN00931-00
37
SEN00931-00
38
D275AX-5E0
SEN00932-00
BULLDOZER
1SHOP MANUAL
D275AX-5E0
Machine model
Serial number
D275AX-5E0
30001 and up


HSS charge filter bypass...................................................................................................................... 2
HSS oil cooler bypass valve................................................................................................................. 4
PPC valve ............................................................................................................................................ 6
PCCS lever ........................................................................................................................................ 18
PPC lock valve ................................................................................................................................... 21
Work equipment cylinder.................................................................................................................... 22
Piston valve........................................................................................................................................ 25
Quick drop valve ................................................................................................................................ 26
Pin puller switch ................................................................................................................................. 27
Pin puller solenoid valve .................................................................................................................... 28
Blade control knob ............................................................................................................................. 30
Pitch, dual tilt solenoid valve .............................................................................................................. 31
Accumulator ....................................................................................................................................... 32
D275AX-5E0
SEN00932-00

HSS charge filter bypass
C1:
C2:
P:
P1:
T:
1
1
Outline
When the difference between the charge inlet pressure and charge outlet pressure is increased, the
HSS charge filter bypass valve drains the oil into
the tank without sending it to the HSS charge circuit.
(Cracking differential pressure:
490 98 kPa {5 1 kg/cm2})
To HSS motor
To HSS pump
Charge filter outlet
Charge filter inlet
To hydraulic tank
Unit: mm
No.
Check item
Clearance between filter

bypass valve and valve body
Clearance between filter

bypass valve and piston
Filter bypass valve spring
Criteria
Tolerance
Shaft
Hole
0.035
+ 0.013
28
0.045
+ 0.013
0.020
+ 0.018
15
0.030
+ 0.018
Standard size
Installed
Installed
Free length
length
load
71.15
N
70.3
64.3
{7.26 kg}
Standard
size
Remedy
Standard
Clearance
clearance
limit
0.035
0.08
0.058
0.020
0.06
Replace
0.048
Repair limit
Installed
Free length
load
D275AX-5E0
SEN00932-00
HSS oil cooler bypass valve
1.
2.
3.
4.
5.
6.
Plug
Valve
Shim
Plug
Spring
Body
A:
B:
C:
D:
E:
From charge relief valve

To hydraulic tank
From oil cooler
To oil cooler
From charge safety valve
Outline
q
This valve is installed in the circuit between the
HSS pump and HSS motor charge relief valve
oil return circuit and the oil cooler. If any abnormal pressure is generated in the oil flowing to
the oil cooler, this valve acts to return the oil
directly to the hydraulic tank.
Set pressure
Cracking pressure
(MPa {kg/cm2 })
0.487 {4.97}
D275AX-5E0
SEN00932-00
Unit: mm
No.
Check item
Clearance between oil cooler

bypass valve and valve body
Criteria
Standard
size
22
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
0.035
0.045
+ 0.013
+ 0.013
0.035
0.058
0.08
Standard size
2
Spring
D275AX-5E0
Remedy
Repair limit
Free length
Installed
length
Installed
load
Free length
Installed
load
52
46
156.9 N
{16 kg}
149.1 N
{15.2 kg}
Replace
SEN00932-00
PPC valve
1. Blade PPC valve
P: From self pressure reducing valve

P1: To blade lift valve (LOWER) PPC port
P2: To blade lift valve (RAISE) PPC port
P3: To blade tilt valve (LEFT TILT) PPC port

P4: To blade tilt valve (RIGHT TILT) PPC port
T: To hydraulic tank
D275AX-5E0
1.
2.
3.
4.
5.
6.
Spool
Metering spring
Centering spring
Piston
Disc
Nut (For connecting lever)
D275AX-5E0
SEN00932-00
7.
8.
9.
10.
11.
Joint
Plate
Retainer
Body
Filter
SEN00932-00
Unit: mm
No.
Check item
Criteria
Standard size
Centering spring
12
(For port P1)
Remedy
Repair limit
Free length
x Outside
diameter
Installed
length
Installed
load
Free length
Installed
load
34.0 x 15.5
31.9
94 N
{9.6 kg}
75.2 N
{7.68 kg}
13
Centering spring
(For port P2)
43.2 x 15.5
34.0
78.5 N
{8 kg}
62.8 N
{6.4 kg}
14
Centering spring
(For ports P3 and P4)
48.57 x 15.5
32.5
107.9 N
{11 kg}
86.3 N
{8.8 kg}
15
Metering spring
(For port P1)
29.27 x 8.15
25.4
16.7 N
{1.70 kg}
13.3 N
{1.36 kg}
16
Metering spring
(For port P2)
26.3 x 8.15
24.1
16.7 N
{1.70 kg}
13.3 N
{1.36 kg}
17
Metering spring
26.53 x 8.15
24.9
16.7 N
{1.70 kg}
13.3 N
{1.36 kg}
If spring is
damaged or
deformed,
replace it
D275AX-5E0
Operation
1) When in neutral
(1) For lifting blade
q
Ports (A) and (B) of the blade lift valve of thecontrol valve and ports (P1) and (P2) of
thePPC valve are connected through fine control hole (f) of spool (1) to drain chamber (D).
D275AX-5E0
SEN00932-00
(2) For tilting blade

q
Ports (C) and (D) of the blade tilt valve of the
control valve and ports (P3) and (P4) of the
PPC valve are connected through fine control
hole (f) of spool (1) to drain chamber (D).
SEN00932-00
2)
q
10
When in fine control

(Neutral o Fine control)
If piston (4) is pushed by disc (5), retainer (9) is
pushed and spool (1) is also pushed down
through metering spring (2).
Accordingly, fine control hole (f) is disconnected from drain chamber (D) and connected
to pump pressure chamber (PP) almost simultaneously, and then the pilot oil flows from port
(P1) through fine control hole (f) to port (B).
If the pressure in port (P1) rises, spool (1) is
pushed back and fine control hole (f) is disconnected from pump pressure chamber (PP) and
connected to drain chamber (D) almost simultaneously to release the pressure in port (P1).
As a result, spool (1) moves up and down to
balance the force of metering spring (2) with
the pressure in port (P1).
The positional relationship between spool (1)
and body (10) [where fine control hole (f) is
between drain chamber (D) and pump pressure chamber (PP)] does not change until
retainer (9) comes in contact with spool (1).
Since metering spring (2) is compressed in
proportion to the stroke of the control lever, the
pressure in port (P1) rises in proportion to the
stroke of the control lever.
Accordingly, the control valve spool moves to a
position at which the pressure in port (B) [equal
to the pressure in port (P1)] is balanced with
the force of the control valve spool return
spring.
D275AX-5E0
3)
q

(When control lever is returned)
If lever (5) begins to return, the force of centering spring (3) and the pressure in port (P1)
push up spool (1).
As a result, fine control hole (f) is connected to
drain chamber (D) and the oil in port (P1) is
released.
If the pressure in port (P1) lowers too much,
spool (1) is pushed down by metering spring
(2) and fine control hole (f) is disconnected
from drain chamber (D) and connected to
pump pressure chamber (PP) almost simultaneously. Then, the pump pressure is applied
until the pressure in port (P1) is restored to the
level corresponding to the position of the lever.
When the control valve spool returns, the oil in
drain chamber (D) flows in through fine control
hole (f) of the valve which is not in operation
and then flows through port (P2) into port (A).
D275AX-5E0
SEN00932-00
4)
q
When lever is operated to stroke end

If disc (5) pushes down piston (4) and retainer
(9) pushes down spool (1), fine control hole (f)
is disconnected from drain chamber (D) and
connected to pump pressure chamber (PP).
Accordingly, the pilot oil flows through fine control hole (f) and port (P1) into port (B) and
pushes the control valve spool.
The oil returning from port (A) flows through
port (P2) and fine control (f) into drain chamber (D).
11
SEN00932-00
5)
q
q
q
q
q
12
When blade is floated

If piston (4) on the LOWER side of port (P1)
is pushed down by disc (5), ball (11) touches
projection (a) of the piston in the middle of the
stroke (The detent starts to operate).
If piston (4) is pushed in further, ball (11)
pushes up collar (12) supported on detent
spring (13) and escapes out to go over projection (a) of the piston.
At this time, piston (4') on the opposite side is
pushed up by spring (14).
As a result, the oil in chamber (F) flows
through (b) and (c) to chamber (E) and piston
(4') follows disc (5). Since passage (d) is connected to port (P1), almost the same pressure
is applied to passage (d) and port (P1).
Chamber (E) is normally connected to drain
chamber (D). If ball (11) goes over projection
(a) of the piston, passage (d) and chamber (E)
are connected and the oil starts flowing.
At this time, the control valve moves to the
FLOAT position and the blade is floated.
Since piston (4') is pushed up by the pressure
in chamber (E), the FLOAT state is kept even
if the lever is released.
6)
q
When FLOAT state of blade is reset

Disc (5) is pushed down with a force larger
than the oil pressure in chamber (E) to return
from the FLOAT position.
As a result, chamber (E) is disconnected from
passage (d) and connected to the drain chamber. Accordingly, the oil pressure in chamber
(E) is lost and the FLOAT state is reset.
D275AX-5E0
SEN00932-00
2. Ripper PPC valve
P:
P1:
P2:
P3:
P4:
T:
14
From self pressure reducing valve

To ripper tilt valve PPC port
To ripper tilt valve PPC port
To ripper lift valve PPC port
To ripper lift valve PPC port
To tank
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Spool
Metering spring
Centering spring
Piston
Disc
Nut (For connecting lever)
Joint
Plate
Retainer
Body
Filter
D275AX-5E0
SEN00932-00
Unit: mm
No.
Check item
Criteria
Standard size
12
13
Centering spring
Centering spring
14 Metering spring
D275AX-5E0
Remedy
Repair limit
Free length
x Outside
diameter
Installed
length
Installed
load
Free
length
Installed
load
50.4 x 15.5
34.0
55.9 N
{5.7 kg}
44.7 N
{4.56 kg}
50.1 x 15.5
34.0
71.4 N
{7.28 kg}
56.9 N
{5.8 kg}
26.5 x 8.20
24.9
16.7 N
{1.70 kg}
13.3 N
{1.36 kg}
If spring is
damaged or
deformed,
replace it
15
SEN00932-00
Operation
1) When in neutral
q
Ports (A) and (B) of the control valve and ports
(P1) and (P2) of the PPC valve are connected
through fine control hole (f) of spool (1) to drain
chamber (D).
2)
q
16
Since metering spring (2) is compressed in

proportion to the stroke of the control lever, the
pressure in port (P1) rises in proportion to the
stroke of the control lever.
Accordingly, the control valve spool moves to a
position at which the pressure in chamber (A)
[equal to the pressure in port (P1)] is balanced
with the force of the control valve spool return
spring.

(Neutral o Fine control)
If piston (4) is pushed by disc (5), retainer (9) is
pushed and spool (1) is also pushed down
through metering spring (2).
Accordingly, fine control hole (f) is disconnected from drain chamber (D) and connected
to pump pressure chamber (PP) almost simultaneously, and then the pilot oil flows from port
(P1) through fine control hole (f) to port (A).
If the pressure in port (P1) rises, spool (1) is
pushed back and fine control hole (f) is disconnected from pump pressure chamber (PP) and
connected to drain chamber (D) almost simultaneously to release the pressure in port (P1).
As a result, spool (1) moves up and down to
balance the force of metering spring (2) with
the pressure in port (P1). The positional relationship between spool (1) and body (10)
[where fine control hole (f) is between drain
chamber (D) and pump pressure chamber
(PP)] does not change until retainer (9) comes
in contact with spool (1).
D275AX-5E0
3)
q

(When control lever is returned)
If disc (5) begins to return, the force of centering spring (3) and the pressure in port (P1)
push up spool (1).
As a result, fine control hole (f) is connected to
drain chamber (D) and the oil in port (P1) is
released.
If the pressure in port (P1) lowers too much,
spool (1) is pushed down by metering spring
(2) and fine control hole (f) is disconnected
from drain chamber (D) and connected to
pump pressure chamber (PP) almost simultaneously. Then, the pump pressure is applied
until the pressure in port (P1) is restored to the
level corresponding to the position of the lever.
When the control valve spool returns, the oil in
drain chamber (D) flows in through fine control
hole (f) of the valve which is not in operation
and then flows through port (P2) into chamber
(B).
D275AX-5E0
SEN00932-00
4)
q
When lever is operated to stroke end

If disc (5) pushes down piston (4) and retainer
(9) pushes down spool (1), fine control hole (f)
is disconnected from drain chamber (D) and
connected to pump pressure chamber (PP).
Accordingly, the pilot oil flows through fine control hole (f) and port (P1) into chamber (A) and
pushes the control valve spool.
The oil returning from chamber (B) flows
through port (P2) and fine control (f) into drain
chamber (D).
17
SEN00932-00
PCCS lever
Travel and steering PCCS lever

a
Do not disassemble the PCCS lever. If it is disassembled, the output voltage characteristics and operating effort characteristics will need to be adjusted.
1.
2.
3.
4.
Bellows
Bracket
Plate
Bolt
18
5.
6.
7.
Screw
Lever
Connector
D275AX-5E0
Function
1. Operating effort characteristics
1) Operation for forward and reverse travel
q
The control lever is held at 3 positions of Forward, Neutral, and Reverse.
D275AX-5E0
SEN00932-00
2)
q
Operation for steering

Free return.
19
SEN00932-00
2.
q
20
Output voltage characteristics

The control unit is installed to the left control
stand and the control lever is installed directly
onto it.
The operating angle (stroke) of the control
lever is sensed with potentiometers and signal
voltages are output to the transmission and
steering controller.
A potentiometer is installed in each of longitudinal direction and lateral direction. Each
potentiometer outputs 2 signal voltages which
are opposite to each other as shown in the figure at right.
D275AX-5E0
PPC lock valve
1.
2.
3.
4.
5.
SEN00932-00
Lever
End cap
Ball
Seat
Body
Outline
q
The PPC lock valve is installed in the PPC circuit 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 equipment lock lever. This stops the oil in the PPC
circuit and makes it impossible to operate the
work equipment.
D275AX-5E0
21
SEN00932-00
Work equipment cylinder
Blade lift cylinder
Blade tilt cylinder
22
D275AX-5E0
SEN00932-00
Ripper tilt cylinder
Unit: mm
No.
Check item
Criteria
Standard
size
Shaft
Hole
Standard
clearance
Clearance
limit
Blade lift
80
+ 0.258
+ 0.048
0.078
0.334
0.745
Clearance between
piston rod and bush- Blade tilt
ing
0.030
0.076
100
0.036
0.090
+ 0.257
+ 0.047
0.084
0.347
0.693
Ripper lift
100
0.036
0.090
+ 0.257
+ 0.047
0.084
0.347
0.693
Ripper tilt
90
0.036
0.090
+ 0.257
+ 0.047
0.084
0.347
0.693
100
(Ball)
+ 0.300
0
1.0
Blade lift
90
1.0
Clearance between
piston rod spherical Blade tilt
shaft and bushing
+ 0.207
+ 0.120
70
+ 0.200
0
1.0
90
+ 0.207
+ 0.120
1.0
Clearance between
cylinder support
Blade lift
shaft bushing and
yoke
95
0.120
0.207
+ 0.035
0
0.120
0.242
1.0
Blade tilt
70
+ 0.174
+ 0.100
2.0
90
+ 0.207
+ 0.120
1.0
90
+ 0.207
+ 0.120
1.0
Clearance between
piston rod spherical
Blade lift
surface and blade
ball portion
Ripper lift
Tolerance
Remedy
Clearance between
cylinder bottom supRipper lift
port shaft and bushing
Ripper tilt
Thickness of standard shim between
Blade lift
tip of piston rod and
cap
D275AX-5E0
4.0
Replace
Adjust
23
SEN00932-00
Dual tilt cylinder (If equipped)
Pin puller cylinder (If equipped)
Unit: mm
No.
Check item
Criteria
Clearance between
piston rod and bush- Dual tilt
ing
Pin puller
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
100
0.036
0.090
+ 0.257
+ 0.047
0.084
0.347
0.693
30
0.065
0.117
+ 0.133
+ 0.007
0.072
0.250
0.55
70
+ 0.200
0
1.0
Clearance between piston rod

support shaft and bushing
Clearance between piston rod

spherical surface and bushing
29
0.100
0.200
Clearance between cylinder

bottom support shaft and bushing
70
+ 0.174
+ 0.100
2.0

bottom support shaft and bushing
26
+ 0.100
0.100
24
Replace
D275AX-5E0
Piston valve
SEN00932-00
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 contact with the cylinder head or the bottom and
serves to redure the subsequent surge pressure in the cylinder by letting the oil escape
from the 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 cylinder to rise and moving piston (2) in the direction 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 cylinder 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 rising.
D275AX-5E0
25
SEN00932-00
Quick drop valve
For blade lift cylinder
Unit: mm
No.
Check item
Clearance between spool and

valve body
Criteria
Standard
size
38.0
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
0.011
0.016
+ 0.010
+ 0.010
0.011
0.026
0.03
Standard size
2
26
Valve spring
Remedy
Repair limit
Free length
Installed
length
Installed
load
Free length
Installed
load
75.2
55.9
136.3 N
{13.9 kg}
67.7
122.6 N
{12.5 kg}
Replace
D275AX-5E0
Pin puller switch
1.
2.
3.
4.
SEN00932-00
Connector
Wire
Switch
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.
D275AX-5E0
27
SEN00932-00
Pin puller solenoid valve
1.
2.
3.
4.
5.
6.
7.
8.
9.
28
Plug
Spring
Spring retainer
Valve body
Spool
Spring retainer
Spring
Push in
Solenoid assembly
A:
B:
P:
T:
To pin puller cylinder bottom

To pin puller cylinder head
From power train pump
To HSS case
D275AX-5E0
SEN00932-00
Operation
1. Pin puller switch at PUSH IN position
When the pin puller switch is set to the PUSH
IN position, no electric current flows to solenoid (9) and it is deenergized.
Then, ports (P) and (A) and ports (B) and (P) of
spool (5) open, and the oil from the power train
pump flows from port (P) to port (A), and
enters the bottom end of pin puller cylinder
(10).
When the oil enters the bottom end of the cylinder 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).
D275AX-5E0
29
SEN00932-00
Blade control knob
1.
2.
3.
4.
5.
Switch (dual-single selector switch)

Switch (pitch)
Cover
Connector (male)
Connector (femele)
Outline
q
If the blade control knob is tilted forward, backward, to the right, or to the left, the blade is
raised, lowered, tilted to the right, or tilted to
the left. If switch (1) is set to the DUAL position and the lever is tilted to the right or left,
dual tilt operation is carried out. If the lever is
tilted to the right or left while (2) is pressed and
held, pitching operation is carried out.
30
If switch (2) is pressed and the lever is operated, the blade is pitched. If the lever is tilted
to the left, the blade is pitched back. If the
former is tilted to the right, the latter is pitched
forward.
If switch (1) is set to the DUAL position and the
lever is operated, blade carries out dual tilt
operation. If the lever is tilted to the left, the
blade carries out left dual tilt operation. If the
lever is tilted to the right, the blade carries out
right dual tilt operation.
If switch (1) is set in either DUAL or SINGLE
position and the lever is tilted to the right or left
while switch (2) is pressed and held, the blade
is pitched.
D275AX-5E0
Pitch, dual tilt solenoid valve

P3
SEN00932-00
1
PA1
P3 P4
PB2 PA1
PB1
1.
2.
3.
4.
5.
Connector
Solenoid (b)
Valve
Solenoid (a)
Manual push pin
P3: To PPC valve port, hydraulic tank

P4: To PPC valve port, control valve P3 port
PB1:To control valve port
PA1: To control valve port
D275AX-5E0
P4
Outline
q
The pitch switch solenoid valve is located
between the PPC valve and the blade valve,
and at the downstream of the pitch tilt switch
solenoid valve, and its function is to switch the
PPC pilot pressure.
q
By operating the pitch back switch or the pitch
dump switch of the blade control lever, the pilot
pressure can be delivered to the left pitch cylinder 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.
31
SEN00932-00
Accumulator
For PPC valve
1
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 compressed inside the accumulator sends the pilot
pressure to the main control valve to actuate it
and enable the work equipment to move down
under its own weight.
Operation
After the engine is stopped, when the PPC
valve is at neutral, chamber (A) inside the bladder is compressed by the oil pressure in chamber (B).
q
When the PPC valve is operated, the oil pressure in chamber (B) goes below 2.9 MPa {30
kg/cm2}, and the pressure of the nitrogen gas in
chamber (A) expands the bladder, so the oil in
chamber (B) acts as the pilot pressure and
actuates the main control valve.
q
1.
2.
3.
4.
5.
6.
Glass plug
Shell
Poppet
Holder
Bladder
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}
32
D275AX-5E0
SEN00932-00
34
D275AX-5E0
SEN00933-00
BULLDOZER
1SHOP MANUAL
D275AX-5E0
Machine model
Serial number
D275AX-5E0
30001 and up

Work equipment
Work equipment .............................................................................................................................................. 2
Cylinder stay ........................................................................................................................................ 2
Blade .................................................................................................................................................... 4
Cutting edge, end bit ............................................................................................................................ 8
Ripper................................................................................................................................................. 10
D275AX-5E0
SEN00933-00
Work equipment
Cylinder stay
1.
2.
3.
Yoke
Oil seal
Bushing
4.
5.
Bushing
Air Breather plug
Unit: mm
No.
Check item
Criteria
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
140
0.172
0.235
+ 0.088
+ 0.046
0.218
0.323

yoke and bushing
105
0.160
0.214
+ 0.075
+ 0.039
0.199
0.289
Clearance between lift cylinder support shaft and bushing
95
0.120
0.207
+ 0.035
+ 0.046
0.120
0.242
0.5

yoke and bushing
Standard
size
Tolerance
Replace
D275AX-5E0
SEN00933-00
Blade
Semi U-dozer
D275AX-5E0
SEN00933-00
Unit: mm
No.
Check item
Clearance between brace and

brace
Criteria
Standard
size
Tolerance
Remedy
Standard
clearance
Clearance
limit
+ 0.5
+ 0.3
0.6 1.0
Shaft
Hole
70
0.3
0.5
Clearance between brace pin

and bracket
70
0.3
0.5
+ 0.5
+ 0.3
0.6 1.0
Clearance between brace

spherical surface and cap
115
0.2
0.3
+ 0.3
0
0.2 0.6
Clearance between center

brace spherical surface and
cap
130
0.2
0.3
+ 0.3
0
0.2 0.6
Clearance between joint and

blade bracket
120
0.2
0.7
+ 0.5
+ 0.3
0.5 1.2

frame
120
0.2
0.7
+ 0.5
+ 0.3
0.5 1.2
Clearance between frame pin

and joint
60
0.3
0.5
+ 0.3
0
0.3 0.8

and frame
60
0.3
0.5
+ 0.3
0
0.3 0.8
Clearance between blade

bracket pin and joint
60
0.3
0.5
+ 0.3
0
0.3 0.8

10 bracket pin and blade bracket
60
0.3
0.5
+ 0.3
0
0.3 0.8

11 brace spherical surface and
cap
130
0.2
0.3
+ 0.3
0
0.2 0.6
Clearance between center link

12 pin and center link
115
0.04
0.10
+ 0.3
+ 1.0
0.14 0.40

13 pin and blade bracket
115
0.04
0.10
+ 0.3
+ 1.0
0.14 0.40

14
and blade bracket
400
0.2
0.4
+ 0.5
0
0.2 0.9
Clearance between trunnion

15 and cap spherical surface
195
0.5
1.0
+ 1.0
0
0.5 2.0
D275AX-5E0
Replace
Adjust shim or
replace
Replace
Adjust shim or
replace
Replace
SEN00933-00
U-dozer
D275AX-5E0
SEN00933-00
Unit: mm
No.
Check item
Clearance between brace and

brace
Criteria
Standard
size
Tolerance
Remedy
Standard
clearance
Clearance
limit
+ 0.5
+ 0.3
0.6 1.0
Shaft
Hole
70
0.3
0.5
Clearance between brace pin

and bracket
70
0.3
0.5
+ 0.5
+ 0.3
0.6 1.0
Clearance between brace

spherical surface and cap
115
0.2
0.3
+ 0.3
0
0.2 0.6

brace spherical surface and
cap
130
0.2
0.3
+ 0.3
0
0.2 0.6

blade bracket
120
0.2
0.7
+ 0.5
+ 0.3
0.5 1.2

frame
120
0.2
0.7
+ 0.5
+ 0.3
0.5 1.2

and joint
60
0.3
0.5
+ 0.3
0
0.3 0.8

and frame
60
0.3
0.5
+ 0.3
0
0.3 0.8

bracket pin and joint
60
0.3
0.5
+ 0.3
0
0.3 0.8
10

bracket pin and blade bracket
60
0.3
0.5
+ 0.3
0
0.3 0.8
130
0.2
0.3
+ 0.3
0
0.2 0.6

11 brace spherical surface and
cap
pin and center link
115
0.04
0.10
+ 0.3
+ 1.0
0.14 0.40
13

pin and blade bracket
115
0.04
0.10
+ 0.3
+ 0.1
0.14 0.40
400
0.2
0.4
+ 0.5
0
0.2 0.9
195
0.5
1.0
+ 1.0
0
0.5 2.0
15
Clearance between trunnion

and cap spherical surface
D275AX-5E0
Adjust shim or
replace
Replace
12

14
and blade bracket
Replace
Adjust shim or
replace
Replace
SEN00933-00
Cutting edge, end bit
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
415
300
Width of end bit
662
500
Height of inside of end bit
330
260
Height of cutting edge
330
260 (215 to turning)
Height of outside of end bit
Replace
Turn or replace
D275AX-5E0
SEN00933-00
Ripper
Variable multiple shank ripper
10
D275AX-5E0
SEN00933-00
Giant ripper
Unit: mm
No.
Check item
Clearance between bushing
and bracket and arm mount pin
Clearance between bushing

and beam and arm mount pin

mount pin and bushing
Clearance between shank and

mount pin
Wear of point
Wear of protector
D275AX-5E0
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
110
0.036
0.090
+ 0.207
+ 0.120
0.156
0.297
1.5
120
0.036
0.090
+ 0.207
+ 0.120
0.156
0.297
1.5
90
0.036
0.090
+ 0.207
+ 0.120
0.156
0.297
1.5
Standard size
Tolerance
Repair limit
82
0.3
Standard size
Repair limit
420
255
155
115
Replace
11
SEN00933-00
12
D275AX-5E0
SEN00934-00
BULLDOZER
1SHOP MANUAL
D275AX-5E0
Machine model
Serial number
D275AX-5E0
30001 and up


Cab and its attachments ................................................................................................................................. 2
Cab mount............................................................................................................................................ 2
Cab....................................................................................................................................................... 3
Air conditioner ...................................................................................................................................... 5
D275AX-5E0
SEN00934-00

Cab mount
1.
2.
3.
Support
Damper mount (front)
Damper mount (rear)
1
1
Outline
q
Viscous mounts are installed at two places at
the front and two places at the rear to secure
the floor frame and cab.
q
An oil-filled damper mount is used to absorb
the vibration.
D275AX-5E0
Cab
SEN00934-00
Cab assembly
1.
2.
3.
4.
Front wiper
Front glass
Rear wiper
Door
D275AX-5E0
SEN00934-00
ROPS guard
1.
ROPS guard
D275AX-5E0
Air conditioner
SEN00934-00
Air conditioner piping
1.
2.
3.
4.
5.
6.
7.
8.
9.
Air conditioner compressor

Condenser
Window defroster
Side defroster
Air conditioner control unit
Vent
Blower motor
Hot water pick-up piping
Valve (hot water outlet)
D275AX-5E0
10.
11.
12.
13.
Receiver tank
Hot water return piping
Valve (hot water inlet)
Refrigerant piping
A:
B:
C:
Fresh air
Recirculated air
Hot air/cold air
SEN00934-00
D275AX-5E0
SEN00935-00
BULLDOZER
1SHOP MANUAL
D275AX-5E0
Machine model
Serial number
D275AX-5E0
30001 and up

Electrical system
Electrical system ............................................................................................................................................. 2
Engine control ...................................................................................................................................... 2
Engine control system ......................................................................................................................... 3
Engine controller .................................................................................................................................. 4
Deceleration potentiometer .................................................................................................................11
CRI engine control system ................................................................................................................. 12
Monitor system................................................................................................................................... 14
Monitor panel ..................................................................................................................................... 16
Sensors .............................................................................................................................................. 20
Mode selection system....................................................................................................................... 24
Electrical equipment........................................................................................................................... 30
Palm Command Control System........................................................................................................ 33
KOMTRAX terminal system ............................................................................................................... 35
D275AX-5E0
SEN00935-00
Electrical system
Engine control
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Decelerator pedal
Decelerator potentiometer
Starter switch
Transmission controller
Steering controller
Fuel control dial
Battery
Breaker
Battery relay
Starter
Engine throttle controller
Alternator
Outline
q
The throttle signals of the fuel control dial are
input to the steering controller and transmission controller and processed together with the
other information, then the result is sent as the
throttle command to the engine controller. The
engine throttle controller controls the fuel supply pump according to the command.
D275AX-5E0
SEN00935-00
Engine control system
Outline
q
The engine throttle controller receives the 1st
and 2nd throttle signal which is the manual signal and the 3rd throttle signals which is the
control signals from the machine body, then
selects the lower engine speed and controls
the fuel supply pump.
The 3rd throttle control signals contain the following.
q
SSC (Shoe Slip Control) control
q
Automatic deceleration (F3, R3, R2)
q
The information of the engine controller is used

commonly by the all controllers through the
network for the optimum control of the engine
and machine body.
The automatic deceleration function sets the
engine speed to 1,000 rpm temporarily when
the travel direction is changed from F3, R3, or
R2 (to protect the transmission clutch).
The steering controller selects the lowest

engine speed from these information and
transmits to the engine controller.
D275AX-5E0
SEN00935-00
Engine controller
Meanings of signal classes in the terminal

table shown below are as follows.
A: Power Supply
B: Input
C: Ground/Shield/Return
D: Output
E: Communication
CN-CE01
Input/
output
1
NC(*)
2
NC(*)
3
Atmosphere sensor
D
4
Supply pump #1 (+)
B
5
Supply pump #1 ()
C
6
CAN()
C
7
NC(*)
8
CAN(+)
B
9
Supply pump #2 (+)
B
10
Supply pump #2 ()
C
*: Never connect to NC or malfunctions or failures will
occur.
Pin No.
Signal name
CN-CE01
Input/
output
11
EGR val ve
C
12
NC(*)
13
Engine oil pressure sensor
D
14
NC(*)
15
Coolant temperature sensor
D
16
5V electric power supply for sensor
A
17
NC(*)
18
NC(*)
19
EGR valve position sensor
D
20
EGR inlet pressure sensor
B
21
NC(*)
22
EGR valve (+)
B
23
Boost temperature sensor
D
24
NC(*)
25
Common rail pressure sensor
D
26
Buckup sensor
D
27
NE sensor (+)
D
28
NC(*)
29
Bypass valve position sensor
B
occur.
Pin No.
Signal name
D275AX-5E0
CN-CE01
CN-CE02
Input/
output
30
Fuel temperature sensor
D
31
Bypass valve (+)
D
32
NC(*)
33
5 V electric power supply for sensor
A
34
NC(*)
35
NC(*)
36
NC(*)
37
5 V electric power supply for sensor
A
38
GND
C
39
NC(*)
40
NC(*)
41
NC(*)
42
NC(*)
43
NC(*)
44
Boost pressure sensor
D
45
Injector #1 (+)
B
46
Injector #5 (+)
B
47
Sensor GND
C
48
Ne sensor ()
C
49
NC(*)
50
NC(*)
51
Injector #2 ()
C
52
Injector #3 ()
C
53
Injector #1 ()
C
54
Injector #2 (+)
B
55
Injector #3 (+)
B
56
Injector #4 (+)
B
57
Injector #6 (+)
B
58
Injector #4 ()
C
59
Injector #6 ()
C
60
Injector #5 ()
C
occur.
Pin No.
Signal name
CN-CE02
Input/
output
1
NC(*)
B
2
NC(*)
B
3
NC(*)
B
4
NC(*)
B
5
NC(*)
B
6
NC(*)
B
7
NC(*)
B
8
NC(*)
B
9
Decelerator signal
B
10
NC(*)
E
11
NC(*)
B
12
NC(*)
B
13
NC(*)
B
14
NC(*)
B
15
NC(*)
B
16
NC(*)
B
occur.
Pin No.
D275AX-5E0
SEN00935-00
Signal name
Input/
output
17
NC(*)
B
18
NC(*)
B
19
NC(*)
B
20
NC(*)
E
21
NC(*)
A
22
5V electric power supply for sensor
A
23
GND
C
24
NC(*)
B
25
NC(*)
B
26
NC(*)
B
27
NC(*)
B
28
NC(*)
B
29
NC(*)
C
30
NC(*)
B
31
NC(*)
B
32
NC(*)
C
33
GND
C
34
NC(*)
C
35
NC(*)
B
36
NC(*)
B
37
CAN shield
C
38
NC(*)
D
39
Key switch (ACC)
B
40
Electrical intake air heater relay drive
D
41
NC(*)
D
42
Electrical intake air heater relay return
C
43
NC(*)
D
44
NC(*)
D
45
NC(*)
46
CAN(+)
E
47
CAN()
E
48
NC(*)
D
PWM OUTPUT
49
D
(Power train relay output)
50
NC(*)
D
occur.
Pin No.
Signal name
CN-CE03
Pin No.
1
2
Signal name
Input/
output
C
C
GND
NC(*)
Electric power supply
3
A
(+24V constantly)
4
NC(*)
A
occur.
SEN00935-00

q
This sensor is used to sense the EGR pressure.

q
The fuel temperature sensor senses the fuel

temperature and sends it to the engine controller. The sensor unit is a thermistor the resistance of which changes according to the
temperature.
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.
The following graph shows the output characteristics of the EGR inlet pressure sensor.
D275AX-5E0
SEN00935-00

q
These sensors sense the opening and closing positions of the EGR valve and bypass valve.
1.
EGR and bypass valve position sensors
The following graph shows the output characteristics of the position sensor.
D275AX-5E0
SEN00935-00
Engine controller
NE speed sensor (Crank angle sensor)
q
q

Oil pressure sensor
If the signal hole made on the flywheel passes

the sensor, the magnetic line of force changes.
If the magnetic line of force changes, the output of the Hall element sensor changes linearly
and it is converted into pulse of 0 5 V by the
wave form shaping circuit in the sensor, and
then output.
Atmospheric pressure sensor

q
This sensor is used to correct altitude.
D275AX-5E0
Bkup speed sensor (G 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.
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.
In addition to the above teeth, one more tooth
is installed. Accordingly, 7 pulses are generated every 2 revolutions of the engine.
The standard pulse of the No. 1 cylinder is recognized by the combination of the NE speed
sensor pulse and Bkup speed sensor pulse.
D275AX-5E0
SEN00935-00
Charge pressure sensor

q
This sensor is used to sense the charge pressure (boost pressure).
SEN00935-00
Charge temperature sensor

q
10
The charge temperature sensor senses the

intake air temperature (boost temperature) and
sends it to the engine controller.
The sensor unit is a thermistor the resistance
of which changes according to the temperature. 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.
Coolant temperature sensor

q
The coolant temperature sensor senses the

coolant temperature and sends it to the engine
controller.
The sensor unit is a thermistor the resistance
of which changes according to the temperature. 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.
D275AX-5E0
Deceleration potentiometer
1.
2.
3.
4.
5.
6.
7.
Connector
Lever
Body
Potentiometer
Coupling
Shaft
Stopper
D275AX-5E0
SEN00935-00
Outline
q
The deceleration potentiometer is installed to
the front lower part of the operator's cab and
connected to the decelerator pedal by linkage.
q
If the decelerator pedal is pressed, the throttle

potentiometer shaft rotates by the linkage and
the potentiometer resistance changes.
Constant voltage is applied between pins A
and C of the potentiometer and an electric signal is sent through pin B to the steering controller according to the position of the
decelerator pedal.
11
SEN00935-00
CRI engine control system

a
"CRI" is an abbreviation for Common Rail Injection.
System diagram
12
D275AX-5E0
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
NE speed sensor
Injector assembly
3A. Orifice
3B. Control chamber
3C. Hydraulic piston
3D. Injector
3E. Nozzle
Fuel cooler
Fuel tank
Strainer
Pre fuel filter (with water separator)
Priming pump
Fuel filter
Engine throttle controller cooler
Pressure limiter
Flow damper
High pressure injection pipe
Common rail
Fuel supply pump assembly
15A. PCV
15B. High pressure pump
15C. Priming pump
15D. Feed pump
15E. Bypass valve
15F. Bkup speed sensor (G sensor)
Overflow valve
Outline
q
The signals detected by various sensors are
input to the engine controller.
q
The input signals are processed by the controller and output to each actuator to control the
fuel injection rate and fuel injection timing.
D275AX-5E0
SEN00935-00
System configuration
q
The CRI system consists of fuel supply pump
(15), common rail (14), injector (3), engine
throttle controller (2) to control them, and sensors.
q
The fuel supply pump generates fuel pressure
in the common rail. The fuel pressure is controlled by the fuel discharge rate of the supply
pump. The discharge rate is controlled by
turning on and off PCV (discharge control
valve) (15A) of the fuel supply pump according
to the electric signals from the engine throttle
controller.
The common rail receives the pressurized fuel
from the fuel supply pump and distributes it to
the cylinders.
The fuel pressure is sensed by the common
rail fuel pressure sensor installed to the common rail and controlled by the feedback
method so that the actual fuel pressure will
match to the command pressure set according
to the engine speed and the load on the
engine.
The fuel pressure in the common rail is applied
to the nozzle (3E) side of the injector and control chamber (3B) through the fuel injection
pipe of each cylinder.
q
The injector controls the fuel injection rate and
fuel injection timing by turning on and off the
TWV (2-way solenoid valve). If the TWV is
turned on, the fuel circuit is so changed that
the high-pressure fuel in the control chamber
will flow through orifice (3A). The needle valve
is raised to start fuel injection by the nozzle
cracking pressure applied as the high-pressure
fuel on the nozzle side. If the TWV is turned
off, the fuel circuit is so change that the highpressure fuel will be applied to the control
chamber through the orifice. As a result, the
needle valve lowers and finishes fuel injection. Accordingly, the fuel injection timing and
fuel injection rate are controlled respectively by
the timing to turn on the TWV and the length of
the turn-on time of the TWV.
13
SEN00935-00
Monitor system
The monitor system monitors the machine condition with the sensors installed to various
parts of the machine and processes and displays the obtained information on the panel
quickly to notify the operator of the machine
condition.
The main display sections and functions of the
panel are as follows.
1) Monitor unit which turns on the alarm
when the machine has a trouble.
2) Gauge unit which constantly displays the
machine condition (coolant temperature,
torque converter oil temperature, fuel
level, etc.)
3) Function of displaying error codes.
4) Function of monitoring the current and
voltage of the sensors and solenoids.
In the monitor panel, there are various mode

selector switches of the SSC (Shoe Slip Control), which are used to operate the machine
control system.
14
The monitor panel has functions of displaying

data and selecting the SSC mode.
The CPU (Central Processing Unit) in it processes, displays, and outputs the information.
The display unit is LCD (Liquid Crystal Display)
and the switches are seat switches.
D275AX-5E0
SEN00935-00
Processing in monitor system (Common to all specifications)

Display of monitor panel
(1) Contents and conditions of processing
1)
(2) Method
(3) Flow of signals
Display of travel direction and gear speed.

F1, R3, etc. are notified by CAN according to information of transmission controller.
Transmission controllerSteering
controllerMonitor panel
2)
CAN
Engine speed sensorEngine
Display of engine speed in gauge number.
The number of pulses the engine rotation is converted (Controller Area Network) controller Steering controller
Monitor panel
into a gauge number and notified to the monitor panel
by CAN.
3)
CAN
Display of troubleshooting
When the machine has a trouble, the corresponding
failure code is notified to the monitor panel by CAN.
Which one should be turned on, the buzzer or the caution lamp, is notified, too.
(1) In normal state
User code
(2) In trouble history display mode
The service code (6-digit code) and the follow
ingitems are displayed
1. Time after first occurrence
2. Time after latest occurrence
3. Number of past occurrences
The monitor panel displays the code on the hour meter
section.
Each sensor/solenoidControllerMonitor panel
Display of monitoring condition

1)
(2) Method
(3) Flow of signals
The communication conditions of each sensor, each CAN

solenoid, and CAN are displayed.
The item Nos. and device conditions are notified to the
monitor panel by CAN.
The monitor panel displays the items and each value
on its multi-information section.
Each sensorControllerMonitor
panel
2) Each items is selected by using the cursor switches,

selector switches, buzzer cancel switch, and shift UP/
DOWN switches.
Monitor panelControllerMonitor panel
Other items
1)
2)
3)
4)
Function selection mode (Displayed each time cancel

switch is turned to left)
(1) Replacement periods of oil filter and oil are displayed.
(2) Engine speed, oil pressure in work equipment circuit, etc. are displayed.
(3) Failure codes related to electronic control are dis
played.
(4) Brightness of display, etc. are adjusted.
Mode to change replacement periods of maintenance
mode
Mode to display failure codes related to machine body
such as overheating, abnormal coolant temperature,
etc.
Mode to display service meter and information related
to load on machine
D275AX-5E0
(2) Method
(3) Flow of signals
15
SEN00935-00
Monitor panel
Monitor portion
1.
2.
3.
4.
5.
6.
7.
8.
Display plate (Speed range display)

Charge lamp
Power train oil temperature gauge
Engine coolant temperature gauge
Fuel gauge
Hydraulic oil temperature gauge
Hydraulic oil temperature caution lamp
HSS charge pressure caution lamp
Outline
q
The monitor portion consists of a monitor that
issues an alarm when an error occurred in a
vehicle, a gauge that always displays the state
of the vehicle, and the service meter.
The monitor portion installs a microcomputer
and processes and displays signals from each
sensor.
Besides, the items displayed on the monitor
portion and gauge portion are listed in the table
on the next page.
Operation
1. When the power turns on (When the starter
switch is ON)
1) All items of the gauge and monitor portions come on for three seconds.
2) The alarm lamp comes on for two seconds.
2.
16
9.
10.
11.
12.
13.
14.
15.
16.
Power train oil temperature caution lamp

Engine coolant temperature caution lamp
Dual tilt display lamp
Engine oil pressure caution lamp
Maintenance caution lamp
Preheat pilot lamp
Radiator water level check lamp
Display plate (Multi information)
2)
3.
a
a
If the engine is started, the check items

before starting go off. (If the engine is running is judged by the signal (CAN) from
the engine controller.)
Cautions
Caution items are checked until the engine
stops after the engine starts.
If an error occurs, the error is displayed by
flashing and the alarm lamp synchronously
flashes.
Further, if an emergency item flashes, the
alarm buzzer also sounds synchronously.
Flashing of the monitor and alarm lamp is
repeated. They come on and off for about 0.8
second.
The flashing period of the monitor slightly
changes when atmospheric temperature is low
(below about 10C), but this case in not
abnormal.
Star-up inspection
1) After all lighting of Section 1 is terminated,
if there is an error in a start-up inspection
item, the item flashes.
D275AX-5E0
SEN00935-00
Monitor panel displa

Symbol
Display item
Caution 1
Caution 2
Display method
Radiator water level
Below low level
Engine oil pressure
When sensor is abnormal or when wiring harness is disconnected
Display when normal: OFF

Display when abnormal: ON
Battery charge
When charge is defective
Displays when starting switch is ON and

engine is running
Display when abnormal: Flashes
CAUTION lamp also flashes
Engine oil pressure
Below 49.0kPa
{0.5kg/cm2}
Below low level
SAP00522

engine is running
Alarm buzzer sounds

engine is running.
When in red range of
102C 107C (when at 1st level of red
Engine coolant tempera- coolant temperature
range) : Flashes
Min. 108C (when at 2nd level of red
ture
gauge
range): Flashes
(102C or above)
Alarm buzzer sounds
engine is running.
When in red range of
120C 129C (when at 1st level of red
Torque converter oil tem- power train oil tempera- range) : Flashes
perature
ture gauge
range): Flashes
(120C or above)
Alarm buzzer sounds
engine is running.
When in red range of hy- 100C 109C (when at 1st level of red
draulic oil temperature range) : Flashes
Hydraulic oil temperature
gauge
range): Flashes
(100C or above)
Alarm buzzer sounds
HSS charge pressure
Maintenance
D275AX-5E0
Display range
Displays when engine is stopped and

starting switch is ON
Check
Display
category
When HSS charge

pressure is reduced

engine is running
When replacement time CAUTION lamp also flashes
of filter or oil has been
Alarm buzzer sounds
passed
17
SEN00935-00
Display
category
Symbol
Display item
Dual tilt
Display method
When preheating
When preheating: ON
(Engine controller determined at the time of preheat
by coolant temperature or
switch at preheat position
(turning it counterclockwise)
start the preheating.)
At the time of operation
Display lights at the time of

operation.
It goes off at the time of nonoperation.
Pilot
Preheating
Display range
Engine coolant temperature
One place lights up to show

applicable level
Gauges
Torque converter oil

temperature
All lamps light up below applicable level
Multi information
Fuel level
18
Service meter
(Hours meter)
From 0 to 99999
Actuated when the engine is

rotating
D275AX-5E0
SEN00935-00
Switch Portion
1.
Switch functions
a) ON-OFF switching in lock-up mode
b) Economy mode setting - OFF, mode 1, mode 2
c) ON-OFF switching in reverse slow mode
d) ON-OFF switching in SSC mode
e) SSC mode level setting - Mode 1 to 5
(a), (b), and (c) are mounted for all specifications and (d) and (e) are mounted for the SSC specifications.
SSC specifications
Without SSC specifications
Economy mode function

In a field, such as a rock-bed place where many
shoe slips are generated, the following power is
output in each mode so that the frequency of decelerator operation can decrease.
q
Economy mode 1 o Set to about 90% of the
full power.
q
Economy mode 2 o Set to about 70% of the
full power.
q
Reverse slow mode o Set to about 80% of the
full travel speed at reverse time.
D275AX-5E0
2.
Initial Setup at key ON

The function the operator desires according to
the situation of an operating place is selected
and all functions shall be set to the OFF state.
19
SEN00935-00
Sensors
Type of sensor
Sensor method
When normal
When abnormal
Torque converter
oil temperature
Resistance
Resistance
Contact
ON
OFF
Fuel level
Resistance
HSS charge pressure
Contact
ON
OFF
20
D275AX-5E0
SEN00935-00
Torque converter oil temperature sensor

Hydraulic oil temperature sensor
Radiator water level sensor
1.
2.
3.
Float
Sensor
Tube
D275AX-5E0
4.
5.
Wire
Connector
21
SEN00935-00
Fuel level sensor
1.
2.
3.
4.
5.
6.
7.
22
Connector
Float
Arm
Body
Spring
Contact
Spacer
Function
q
The fuel sensor is installed to the side face of
the fuel tank. The float moves up and down
according go to the fuel level. This movement
of the float is transmitted by the arm and actuates a variable resistance. This sends a signal
to the monitor panel to indicate the remaining
fuel level. When the display on the monitor
panel reaches a certain level, a warning lamp
flashes.
D275AX-5E0
SEN00935-00
HSS charging pressure sensor
1.
2.
3.
4.
Switch
Case
Wire
Connector
D275AX-5E0
23
SEN00935-00
Mode selection system
(SSC (Shoe Slip Control) System)

System diagram
Outline
q
The mode selection system automatically carries out engine control to match the operating
mode selected by the operator, and acts to
reduce fuel consumption, extend the life of the
track shoes, and reduce the frequency of operation of the deceleration.
q
The engine control modes consist of the economy 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.
24
The lock-up control mode is the same as the

conventional lock-up function. It cannot be
selected in combination with the above modes.
D275AX-5E0
Function of model selection system

q
This system consists of the mode selection

panel (containing a microcomputer) to select
working condition, steering controller (containing a microcomputer) to control the engine,
engine controller to receive the commands
from the steering controller and controls the
fuel 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.
SEN00935-00
Function of engine controller

1.
The engine controller controls the fuel supply

pump according to the lowest engine speed
(highest voltage) in the 3 signals of the manual
command input from the deceleration potentiometer, manual signal of the throttle dial, and
the SSC command signal.
Functions of steering controller and

transmission controller
1.
2.
3.
4.
The steering controller calculates the travel

speed to the ground from the signals of the
acceleration sensor and inputs the transmission output speed sensor signal to it to calculate the shoe speed, then obtains the shoe slip
rate.
If the engine speed sensor signal and transmission output speed sensor signal are input,
the steering controller calculates the traction
force.
The steering controller calculates the optimum
engine speed from the results of 1 and 2
above, mode set signal of the monitor panel,
and speed information from the transmission
controller, then sends it as the SSC command
to the engine controller.
The transmission controller sends the lock-up
signal to the lock-up solenoid valve, judging
from the input gear speed information of the
transmission controller.
a See "Operation of torque converter lockup control system".
D275AX-5E0
25
SEN00935-00
Operation of mode selection system

q
Work can be performed under the optimum conditions by simply or simultaneously selecting five modes
in accordance with the contents of work
Work
Single
Mode
switch selection
Simultaneous
selection
Mode work condition
ON/OFF switching is automatically per- 1.

formed in accordance with a load.
Economy
1.
Low
High
speedside speedside
T/Coutput
shaftspeed
Dozing
Lock-up
Speednumber
ofgearratios
Mode operation, characteristic
F1
F2,F3,
R1,R2,R3
ON
1,230rpm
ormore
1,260rpm
ormore
2.
3.
OFF
1,200rpm
ormore
1,230rpm
ormore
4.
2,140rpm
ormore
ON
OFF
2,200rpm
ormore
When F1 is shifted with the economy 1.

mode switch [1] or [2] ON
2.
Reverse slow
3.
1.
When R1, R2, and R3 are shifted
1.
2.
SSC (Shoe Slip Control)
Ripping
The following conditions are satisfied:

1.
[1] When F1 is shifted.
[2] After the ripper down, ripper tilt levers
are actuated and the switch is set to ON
2.
3.
Rock-bed
selection
4.
26
When the torque converter approaches to

the stall area or performs gear shaft operation, lock-up is set to OFF. When the torque
converter reaches a light lode, lock-up is set
to ON.
Can be used in all number of gear ratios.
Simultaneous selection disabled with another mode
Suitable for dozing work of comparatively a
few load fluctuations
Set to ON in connection with SSC
1.
2.
When the economy mode ([1] or [2]) and

SSC are set simultaneously, the F1 shift
economy control is performed. When the ripper lever is actuated and the switch is turned
on, the slip control is performed.
The engine output can be suppressed in two
stages without performing the decelerator
operation of the engine.
Mode [1]: 90% (at 1.5 km/h)
Mode [2]: 65% (at 1.5 km/h)
At neutral time, the engine speed can be
suppressed partially
The engine speed can be suppressed without performing the decelerator operation of
the engine.
Target travel speed at reverse time
R1
R2 70% at full operation
R3
At start, to prevent rashing out, the modulating valve is actuated. At this time, the steering controller performs index characteristic
down of about 40% and performs the engine
outpuut control if a ripper down signal is input.
The seering controller performs the engine
output control in accordance with the index
force characteristic (refer to the rock-bed selection shown below) selected by the operator among the index force characteristics set
in five stages and suppresses the generation of a slip.
The steering controller regards the index
force immediately before the slip (exceeding
the shoe ripping ratio of 30% is generated,
as the maximum, and performs the engine
output control. At this time, the steering controller 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.
At neutral time, the engine speed is suppressed partially.
When the SSC is set to ON, the selection
mode 3 comes on.
1i
o3 i
o 5 is selected in accordance with
the state and load of the rock-bed
When the above mode is set, the throttle lever and decelerator operations are enabled. In that case, the
engine output control is performed in accordance with the command having the smallest value among
the control command, throttle command, and decelerator command.
D275AX-5E0
SEN00935-00
Sensors
Transmission output shaft speed sensor
1.
2.
3.
4.
5.
Magnet
Terminal
Case
Boots
Connector
D275AX-5E0
27
SEN00935-00
Acceleration sensor
1.
2.
3.
Sensor portion
Wire
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.
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 sensor are shown in the diagram on the right.
28
D275AX-5E0
SEN00935-00
Pitch angle sensor
1.
2.
3.
4.
Body
Tube
Wire
Connector
D275AX-5E0
29
SEN00935-00
Electrical equipment
Relay box
30
D275AX-5E0
SEN00935-00
Operation of lamp system
Lamp system circuit diagram
D275AX-5E0
31
SEN00935-00
Preheat (Electrical intake air heater) control
Preheat circuit
32
D275AX-5E0
SEN00935-00
Palm Command Control System
1.
2.
3.
4.
5.
Monitor panel (Multi-information)

Auto shift-down switch
Steering controller
D275AX-5E0
6.
7.
8.
9.
Steering control valve

Transmission output speed sensor
Transmission control valve
Engine speed sensor
33
SEN00935-00
1.
2.
3.
Shift Mode Function

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

Operating condition
This function automatically shifts the gear
speed down if load is increased while the
machine is travelling at 2nd or 3rd speed or
while the machine is in operation.
Selecting method
Turn the auto shift-down switch (1) ON.
Operation and features of the mode
1) This function turns on the shift-down automatically by calculating the drawbar pull
(load to the machine body) based the
engine speed, transmission speed and
throttle information from the steering controller.
2) Once the machine is automatically shifted
down, shit-up wont be turned on automatically (shift up from the manual switch is
available, though).
3) This function is available for both the forward and reverse travel.
1.
2.
3.
34
Shift mode 2
Shift down switch ON
D275AX-5E0
KOMTRAX terminal system
SEN00935-00
The KOMTRAX terminal system transmits various kinds of machine information wirelessly.
Persons to operate the KOMTRAX can refer to
the information at office to provide various
kinds of services for customers.
* Information transmittable from the KOMTRAX
terminal system includes the following.
1. Operation map
2. Service meter
3. Position information
4. Error history
and others.
D275AX-5E0
35
SEN00935-00
KOMTRAX terminal
1.
2.
3.
Communication antenna connection

GPS antenna connection
DRC connector connection (40 poles)
Input and output signals

DRC conector
Pin No.
Signal name
Input/output
1
NC(*)
2
NC(*)
3
NC(*)
4
NC(*)
5
NC(*)
6
CAN shield GND
7
CAN signal (L)
Input/output
8
CAN signal (H)
Input/output
9
NC(*)
10
NC(*)
Input/output
11
NC(*)
12
NC(*)
13
NC(*)
14
NC(*)
15
NC(*)
16
NC(*)
17
NC(*)
18
NC(*)
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.
36
The KOMTRAX terminal obtains various kinds

of machine information from the network signals and input signal in the machine and transmits them via the wireless communication
antenna. It contains a CPU (Central Processing Unit) and has wireless communication
function and GPS function.
q
This terminal has an LED lamp unit and a 7segment display lamp unit used for inspection
and troubleshooting.
DRC conector
q
Pin No.
26
27
28
29
30
31
32
33
34
35
36
37
38
Signal name
Input/output
NC(*)
C-terminal input
Input
R-terminal input
Input
NC(*)
NC(*)
NC(*)
NC(*)
NC(*)
NC(*)
NC(*)
ACC input
Input
Power GND
Power GND

39
Input
(+24V constantly)
40
Input
(+24V constantly)
occur.
D275AX-5E0
SEN00935-00
38
D275AX-5E0
SEN01413-00
BULLDOZER
1SHOP MANUAL
D275AX-5E0
Machine model
Serial number
D275AX-5E0
30001 and up

Standard value table for engine ...................................................................................................................... 2
Standard value table for machine ................................................................................................................... 3
D275AX-5E0
SEN01413-00
Standard value table for engine
Category
Item
Speed
Machine model
D275AX-5E0
Engine
SAA6D140E-5
Measurement conditions
High idle
Engine coolant temperaLow idle
ture: Within operating
range
Rated speed
Unit
Standard value
for new machine
Service limit
value
rpm
2,150 25
2,150 25
rpm
700 50
700 50
rpm
2,000
2,000
Min. 169
{Min. 1,270}
144
{1,080}
Max. 620
670
%
(Bosch
index)
Max. 25
{Max. 2.5}
35
{3.5}
(Bosch
index)
Max. 1.0
2.0
Engine coolant temperature:

Within operating range
Intake air pressure
kPa
Power train oil temperature:
(Boost pressure)
{mmHg}
Torque converter: Stalled
Exhaust temperature
Whole speed range

(Outside temperature: 20C)
Exhaust gas color
At sharp accel Engine coolant tempera- eration

range
High idle
Intake valve
mm
0.35
Exhaust valve
mm
0.57
MPa
{kg/cm2}
Min. 4.1
{Min 42}
2.8
{29}
rpm
200 250
200 250
Max. 2.94
{Max. 300}
3.92
{400}
MPa
{kg/cm2}
Min. 0.34
{Min. 3.5}
0.21
{2.1}
MPa
{kg/cm2}
Min. 0.10
{Min. 1.0}
0.08
{0.8}
90 110
120
Between water pump pulley alternator

Alternator belt tenpulley
sion
Deflection under finger pressure of 98 N
{10 kg}
mm
13 16
13 16
Between compressor pulley fan pulley

Air compressor belt
Deflection under finger pressure of 59 N
tension
{6 kg}
mm
Approx. 10
Approx. 10
Engine
Valve clearance
Normal temperature
Compression
Compression pres- Engine oil temperature: pressure
sure
40 60C
Engine speed
Blow-by pressure

kPa
{mmH2O}
Torque converter: Stalled
SAE0W30EOS,
SAE5W40EOS,
High idle
SAE10W30DH,
Engine oil pressure
SAE15W40DH
SAE30DH Oil
Engine oil temperature: Low idle
Min. 80 C
Oil temperature
Whole speed range (In oil pan)
D275AX-5E0
SEN01413-00
Standard value table for machine
Machine model
Category
Item
Engine speed
Decelerator pedal
speed
Auto deceleration
speed
Torque converter
stall speed
Stroke of control lever/pedal
PCCS lever
Torque converter
stall + Work equipment relief speed
Torque converter oil temperature:
Hydraulic oil temperature:
Decelerator pedal speed: Press pedal.
Auto deceleration speed:
Set all equipment in neutral.
Torque converter stall speed: F3
Torque converter stall + Work equipment relief speed: F3 + Ripper RAISE
Stop engine.
Operation of lever knob
Steering
900 50
2,000 25
2,000 25
1,620 50
1,510
1,580 50
1,450
30 10
30 10
30 10
30 10
Neutral o Left
40 10
(Play: Max. 3)
40 10
(Play: Max. 3)
Neutral o
Right
40 10
(Play: Max. 3)
40 10
(Play: Max. 3)
47 5
47 5
75 8
75 8
61 10
61 10
60 10
(84 10)
60 10
(84 10)
53 10
53 10
85 10
85 10
85 10
85 10
56.9 6.9
{5.8 0.7}
56.9 6.9
{5.8 0.7}
51 6.9
{5.2 0.7}
51 6.9
{5.2 0.7}
25.5 4.9
{2.6 0.5}
25.5 4.9
{2.6 0.5}
28.4 4.9
{2.9 0.5}
28.4 4.9
{2.9 0.5}
Neutral o
Reverse
Stop engine.
Pressing pedal
Brake pedal
Engine: Low idle

Pressing pedal
Blade lever
Neutral
Engine: Low idle
Raise/Lower
Hydraulic oil tempera(Float)
range
Neutral
Operation of lever knob Left/Right tilt
PCCS lever
Steering
Standard value for

Service limit value
new machine
900 50
Decelerator pedal
Forward and
reverse
Unit
rpm
Neutral o
Forward
Forward and
reverse
Ripper lever
Operating effort of control lever/pedal
D275AX-5E0
mm
mm
All stroke
Stroke to 0 of
oil pressure
Neutral
Engine: Low idle
Raise/Lower
Hydraulic oil temperature: Within operating
Neutral
range
Forward/
Reverse tilt
mm
mm
mm
Neutral o
Forward/
Reverse
Forward/
Reverse o
Stop engine.
Neutral
Neutral o
Left
N
{kg}
Neutral o
Right
Decelerator pedal
Stop engine.
Pressing pedal
N
{kg}
49.0 9.8
{5.0 1.0}
49.0 9.8
{5.0 1.0}
Brake pedal
Engine: Low idle

Pressing pedal
N
{kg}
490.0 49.0
{50.0 5.0}
490.0 49.0
{50.0 5.0}
D275AX-5E0
SEN01413-00
Machine model
Operating effort of control lever/pedal
Category
Item
Blade lever
Ripper lever
Power train oil pressure
Torque converter
stator clutch
pressure
Transmission main
relief pressure
Transmission F
clutch pressure
Transmission R
clutch pressure
Transmission 1st
clutch pressure
Transmission 2nd
clutch pressure

temperature: Within
operating range

temperature: Within
operating range
Standard value for

Service limit value
new machine
39.2 9.8
{4.0 1.0}
77.6 13.9
{7.9 1.4}
77.6 13.9
{7.9 1.4}
29.4 9.8
{3.0 1.0}
29.4 9.8
{3.0 1.0}
24.5 9.8
{2.5 1.0}
24.5 9.8
{2.5 1.0}
24.5 9.8
{2.5 1.0}
24.5 9.8
{2.5 1.0}
Engine:
Low idle
Max. 0.2
{Max. 2}
Max. 0.2
{Max. 2}
Engine:
High idle
0.49 1.0
{5 10}
0.49 1.0
{5 10}
Engine:
Low idle
Max. 0.2
{Max. 2}
Max. 0.2
{Max. 2}
0.49 0.1
{5 1}
0.49 0.1
{5 1}
1.27 0.2
{13 2}
1.27 0.2
{13 2}
Engine:
High idle
1.27 0.2
{13 2}
1.27 0.2
{13 2}
Engine:
Low idle
2.65 0.2
{27 2}
2.65 0.2
{27 2}
Engine:
High idle
2.65 0.2
{27 2}
2.65 0.2
{27 2}
Engine:
Low idle
2.74 3.06
{28 31.2}
Min. 2.65
{Min. 27}
Engine:
High idle
3.04 3.30
{31 33.7}
Min. 2.94
{Min. 30}
Engine:
Low idle
2.84 3.14
{29 32}
Min. 2.65
{Min. 27}
Engine:
High idle
3.14 3.43
{32 35}
Min. 2.94
{Min. 30}
Engine:
Low idle
2.84 3.14
{29 32}
Min. 2.65
{Min. 27}
3.14 3.43
{32 35}
Min. 2.94
{Min. 30}
Engine:
Low idle
2.84 3.14
{29 32}
Min. 2.65
{Min. 27}
Engine:
High idle
3.14 3.43
{32 35}
Min. 2.94
{Min. 30}
Engine:
Low idle
2.84 3.14
{29 32}
Min. 2.65
{Min. 27}
Engine:
High idle
3.14 3.43
{32 35}
Min. 2.94
{Min. 30}
Neutral o
Engine: Low idle
Raise/Lower
range
Neutral o
Tilt in/out
Torque converter
outlet pressure
Unit
39.2 9.8
{4.0 1.0}
Neutral o
Engine: Low idle
Raise/Lower
Hydraulic oil temperaNeutral o
Float
range
Operation of lever knob Neutral o
Left/Right tilt
Torque converter
inlet pressure
Torque converter
lock-up clutch
pressure
D275AX-5E0
Engine:
High idle
Engine:
Low idle
N
{kg}
N
{kg}
MPa
{kg/cm2}
MPa
{kg/cm2}
Engine:
High idle
D275AX-5E0
SEN01413-00
Machine model
Category
Item
Power train oil pressure
Transmission 3rd
clutch pressure
Transmission lubricating oil pressure
(For reference)
Steering left brake
pressure

temperature: Within
operating range
Steering right brake

pressure
Performance of power train
HSS
pressure
Ripper pin puller

operating pressure
HSS main relief
pressure
HSS charge relief
pressure
Travel speed
D275AX-5E0
Unit
Engine:
Low idle
2.84 3.14
{29 32}
Min. 2.65
{Min. 27}
Engine:
High idle
3.14 3.43
{32 35}
Min. 2.94
{Min. 30}
Engine:
High idle
0.05 0.29
{0.5 3.0}
0.05 0.29
{0.5 3.0}
2.84 3.14
{29 32}
Min. 2.26
{Min. 23}
3.14 3.43
{32 35}
Min. 2.45
{Min. 25}
Engine:
Low idle
2.84 3.14
{29 32}
Min. 2.26
{Min. 23}
Engine:
High idle
3.14 3.43
{32 35}
Min. 2.45
{Min. 25}
Engine:
High idle
3.14 3.43
{32 35}
Min. 2.45
{Min. 25}
38.2 41.7
{390 425}
38.2 41.7
{390 425}
2.6 3.4
{27 35}
2.6 3.4
{27 35}
F1
3.5 0.2
3.5 0.2
F2
Lock-up
F3
switch:
OFF R1
R2
6.6 0.3
6.6 0.3
10.6 0.6
10.6 0.6
4.6 0.2
4.6 0.2
8.5 0.4
8.5 0.4
R3
14.3 0.7
14.3 0.7
F1
3.6 0.2
3.6 0.2
Engine:
Low idle
Engine:
High idle
MPa
{kg/cm2}

MPa
{kg/cm2}
Engine: High idle
Flat road
Engine coolant temperature: Within operating
range
temperature: Within
operating range
Engine: High idle
Run up distance:
10 30 m
Measuring distance:
20 m
F2
Lock-up
F3
switch:
ON R1
R2
km/h
km/h
R3
Work equipment oil pressure
Engine:
Low idle
Unload pressure
Blade lift relief

pressure
Blade tilt relief

pressure
D275AX-5E0

range
Unload pressure: Set all
equipment in neutral.
Relief pressure: Set cylinder to stroke end.
LS pressure: Set cylinder to stroke end.
Standard value for

Service limit value
new machine
6.7 0.3
6.7 0.3
11.2 0.6
11.2 0.6
4.7 0.2
4.7 0.2
8.7 0.4
8.7 0.4
14.9 0.7
14.9 0.7
+1.37
2.45 +0
Engine:
High idle
{25
+14
+0 }
+1.37
2.45 +0
{25
+14
+0 }
27.44 1.37
{280 14}
27.44 1.37
{280 14}
27.44 1.37
{280 14}
27.44 1.37
{280 14}
Engine:
Low idle
27.44 1.37
{280 14}
27.44 1.37
{280 14}
Engine:
High idle
27.44 1.37
{280 14}
27.44 1.37
{280 14}
Engine:
Low idle
Engine:
High idle
MPa
{kg/cm2}
SEN01413-00
Machine model
Category
Item
Ripper tilt relief

pressure
LS pressure
(Load sensing
pressure)

range
Unload pressure: Set all
equipment in neutral.
Relief pressure: Set cylinder to stroke end.
LS pressure: Set cylinder to stroke end.
Unit
Standard value for

Service limit value
new machine
Engine:
Low idle
27.44 1.37
{280 14}
27.44 1.37
{280 14}
Engine:
High idle
27.44 1.37
{280 14}
27.44 1.37
{280 14}
27.44 1.37
{280 14}
27.44 1.37
{280 14}
27.44 1.37
{280 14}
27.44 1.37
{280 14}
Engine:
Low idle
25.48 1.27
{260 13}
25.48 1.27
{260 13}
Engine:
High idle
25.48 1.27
{260 13}
25.48 1.27
{260 13}
3.43 +0.49
+0
+0.49
3.43 0.20
{35 +5
+0 }
+5
{35 2
}
3.14 3.92
{32 40}
3.14 3.92
{32 40}
Low idle
8 15
20
High idle
35
Low idle
1 1.5
High idle
1 1.5
Low idle
35
High idle
2.8 0.5
3.5
Low idle
35
High idle
2.8 0.5
3.5
Engine:
Low idle
Engine:
High idle
MPa
{kg/cm2}
Control circuit main

pressure
(HSS, PPC, fan)
MPa
{kg/cm2}
Engine: High idle
PPC valve output
pressure
Raise
Work equipment oil pressure
Ripper lift relief

pressure
D275AX-5E0
Left tilt
Lower
sec
Hydraulic oil temperature: 45 55C
Apply no load to blade.
Between ground level
and rising end of blade
Work equipment speed
Work equipment
Blade lift
Blade tilt
Between left tilt end and
right tilt end
Right tilt
sec
D275AX-5E0
SEN01413-00
Machine model
Category
Unit
Standard value for

Service limit value
new machine
Low idle
58
10
High idle
2.8 0.5
3.5
Low idle
58
10
High idle
2.8 0.5
3.5
Low idle
69
12
High idle
2.8 0.5
3.5
Low idle
58
10
High idle
2.8 0.5
3.5
Low idle
7 10
13
High idle
2.8 0.5
3.5
Low idle
3.3 4.3
High idle
3.5 0.5
4.5
Low idle
12 18
21
High idle
4.5 0.5
5.5
Low idle
8 14
17
High idle
3.5 0.5
4.5
Left tilt
Item
D275AX-5E0
sec
Forward

Between left tilt end and
right tilt end
Right tilt
Blade dual tilt
sec
Backward

Between forward end
and backward end
Raise

Apply no load to ripper.
Between ground level
and rising end of blade
sec
Tilt in
Ripper lift
Lower
Work equipment
Blade pitch
D275AX-5E0

Apply no load to ripper.
Between tilt-in end and
tilt-out end
sec
Tilt out
Ripper tilt
SEN01413-00
Machine model
Category
Item
Time lag
Blade
Ripper
D275AX-5E0
45 55C
Move lever to stroke end.
Lower blade from max. rising position and measure
time after blade comes in
contact with ground until
idler is lifted.
45 55C
Move lever to stroke end.
Lower ripper from max. rising position and measure
time after ripper comes in
contact with ground until
sprocket is lifted.
Unit
Standard value for

Service limit value
new machine
Low idle
Max. 8
11
High idle
Max. 1.8
2.5
Low idle
Max. 6
High idle
Max. 1.5
2.5
Max. 200/15
minutes
300/15 minutes
Max. 50/5 minutes
100/15 minutes
Max. 50/5 minutes
100/15 minutes
sec
Hydraulic drift
of lifted blade
Hydraulic drift
Work equipment

Engine: Stopped
Measure reduction of blade bottom
height h (for 15 minutes).
Hydraulic drift
of machine
lifted by blade
mm

Engine: Stopped
Measure reduction of idler center height
h (for 5 minutes).
Hydraulic drift
of machine
tilted by blade
Engine: Stopped
Measure reduction of idler center height
h (for 5 minutes).
D275AX-5E0
SEN01413-00
Machine model
Category
Item
D275AX-5E0
Unit

Engine: Stopped
Measure reduction of shank bottom
Hydraulic drift
Work equipment
Hydraulic drift
of lifted ripper
Standard value for

Service limit value
new machine
Max. 80/15
minutes
160/15 minutes
Max. 30/5 minutes
60/5 minutes
16
16
16
450 30
400
1,450 50
1,350
16.17 19.11
{165 195}
16.17 19.11
{165 195}
mm
Hydraulic drift
of machine
lifted by ripper
Cooling fan
Leakage from cylinder

Engine: Stopped
Measure reduction of sprocket center
Blade tilt
cylinder
Ripper lift
cylinder
Ripper tilt
cylinder
Fan speed
Fan pump oil

pressure
D275AX-5E0
Engine: High idle

Relieve cylinder and measure leakage
for 1 minute.
Fan: 100% speed mode

Engine: Low idle
Min.
speed

Engine: High idle
Max.
speed

Engine: High idle
cc/min
rpm
MPa
{kg/cm2}
SEN01413-00
10
D275AX-5E0
SEN01414-00
BULLDOZER
1SHOP MANUAL
D275AX-5E0
Machine model
Serial number
D275AX-5E0
30001 and up

Tools for testing, adjusting, and troubleshooting............................................................................................. 3
Testing engine speed ...................................................................................................................................... 6
Testing intake air pressure (Boost pressure) .................................................................................................. 9
Testing exhaust temperature..........................................................................................................................11
Testing exhaust gas color ............................................................................................................................. 13
Adjusting valve clearance ............................................................................................................................. 15
Testing compression pressure ...................................................................................................................... 17
Testing blow-by pressure .............................................................................................................................. 19
Testing engine oil pressure ........................................................................................................................... 20
Handling of fuel system devices ................................................................................................................... 21
Releasing residual pressure from fuel system .............................................................................................. 21
Testing fuel pressure..................................................................................................................................... 22
Testing fuel return rate and fuel leakage....................................................................................................... 23
Bleeding air from fuel circuit.......................................................................................................................... 27
Testing fuel circuit for leakage....................................................................................................................... 29
Testing and adjusting alternator belt tension................................................................................................. 30
D275AX-5E0
SEN01414-00
Testing and adjusting air conditioner compressor belt .................................................................................. 31

Testing fan speed .......................................................................................................................................... 32
Testing fan circuit oil pressure....................................................................................................................... 33
Bleeding air from fan pump ........................................................................................................................... 34
Adjusting fuel control dial and decelerator pedal .......................................................................................... 35
D275AX-5E0
SEN01414-00
Testing and adjusting item
Symbol
Testing intake air

pressure (boost pressure)
Testing exhaust
temperature
Testing exhaust gas color
799-201-2202 Boost gauge kit
Commercially
Thickness gauge
available
E
2
F
101 200 kPa

{760 1,500 mmHg}
1 99.9 1,299C
1 For Pm clinic specification
1 Pollution level: 0 70%
(With standard color)
1 (Pollution level x 1/10 C Bosch index)
1
799-101-5002 Hydraulic tester
790-261-1204 Digital hydraulic tester
2 799-401-2320 Hydraulic tester

3
1
2
3
Testing fuel return rate
and fuel leakage
J 4
5
6
Testing fan speed
795-471-1450
07005-00812
6151-51-8490
6206-71-1770
Commercially
available
Commercially
available
Commercially
available
1
8 1.25 mm o R1/8
1
1 Inside diameter: 14 mm
1 Inside diameter of joint: 10 mm
Hose
1 5 mm 2 3 m
Hose
1 15 mm 2 3 m
Measuring cylinder
Commercially
Stopwatch
available
795-205-1100 Tachometer kit
1 6.0 99999.9 rpm

2 799-401-3400 Adapter
799-101-5220 Nipple
3
07002-11023 O-ring
D275AX-5E0
Pressure gauge:
2.5, 5.9, 39.2, 58.8 MPa
{25, 60, 400, 600 kg/cm2}
Pressure gauge: 58.8 MPa
{600 kg/cm2}
{10 kg/cm2}
Pressure gauge:
2.5, 5.9, 39.2, 58.8 MPa
{25, 60, 400, 600 kg/cm2}
{600 kg/cm2}
{10 kg/cm2}
Adapter
Gasket
Spacer
Joint
1
Testing fan circuit
pressure
Air intake: 0.35 mm,

Exhaust: 0.57 mm
795-471-1330 Adapter
6261-71-6150 Gasket
799-201-1504 Blow-by checker
1
Testing fuel pressure
Remarks
1
G
2
1 0 6.9 MPa {0 70 kg/cm }
KIT No.: 795-502-1205
1
1
1
1 795-502-1590 Compression gauge
Testing blow-by pressure
Testing engine oil

pressure
Part name
B
799-101-1502 Digital thermometer
799-201-1150 Adapter connector

1 799-201-9001 Handy smoke checker
C
Commercially
2
Smoke meter
available
Adjusting valve clearance
Testing compression
pressure
Part No.
Q'ty
Tools for testing, adjusting, and troubleshooting
1
Pressure gauge:
2.5, 5.9, 39.2, 58.8 MPa
{25, 60, 400, 600 kg/cm2}
1
{600 kg/cm2}
1 Size: 05
1 Size: 10 1.25 mm
Symbol
Part No.
Part name
799-101-5220 Nipple
07002-11023 O-ring
1

3
799-101-5220 Nipple
07002-11023 O-ring
Testing and adjusting HSS

P
oil pressure
1
799-101-5220
07002-11023
19M-06-32820
1 7824-66-6430
Emergency escape when
Q
power train has trouble
17M-06-41530
2 790-190-1600
2
Nipple
O-ring
Switch assembly
Resistor
Wiring harness
Pump assembly

Testing and adjusting work
R
equipment oil pressure
1
2
1
Testing control circuit
basic pressure
S
2
Testing ripper pin puller

solenoid valve outlet
pressure
1 Size: 02
Pressure gauge:
2.5, 5.9, 39.2, 58.8 MPa
{25, 60, 400, 600 kg/cm2}
1
{600 kg/cm2}
Oil pressure pickup

adapter
02896-11008 O-ring
Oil pressure pickup
799-401-3200
adapter
3
02896-11009 O-ring
799-401-3100
1
U
2
Pressure gauge:
2.5, 5.9, 39.2, 58.8 MPa
{25, 60, 400, 600 kg/cm2}
1
{600 kg/cm2}

T
Oil pressure pickup

adapter
02896-11008 O-ring
799-401-3100
1
Testing PPC valve output
pressure
Remarks
Pressure gauge:
2.5, 5.9, 39.2, 58.8 MPa
{25, 60, 400, 600 kg/cm2}
1
{600 kg/cm2}
1
{10 kg/cm2}
1 Size: 10 1.25 mm
1
Pressure gauge:
2.5, 5.9, 39.2, 58.8 MPa
1
{25, 60, 400, 600 kg/cm2}
1
{600 kg/cm2}
1 Size: 10 1.25 mm
1
1
1
1
1
Pressure gauge:
2.5, 5.9, 39.2, 58.8 MPa
1
{25, 60, 400, 600 kg/cm2}
1
{600 kg/cm2}
1 Size: 10 1.25 mm
1
Testing power train oil

pressure
Q'ty
SEN01414-00
Oil pressure pickup

adapter
02896-11009 O-ring
799-401-3200
1 Size: 02
1
1 Size: 03
Pressure gauge:
2.5, 5.9, 39.2, 58.8 MPa
{25, 60, 400, 600 kg/cm2}
1
{600 kg/cm2}
1 Size: 03
1
D275AX-5E0
Testing leakage in work

equipment cylinder
Testing coolant
temperature and oil
temperature
Testing operating effort
and pressing force
Testing stroke and
hydraulic drift
Testing work equipment
speed
Testing voltage and
resistance
Symbol
Part name
Q'ty
SEN01414-00
Commercially
Measuring cylinder
available
799-101-1502 Digital thermometer
1 99.9 1,299C
79A-264-0021
79A-264-0091
Commercially
available
Commercially
available
Push-pull scale
Push-pull scale
1 0 294 N {0 30 kg}
1 0 490 N {0 50 kg}
Ruler
Stopwatch
Part No.
Commercially
Circuit tester
available
Remarks
For the model names and part Nos. of the T-boxes and T-adapters used for troubleshooting for the
machine monitor, controllers, sensors, actuators, electrical equipment, and wiring harnesses, see Troubleshooting (Information related to troubleshooting), "List of T-boxes and T-adapters".
D275AX-5E0
SEN01414-00
Testing engine speed

k
1.
2.
3.
Testing high idle speed

1) Start the engine and set the fuel control
dial in the high idle position.
2) Set the PCCS lever and work equipment
control lever in neutral and test the engine
speed.
a The high idle speed tested in the "Monitoring mode" or in the "Pm Clinic auxiliary
mode" is the auto-deceleration speed.
a When testing the high idle speed of the
engine, use the "Adjustment mode".
Adjustment code:
0007 (Engine decelerator cut mode)
4.
Testing decelerator pedal speed

dial in the high idle position.
control lever in neutral and press the
decelerator pedal and test the engine
speed.
Stop the machine on level ground, lower

the work equipment to the ground, stop the
engine, and set the parking brake lever and
work equipment lock lever in the lock position.
Test the engine speed under the following condition.
q
q
q
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)
Testing low idle speed

dial in the low idle position.
control lever in neutral and test the engine
speed.
D275AX-5E0
5.
Testing torque converter stall speed

q
Adjustment mode:
0530 (Stall speed check mode)
k This machine is equipped with the
cooling fan speed control function to
protect the radiator when the engine is
not fully warmed up. Since that function does not work while this mode is
used, warm up the engine fully before
using this mode.
2) With the brake pedal depressed securely
and the parking brake lever in the free
position, set the PCCS lever in the forward and 3rd gear speed position.
a Before going to the next step, check
that the upper display unit of the monitor panel is set in the normal display
state and it displays [F3].
a Keep the steering unit in neutral.
3) Press the decelerator pedal and set the
fuel control dial in the high idle position.
4) Return the decelerator pedal slowly to stall
the torque converter with the engine at
high idle.
k Keep pressing the brake pedal
securely and keep your right foot
on the decelerator pedal for safety
until the work is finished.
5) Just after the power train oil temperature
gauge reaches position (a) of the green
range, return the direction of the PCCS
lever into neutral.
6)
7)
SEN01414-00
a
6.
After finishing measurement, finish

the Adjustment mode.
Measuring torque converter stall + work

equipment relief speed (full stall speed)
q
Adjustment mode:
k This machine is equipped with the
cooling fan speed control function to
protect the radiator when the engine is
not fully warmed up. Since that function does not work while this mode is
used, warm up the engine fully before
using this mode.
2) With the brake pedal depressed securely
and the parking brake lever in the free
position, set the PCCS lever in the forward and 3rd gear speed position.
a Before going to the next step, check
that the upper display unit of the monitor panel is set in the normal display
state and it displays [F3].
a Keep the steering unit in neutral.
3) Press the decelerator pedal and set the
fuel control dial in the high idle position.
4) Return the decelerator pedal slowly to stall
the torque converter with the engine at
high idle.
k Keep pressing the brake pedal
5) Operate the ripper lever to raise the ripper
lift cylinder to the stroke end or pitch back
stroke end.
6) Just after the power train oil temperature
gauge reaches position (a) of the green
range, return the direction of the PCCS
lever into neutral.
Repeat above steps 2) 5) 3 times.

Perform steps 2) 4) again and measure
the engine speed when the power train oil
temperature gauge reaches position (a) of
the green range.
a After finishing measurement, return
the direction of the PCCS lever into
neutral and lower the power train oil
temperature with the engine at high
idle.
D275AX-5E0
SEN01414-00
7)
8)
Repeat above steps 2) 6) 3 times.

Perform steps 2) 4) and also operate ripper RAISE relief and pitch back relief and
measure the engine speed when the
power train oil temperature gauge reaches
position (a) of the green range.
a After finishing measurement, return
the direction of the PCCS lever into
neutral and lower the power train oil
temperature with the engine at high
idle.
a After finishing measurement, finish
the Adjustment mode.

a
The engine speed can be tested in the "Pm

Clinic auxiliary mode" of the machine monitor
(Test the high idle speed of the engine in the
"Adjustment mode", however).
D275AX-5E0
SEN01414-00
Testing intake air pressure (Boost

pressure)
1
a
Install nipple [1] of boost gauge kit A and connect gauge [2].
4.
Run the engine at medium or higher speed and

drain the oil from the hose.
a Insert the joint of the gauge and hose halfway and open the self-seal on the hose
side repeatedly, and the oil is drained.
a If Pm kit (A) is available, the air bleeding
coupling (790-261-1130) in it may be
used.
a If any oil is left in the hose, the gauge does
not move. Accordingly, be sure to drain
the oil.
5.
Run the engine at high idle and stall the torque

converter and test the intake air pressure
(boost pressure) at this time.
a For the procedure for stalling the torque
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 converter.
6.
After finishing test, remove the testing instrument and return the removed parts.
Testing instruments for intake air pressure

(boost pressure)
Symbol
Part No.
799-201-2202
a
k
3.
Part name
Boost gauge kit
A nipple (quick coupler) is installed to the

intake air pressure (boost pressure) testing
port of the Pm clinic specification machine.
When installing and removing the testing
instrument, take care not to touch a hot
part.
Test the intake air pressure (boost pressure)
under the following condition.
q
q
q
1.
Open the right side cover of the engine.
2.
Remove boost pressure testing plug (1).
D275AX-5E0
SEN01414-00
a
The boost pressure can be tested in the "Pm

Clinic auxiliary mode" of the machine monitor.
The boost pressure displayed in the Pm clinic

auxiliary mode is absolute pressure.
10
D275AX-5E0
SEN01414-00
Testing exhaust temperature

a
3.
Install sensor [1] of digital thermometer B and

connect them to meter [2].
a Clamp the wiring harness of the digital
thermometer so that it will not touch a hot
part during measurement.
4.
Procedure for testing maximum exhaust temperature for troubleshooting

Operate the machine actually and measure the
maximum exhaust temperature.
a Use the PEAK mode of the digital thermometer.
a The exhaust temperature largely depends
on the outside air temperature (intake air
temperature of the engine). Accordingly, if
any abnormal value is obtained, correct it
by the following calculation.
q
Corrected value [C] = Measured value
+ 2 x (20 Outside air temperature)
Testing instrument for exhaust temperature
Symbol
Part No.
799-101-1502
Part name
Digital thermometer
Testing instruments for exhaust temperature

(Pm clinic specification)
An exhaust temperature sensor is installed to
the Pm clinic specification machine. Accordingly, prepare an adapter connector to connect
the exhaust temperature sensor to a digital
thermometer.
Symbol
Part No.
799-101-1502
Digital thermometer
799-201-1150
Adapter connector
Part name

Install and remove the testing instrument
after the exhaust manifold is cooled.
Test the exhaust temperature under the following condition.
q
q
q
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.
D275AX-5E0
11
SEN01414-00
5.
12
Procedure for measuring exhaust temperature

periodically for preventive maintenance (Pm
clinic)
a If the torque converter is stalled simply,
the torque converter oil temperature is
overheated before the exhaust temperature is stabilized. Accordingly, test according to the following procedure.
1) Stall the torque converter fully to raise the
exhaust temperature to about 650C
according to the following procedure
(Condition a in the figure).
i) Start the engine and set the fuel control dial to the low idle position. 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 decelerator pedal for safety until the work
is finished.
2) Stop only relieving the ripper and lower
the exhaust temperature by only stalling
the torque converter (Condition b in the
figure).
a If the temperature does not lower but
rises, set the temperature in step 1).
3) After the temperature lowers and is stabilized, measure it (Condition c in the figure).

k
6.
Just after the torque converter oil temperature gauge reads the red range,
return the direction of the PCCS lever
into neutral and lower the torque converter oil temperature.
D275AX-5E0
SEN01414-00
Testing exhaust gas color

a
Testing instrument for exhaust gas color
Symbol
C
k
1.
Part No.
Part name
799-201-9001
Handy smoke checker
Commercially
available
Smoke meter

When installing and removing the testing
instrument, take care not to touch a hot
part.
If an air source and a electric power source are
not available in the field, use handy smoke
checker C1. When recording official data, use
smoke meter C2.
Test the exhaust gas color under the following
condition.
q
Measuring with handy smoke checker C1
1) Stock a sheet of filter paper to C1.
2) Insert the exhaust gas intake pipe in the
exhaust pipe.
3) Start the engine.
4) Accelerate the engine suddenly or run it at
high idle and operate the handle of smoke
checker C1 so that the filter paper will
absorb the exhaust gas.
5)
6)
2.
Testing with smoke meter C2

1) Insert probe [1] of smoke meter C2 in the
outlet of the exhaust pipe and fix it to the
exhaust pipe with a clip.
2)
3)
4)
5)
Connect the probe hose, receptacle of the

accelerator switch, and air hose to smoke
meter C2.
a Limit the supplied air pressure to 1.5
MPa {15kg/cm2}.
Connect the power cable to a receptacle
of AC power supply.
a Before connecting the cable, check
that the power switch of the smoke
meter is turned off.
Before connecting the cable, check that
the power switch of the smoke meter is
turned off.
a Fit the filter paper securely so that the
exhaust gas will not leak.
Turn on the power switch of smoke meter
C2.
Remove the filter paper and compare it

with the attached scale.
After finishing test, remove the testing
instrument and return the removed parts.
D275AX-5E0
13
SEN01414-00
6)
7)
8)
9)
14
Start the engine.

Accelerate the engine suddenly or run it at
high idle and press the accelerator pedal
of smoke meter C2 and collect the
exhaust gas into the filter paper.
Place the contaminated filter paper on the
clean filter paper (at least 10 sheets) in the
filter paper holder and read the indicated
value.
D275AX-5E0
SEN01414-00
Adjusting valve clearance

a
Adjusting instrument for valve clearance
Symbol
Part No.
Commercially
available
1.
2.
3.
Part name
Thickness gauge
When the No. 1 cylinder piston is at the

compression top dead center, the No. 1
cylinder rocker arm can be moved with the
hand by the valve clearance. If the rocker
arm does not move, the piston is not at the
compression top dead center. In this case,
revolve the crankshaft 1 more turn.

Open the inspection cover under the universal
joint (1) and disconnect universal joint (1) from
the engine.
4.
While fixing adjustment screw (6), loosen locknut (7).

a After setting the No. 1 cylinder to the compression 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
screw (6).
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.
Open the right side cover of the engine and

remove all cylinder head covers (2).
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.
D275AX-5E0
15
SEN01414-00
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}
16
D275AX-5E0
SEN01414-00
Testing compression pressure

a
Testing tools for compression pressure
Symbol
1
E
k
1.
Part No.
Part name
795-502-1590
Compression gauge
795-471-1310
Adapter
6261-71-6150
Gasket
Disconnect the terminal of the injector wiring harness on the injector side and the
bracket on the rocker housing side and
remove the injector wiring harness
(Loosen the 2 terminal nuts alternately).
Pass a wire under the fuel path projected
sideways and pull up the injector (Do not
pry the injector top up).

When testing the compression pressure,
take care not to burn yourself on the
exhaust manifold, muffler, etc. or get
caught in a rotating part.
Test the compression pressure under the following conditions.
q
Engine oil temperature: 40 60 C
Remove the engine hood assembly and air
cleaner together.
4
2.
5.
Install adapter E2 to the mounting hole on the

injector and connect compression gauge E1.
a Be sure to fit the gasket to the injector
end.
a Fix the adapter with the injector holder.
3 Holder mounting bolt:
58.8 73.5 Nm {6.0 7.5 kgm}
a Apply a little amount of engine oil to the
connecting parts of the adapter and gauge
so that air will not leak easily.
6.
Install rocker arm assembly (2) and adjust the

valve clearance.
3 Rocker arm mounting bolt:
93 103 Nm {9.5 10.5 kgm}
a See "Adjusting valve clearance".
Engine hood assembly: 170 kg
Remove cylinder head cover (1) of the cylinder

to test the compression pressure.
3.
Bring the cylinder to be tested to the compression top dead center and remove rocker arm
assembly (2).
a For the procedure for bringing each cylinder to the compression top dead center,
see "Adjusting valve clearance".
4.
Disconnect fuel high-pressure tube (3) and

injector wiring harness (4) and remove injector
(5) and wiring harness.
D275AX-5E0
17
SEN01414-00
7.
8.
Disconnect power supply connector EGC3 (6)

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 communication etc.

machine monitor to real-time monitoring mode
of the service mode.
q
Monitoring code: 01000 Engine Speed
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.
10. After finishing test, remove the testing instruments and return the removed parts.
a Install the injector and fuel high-pressure
tube according to the following procedure.
a Before installing the injector, replace the
copper gasket and O-ring with new ones.
1) Push in injector (11) with the hand to
assemble holder (12) temporarily.
2) Tighten bolt (13) and washer (14) temporarily.
2 Spherical part of washer:
Engine oil
3) Tighten sleeve nut (15) of the fuel highpressure tube temporarily.
4) Tighten bolt (13) permanently.
3 Bolt: 58.8 73.5 Nm {6 7.5 kgm}
5) Tighten sleeve nut (15) permanently.
3 Sleeve nut:
39.2 49.0 Nm {4 5 kgm}
a
1)
2)
3)
4)
18
Install the injector wiring harness according to the following procedure.

Install the injector wiring harness to the
rocker arm housing and fix the connector
side with the plate.
Fix the intermediate clamp with the clip.
Tighten the nut on the injector side.
3 Nut: 2 0.2 Nm {0.2 0.02 kgm}
Secure the clamp and spacer with the
bolt.
3 Rocker arm assembly mounting
bolt: 93 103 Nm {9.5 10.5 kgm}
Adjust the valve clearance. For details,
see "Adjusting valve clearance".
3 Cylinder head cover mounting bolt:
29.4 34.3 kgm {3.0 3.5 kgm}
D275AX-5E0
SEN01414-00
Testing blow-by pressure

a
Testing instrument for blow-by pressure
Symbol
Part No.
799-201-1504
Part name
Blow-by checker

Test the blow-by pressure under the following
condition.
q
q
q
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.
D275AX-5E0
5.
The blow-by pressure may vary largely

with the engine condition. If the measured
value is judged abnormal, check for
increase of oil consumption, bad exhaust
gas color, deterioration of oil, high deterioration speed of oil, etc. which are related
to the abnormal blow-by pressure.
19
SEN01414-00
Testing engine oil pressure

a
1
2
a
a
Part No.
Run the engine at low idle and high idle and

measure the engine oil pressure in each
speed.
4.
After finishing test, remove the testing instruments and return the removed parts.
Part name
799-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
799-401-2320
Hydraulic tester

engine oil pressure switch mounting part of the
Pm clinic specification machine.
Measure the engine oil pressure under the following condition.
q
1.
Open the engine left side cover and remove

engine oil pressure pickup plug (1) from the
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].
20
3.
Testing instruments for engine oil pressure
Symbol
G
D275AX-5E0
Handling of fuel system devices 1

a
Precautions for testing and adjusting fuel system

The common rail fuel injection system (CRI)
consists of more precise parts than the conventional fuel injection pump and nozzle. If foreign matter enters this system, it can cause a
trouble.
When testing and adjusting the fuel system,
take care more than the past. If dust, etc. sticks
to any part, wash that part thoroughly with
clean fuel.
Precautions for replacing fuel filter capacitor
Be sure to use Komatsu genuine fuel filter cartridge.
Since the common rail fuel injection system
(CRI) consists of more precise parts than the
conventional fuel injection pump and nozzle, it
employs a high-efficiency special filter to prevent foreign matter from entering it.
If a filter other than the genuine one is used,
the fuel system may have a trouble. Accordingly, never use such a filter.
D275AX-5E0
SEN01414-00
Releasing residual pressure from

fuel system
1
a
Pressure is generated in the low-pressure circuit and high-pressure circuit of the fuel system while the engine is running.
Low-pressure circuit:
Feed pump Fuel filter Fuel supply pump
High-pressure circuit:
Fuel supply pump Common rail Fuel
injector
The pressure in both low-pressure circuit and
high-pressure circuit lowers to a safety level
automatically 30 seconds after the engine is
stopped.
Before the fuel circuit is tested and its parts are
removed, the residual pressure in the fuel circuit must be released completely. Accordingly,
observe the following.
Before testing the fuel system or removing
its parts, wait at least 30 seconds after stopping the engine until the residual pressure
in the fuel circuit is released. (Do not start
the work just after stopping the engine
since there is residual pressure.)
21
SEN01414-00
Testing fuel pressure

a
1
2
3
k
a
k
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
799-401-2320
Hydraulic tester
795-471-1450
Adapter
07005-00812
Gasket

Test only the fuel pressure in the low-pressure
circuit from the feed pump through the fuel filter to the supply pump.
Since the pressure in the high-pressure circuit from the supply pump through the
common rail to the injector is very high, it
cannot be tested.
1.
Open the engine left side cover and remove

fuel pressure pickup plug (1) from the top of
the fuel filter.
2.
Install adapter H3 and elbow [1] and nipple [2]

of hydraulic tester H1 and connect them to
hydraulic tester H2.
22
3.
Testing instruments for fuel pressure
Symbol
4.
Run the engine at high idle and test the fuel

pressure.
a If the fuel pressure is in the following
range, it is normal.
Engine speed
Fuel pressure
High idle
0.15 0.3 MPa

{1.5 3 kg/cm}
3 Plug (1): 7.84 9.8 Nm {0.8 1.0 kgm}
D275AX-5E0
SEN01414-00
Testing fuel return rate and fuel leakage
Testing instruments for return rate and fuel

leakage
Symbol
a
k
Part No.
Part name
6151-51-8490
Spacer
6206-71-1770
Joint
Commercially available Hose
Commercially available Hose
Commercially available Measuring cylinder
Commercially available Stopwatch
Prepare an oil pan of about 20 l to receive the

fuel flowing out during the test.
D275AX-5E0
23
SEN01414-00
1.
Preparation work
1) Open the engine left side cover and left
mudguard.
2) Remove tube (3) between supply pump
(1) and common rail (2).
a In the figure, 1 oil filter is removed
temporarily from the common rail
side.
a Disconnect both ends of the tube,
loosen the clamp, and move the tube
to the opposite side of the cylinder
block.
5)
2.
24
3)
Insert spacer J1 on supply pump (1) side

and tighten the removed joint bolt again.
a Connect the return pipe to the fuel
tank again, too.
a Be sure to fit the gaskets to both ends
of the spacer.
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
temporarily from the common rail
side.
a Be sure to fit the gaskets to both ends
of the joint.
Connect test hose J3 to the end of joint

J2.
a Bind the connecting part of the test
hose with a wire, etc. to prevent it
from coming off.
a The above is the preparation work for
testing the leakage from the pressure
limiter.
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.
k If it is not, the radiator may be broken.
3) Turn the starting switch ON and set the
machine monitor to Monitoring function of
the service mode.
q
Adjustment code:
a For the operating method, see "Special functions of machine monitor
(EMMS)".
4)
Run the engine at high idle and stall the

torque converter. After the engine speed
is stabilized, measure the leakage in 1
minute with measuring cylinder J5.
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 seconds and judge by multiplying the
result by 3.
D275AX-5E0

a
If the leakage from the pressure limiter is in the following range, it is normal.
Engine speed
Install torque
converter
5)
3.
SEN01414-00
4)
Turn the starting switch ON set the

machine monitor to Adjusting function of
the service mode.
q
Adjustment code:
a For the operating method, see "Special functions of machine monitor
(EMMS)".
5)
Run the engine at high idle and stall the

torque converter. After the engine speed
is stabilized, measure the return rate in 1
minute with measuring cylinder J5.
a For the procedure for stalling the
torque converter, see "Testing engine
speed".
a You may measure the return rate for
20 seconds and judge by multiplying
the result by 3.
a If the supply pump is not supplying
fuel, the engine speed may not rise.
In this case, record the engine speed,
too, during the test.
a If the return rate (spill) from the injector is in the following range, it is normal.
Leakage
(cc/min)
Max. 10
After finishing test, stop the engine.
Testing return rate from injector

a Keep the hose on the pressure limiter side
connected and keep its end in the oil pan
while testing the return rate from the injector.
1) Disconnect return hose (5) of return block
(4) and connect test hose J4.
a Stop the return hose with a plug, etc.
and fix it to the fuel tank.
Plug: 07376-70315
a Bind the connecting part of the test
hose with a wire, etc. to prevent it
from coming off.
2) Lay test hose J4 so that it will not slacken
and put its end in the oil pan.
Torque converter
stall speed (rpm)
3)
Limit of return rate

(spill) (cc/min)
1,600
960
1,700
1,020
1,800
1,080
1,900
1,140
2,000
1.200
Warm up the machine sufficiently.

If it is not, the radiator may be broken.
D275AX-5E0
25
SEN01414-00
6)
4.
26
After finishing testing, stop the engine.
Work after finishing testing

After finishing all testing, remove the testing
instruments and return the removed parts.
D275AX-5E0
SEN01414-00
Bleeding air from fuel circuit
If fuel is used up or if a fuel circuit part is removed and installed, bleed air from the fuel circuit according to the following procedure.
1.
Open the engine left side cover.
2.
Remove fuel prefilter (1) and fill it with fuel.

a Fill the fuel prefilter with clean fuel and
take care that dirt will not enter it.
a Check that the cap is fitted to part (a)
(central hole) of the fuel prefilter, and then
add fuel through part (b) (holes around the
central hole).
a After filling the fuel prefilter with fuel,
remove the cap from part (a).
a If clean fuel is not available, do not
remove the prefilter but fill it with the fuel
by operating priming pump (4).
a Do not add fuel to fuel main filter (2) from
outside.
D275AX-5E0
3.
Install fuel prefilter (1) to the filter head.

a Apply engine oil thinly over the packing on
the fuel prefilter side.
a After the packing of the fuel prefilter
touches the sealing face of the filter head,
tighten the fuel prefilter 3/4 turns.
27
SEN01414-00
7.
4.
Remove air bleed plug (3) of fuel main filter (2)

and operate priming pump (4).
a Operate the priming pump until the fuel
flows out of the plug hole and install the
plug.
3 Air bleed plug:
7.8 9.8 Nm {0.8 1.0 kgm}
5.
Remove air bleed plug (5) of the fuel main filter

and operate priming pump (4).
flows out of the plug hole and install the
plug.
3 Air bleed plug:
7.8 9.8 Nm {0.8 1.0 kgm}
6.
Loosen air bleeder (6) of the supply pump and

operate priming pump (4) 90 100 times.
flows out of the air bleeder and tighten the
air bleeder. Then, operate the priming
pump several times more until it becomes
heavy.
a Air bleeder: 4.9 6.9 kgm {0.5 0.7 kgm}
28
Start the engine with the starting motor.

a The air in the high-pressure circuit is bled
automatically if the engine is cranked.
a If the engine does not start, there may be
still air in the low-pressure circuit. In this
case, repeat the above procedure from
step 4.
D275AX-5E0
Testing fuel circuit for leakage

k
a
a
SEN01414-00
Very high pressure is generated in the highpressure circuit of the fuel system. If fuel
leaks while the engine is running, it is dangerous since it can catch fire.
After testing the fuel system or removing and
installing its parts, test it for fuel leakage
according to the following procedure.
Clean and degrease the engine and the parts
around it in advance so that you can test it easily 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 leakage.

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.
5.

for fuel leakage.
6.
Run the engine at high idle.
7.

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

a Relieve the ripper circuit by raising the ripper.
D275AX-5E0
9.

for fuel leakage.
a If no fuel leakage is detected, inspection is
completed.
29
SEN01414-00
Testing and adjusting alternator

belt tension
1
k
6.
Install belt cover (1) with the 2 mounting bolts.

a Check for breakage of the pulleys, wear of
the V-grooves, contact of the belts and Vgrooves, and contact of the belt covers
and rotating parts.
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.
a After tightening the bolts, check that the
belt tension is normal according to the
above procedure.
7.
After testing and adjusting, return the removed

parts.

Testing
1. Open the engine right side cover and remove
the inspection plate on the right of the radiator
guard.
2.
Press the intermediate point of the belt

between alternator pulley and water pump pulley 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
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 replacing 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).
30
D275AX-5E0
Testing and adjusting air

conditioner compressor belt
k
SEN01414-00
a

After tightening the bolts, check that the

belt tension is normal according to the
above procedure.
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}
a Deflection (a): 10 mm
5.
After testing and adjusting, return the removed

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 compressor (5) and bracket as a unit with adjustment nut (4) to adjust the belt tension.
3.
While fixing adjustment nut (4), tighten locknuts (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.
D275AX-5E0
31
SEN01414-00
Testing fan speed

a
5.
Start the engine and set the machine monitor

to Adjusting function of the service mode.
a Adjustment code: 1005 (Fan 100% mode)
a If this adjustment code is displayed, the
fan speed is kept at 100% speed in accordance with the engine speed, regardless
of the state of the machine.
6.
While running the engine at low idle and high

idle, test the fan speed
7.
Testing instrument for fan speed
Symbol
Part No.
795-205-1100
Part name
Tachometer kit

Test the fan motor speed under the following
condition.
q
Hydraulic oil temperature: Within operating range
q
Engine coolant temperature: Within operating range
q
Power train oil temperature: Within operating range
k Warm up the machine sufficiently to
prevent breakage of the radiator.
1.
Open the radiator mask and remove the fan

net.
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
a
a
4.
32
Take care that the probe will not interfere with the fan.
Rotate the fan with the hand and check
that the probe can sense the rotation of
the reflection tape.
Set probe [1] 100 200 mm apart from the
fan to stabilize the measured value.
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.
D275AX-5E0
SEN01414-00
Testing fan circuit oil pressure

a
Testing instruments for fan circuit oil pressure
Symbol
1
L
2
3
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
799-401-3400
Adapter (05)
799-101-5220
Nipple (10 x 1.25 mm)
07002-11023
O-ring

Test the fan circuit oil pressure under the following condition.
q
Hydraulic oil temperature: Within operating range
q
Engine coolant temperature: Within operating range
q
Power train oil temperature: Within operating range
k Warm up the machine sufficiently to
prevent breakage of the radiator.
1.
Open the radiator mask and remove the fan

net.
2.
Disconnect supply hose (1) of the fan motor.
3.
Install adapter L2 and connect the disconnected 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/cm}.
D275AX-5E0
5.
6.
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.
Start the engine and set the machine monitor

to Adjusting function of the service mode.
a Adjustment code: 1005 (Fan 100% mode)
a If this adjustment code is displayed, the
fan speed is kept at 100% speed in accordance with the engine speed, regardless
of the state of the machine.
33
SEN01414-00
7.
While running the engine at high idle, test the

fan circuit oil pressure.
Bleeding air from fan pump

a
8.
34
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
Before starting the following work, check that
the hydraulic oil level is normal.
1.
Remove the floor inspection cover.
2.
Loosen air bleeder (1) and leave it for 15 minutes.
3.
After 15 minutes, start the engine and run it at

low idle.
4.
After oil flows out of air bleeder (1), tighten air

bleeder (1) and stop the engine.
3 Air bleeder:
7.8 9.8 Nm {0.8 1.0 kgm}
D275AX-5E0
SEN01414-00
Adjusting fuel control dial and decelerator pedal
1.

Outline of fuel control system
q
The following signals are inputted as rotation command signals to the engine controller.
q
Decelerator pedal potentiometer signal
q
3rd throttle signal
The engine controller controls the fuel
control system of the engine (CRI system)
according to the lowest engine speed signal among those input signals.
q
Adjust the deceleration slow speed by
adjusting the decelerator pedal linkage.
D275AX-5E0
[1] Fuel control dial (2nd throttle signal)

[2] Engine controller
[3] Steering controller
[4] Decelerator pedal (1st throttle signal)
[5] Decelerator potentiometer
[6] Engine (CRI system)
[7] Machine control signal
(3rd throttle signal)
[8] Rod
35
SEN01414-00
2.
Preparatory work
1) Start the engine, set the monitor panel in
the Adjustment mode, and prepare to
measure the engine speed.
a For the operation method, see Special functions of monitor panel
(EMMS).
q
Adjustment code: 0007
(Engine deceleration cut mode)
a The engine speed is displayed by 1 rpm.
3.
Adjusting decelerator pedal speed

Set the fuel control dial at the high idle position,
depress decelerator pedal (2) 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 (1).
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 (3), then
adjust it to the high idle speed.
36

a
If engine speed is too low:

Adjust the high idle speed with stopper
bolt (3).
5.
Check of decelerator position (decelerator

potentiometer signal)
a Measure the decelerator position in the
real-time monitoring mode.
q
Monitoring code: 31701
(Decelerator position)
Check that displayed position is 100% while
the decelerator pedal is released.
If the displayed position is less than 100%,
adjust it to 100% with the pedal linkage.
If this adjustment is not made perfectly, the
engine control function etc. may not operate
normally. Accordingly, be sure to check the displayed position.
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
(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 displayed position.
a The accelerator position can be checked
while the engine is stopped.
D275AX-5E0
SEN01414-00
38
D275AX-5E0
SEN01415-00
BULLDOZER
1SHOP MANUAL
D275AX-5E0
Machine model
Serial number
D275AX-5E0
30001 and up

Testing power train oil pressure ...................................................................................................................... 3
Testing and adjusting HSS oil pressure ........................................................................................................ 12
Adjusting transmission speed sensor ........................................................................................................... 17
Bleeding air from HSS pump ....................................................................................................................... 18
Simple method of testing brake performance ............................................................................................... 18
Adjusting brake pedal and parking brake lever ............................................................................................. 19
Adjusting PCCS lever console position......................................................................................................... 22
Emergency escape method when power train has trouble ........................................................................... 23
Adjusting clearance of idler........................................................................................................................... 26
Inspecting wear of sprocket .......................................................................................................................... 26
Testing and adjusting track shoe tension ...................................................................................................... 27
Testing and adjusting work equipment oil pressure ...................................................................................... 28
Testing control circuit main pressure............................................................................................................. 32
Testing PPC valve output pressure............................................................................................................... 33
Adjusting play of PPC valve.......................................................................................................................... 35
Testing outlet pressure of ripper pin puller solenoid valve ............................................................................ 36
D275AX-5E0
SEN01415-00
Testing parts which cause hydraulic drift of blade and ripper........................................................................ 37

Testing internal leakage of work equipment cylinder..................................................................................... 38
Releasing residual pressure from work equipment cylinder.......................................................................... 39
Bleeding air from work equipment cylinder ................................................................................................... 39
Adjusting ripper lever position ....................................................................................................................... 40
Adjusting work equipment lock lever............................................................................................................. 41
Adjusting blade.............................................................................................................................................. 42
Testing and adjusting operator's cab............................................................................................................. 44
D275AX-5E0
SEN01415-00
Testing power train oil pressure 1

a
Testing instruments for power train oil pressure
Symbol
1
N
2
3
a
k
Part No.
799-101-5002
Hydraulic tester
790-261-1204
799-401-2320
Hydraulic tester
(0.98 MPa {10 kg/cm2})
799-101-5220
07002-11023
O-ring

transmission lubricating oil pressure pickup
port of the Pm clinic specification machine.
Test the power train oil pressure under the following condition.
q
Torque converter oil pressure:
Centralized pressure pickup ports (1) (12)
are installed inside the inspection cover on the
right outside of the operators cab and transmission lubricating oil pressure pickup port
(13) is installed to the top of the power train filter.
List of oil pressure pickup nipples and gauges
used
Oil pressure
gauge
(MPa {kg/cm2})
IN Torque converter inlet oil pressure
2.5 {25}
0.98 {10}
OUT Torque converter outlet oil pressure
No. Stamp
1
2
Part name
Oil pressure to be tested
LU
Torque converter lockup clutch

pressure
2.5 {25}
SC
Torque converter stator clutch

pressure
5.9 {60}
TM
Transmission main relief pressure
5.9 {60}
6
7
Transmission forward clutch oil

FWD
pressure
5.9 {60}
Transmission reverse clutch oil

pressure
5.9 {60}
1ST Transmission 1st clutch oil pressure
5.9 {60}
Transmission 2nd clutch oil

2ND
pressure
5.9 {60}
10
11
12
3RD Transmission 3rd clutch oil pressure

LB Steering left clutch oil pressure
RB Steering right brake oil pressure
5.9 {60}
5.9 {60}
5.9 {60}
13
Transmission lubricating oil

pressure
0.98 {10}
14
Output pressure of sudden stop

prevention valve
5.9 {60}
D275AX-5E0
SEN01415-00
1.
Testing torque converter inlet pressure (IN)

1) Connect oil pressure gauge [1] of hydraulic tester N1 to oil pressure testing nipple
(1).
a Use an oil pressure gauge of 2.5 MPa
{25 kg/cm2}.
2)
3)
4)
2.
Testing torque converter outlet pressure

(OUT)
1) Connect hydraulic tester N2 to oil pressure testing nipple (2).
a Use an oil pressure gauge of 0.98
MPa {10 kg/cm2}.
Start the engine and set the PCCS lever in

the full neutral position.
Test the oil pressure while the engine is
running at low idle and high idle.
2)

4)
3)
Start the engine and set the PCCS lever in


D275AX-5E0
3.
SEN01415-00
Testing torque converter lock-up clutch

pressure (LU)
1) Connect oil pressure gauge [1] of hydraulic tester N1 to oil pressure test nipple (3).
{25 kg/cm2}.
6)
2)
Run the engine and lift up the machine

body with the blade and ripper so that the
track shoes can run idle.
k After lifting up the machine, set the
work equipment lock lever in the
LOCK position.
3)
4)
Turn on the lock-up mode switch.

Set the PCCS lever in the FORWARD and
1st gear speed position and make the
shoes run idle.
k Take care not to be caught in the
track shoes during testing.
Raise the engine speed gradually and test
the oil pressure when the lock-up pilot
lamp lights up.
5)
D275AX-5E0

SEN01415-00
4.
Testing torque converter stator clutch pressure (SC)

(4).
{60 kg/cm2}.
2)
3)
4)
5.
Testing transmission main relief pressure

(TM)
(5).
{60 kg/cm2}.
Run the engine and set the PCCS lever in

2)

4)
3)


D275AX-5E0
6.
Testing transmission forward clutch pressure (FWD)

(6).
{60 kg/cm2}.
2)
3)
4)
5)
SEN01415-00
7.
Testing transmission reverse clutch pressure (R)

(7).
{60 kg/cm2}.
Run the engine and set the parking brake

lever in the FREE position.
Press the brake pedal and set the PCCS
lever in the FORWARD and 3rd gear
speed position.
running at low idle.
k Since the torque converter will be
stalled, press the brake pedal
2)

5)
D275AX-5E0
3)
4)

lever in the REVERSE 3rd gear speed
position.
stalled, press the brake pedal

SEN01415-00
8.
Testing transmission 1st clutch pressure

(1ST)
(8).
{60 kg/cm2}.
2)
3)
4)
5)
9.
Testing transmission 2nd clutch pressure

(2ND)
(9).
{60 kg/cm2}.

lever in the FORWARD and 1st gear
speed position.
stalled, keep pressing the brake
pedal securely.
k Do not raise the engine speed to
high idle during testing.
2)

5)
3)
4)

lever in the FORWARD and 2nd gear
speed position.
pedal securely.

D275AX-5E0
10. Testing transmission 3rd clutch pressure

(3RD)
(10).
{60 kg/cm2}.
SEN01415-00
11. Testing steering left brake pressure (LB)

(11).
{60 kg/cm2}.
2)
2)
3)
4)
5)

lever in the FORWARD and 3rd gear
speed position.
pedal securely.

D275AX-5E0
3)
4)

a Turn the pivot turn mode switch ON
and drive the machine in FORWARD
and 1st (F1) actually and check that
the oil pressure lowers to 0 when the
PCCS lever is moved to 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.

SEN01415-00
12. Testing steering right brake pressure (RB)

(12).
{60 kg/cm2}.
2)
3)
4)
10

a Turn the pivot turn mode switch ON
and drive the machine in FORWARD
and 1st (F1) actually and check that
the oil pressure lowers to 0 when the
PCCS lever is moved to the right
steering stroke end.
a Check that the oil pressure lowers to
0 when the brake pedal is pressed or
the parking brake lever is set in the
LOCK position.

13. Testing transmission lubricating oil pressure

1) Remove oil pressure testing plug (13).
2)
Install nipple N3 and connect hydraulic

tester N2.
MPa {10 kg/cm2}.
3)
Run the engine at high idle and test the oil

pressure.
4)

D275AX-5E0
14. Testing output pressure of sudden stop

prevention valve
1) Connect oil pressure gauge [1] of hydraulic tester N1 to oil pressure testing nipples
(11) and (12).
{60 kg/cm2}.
q
(11): For steering left brake oil pressure
2)
3)
SEN01415-00
4)

a If the brake pressure is as follows when
the sudden stop prevention valve operates, it is normal.
q
1.13 1.57 MPa {11.5 16.0 kg/cm2}
5)

(12):
For steering right brake oil pressure
Run the engine and set the machine monitor in the adjustment mode.
a For the method of operating the
adjustment mode, see "Special functions of machine monitor (EMMS)".
a Adjustment code: 9995
(Operation mode of emergency stop
prevention valve)
Set the parking brake lever in the FREE
position and set the all PCCS levers in the
NEUTRAL position.
D275AX-5E0
11
SEN01415-00
Testing and adjusting HSS oil

pressure
a
Install nipple P2 and connect oil pressure

gauge [1] of hydraulic tester P1.
MPa {600 kg/cm2}.
4)

lever in the FREE position and press the
brake pedal.
k Since the steering circuit will be
pedal securely and keep your right
foot on the decelerator pedal for
safety until the work is finished.
Run the engine at high idle and steer to
the right or left with the PCCS lever. When
the steering circuit is relieved, test the oil
pressure.
a Since a pivot turn will be made with
only the steering system, set the
direction of the PCCS lever into neutral.
Testing and adjusting instrument for HSS oil

pressure
Symbol
1
P
2
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
799-101-5220
07002-11023
O-ring
Testing
k Stop the machine on level ground, lower
a Test the HSS oil pressure under the following
condition.
q
1.
3)
Testing HSS main relief pressure

1) Remove the floor inspection cover.
2) Remove oil pressure testing plug (1) or
(2).
q
(1): For left steering (Port PA)
q
(2): For right steering (Port PB)
5)
6)
12

D275AX-5E0

a
HSS main relief pressure (A) can be tested in

the "Pm Clinic auxiliary mode" of the machine
monitor.
D275AX-5E0
SEN01415-00
a
HSS main relief pressure (B) can be tested in

the "Pm Clinic auxiliary mode" of the machine
monitor.
13
SEN01415-00
2.
Testing HSS charge relief pressure

1) Open the right fender inspection cover.
2) Remove oil pressure testing plug (3).
3)
4)
14
Install nipple P2 and connect oil pressure

gauge [1] of hydraulic tester P1.
{60 kg/cm2}.
3.
5)

running at high idle.
6)

Testing HSS servo charge pressure

a The control circuit main pressure from the
self-pressure reducing valve of the control
valve is used as the HSS servo charge
pressure commonly for work equipment
PPC and fan pump control.
a For the testing method, see "Testing control circuit main pressure".

D275AX-5E0
Adjusting
1. Adjusting HSS main relief pressure
a If the HSS main relief pressure is abnormal, adjust it with main relief valve (4) or
(5) of the HSS pump according to the following procedure.
q
(4): For left steering (Port PA)
q
(5): For right steering (Port PB)
1) Open the inspection cover under the universal joint.
SEN01415-00
2.
Adjusting HSS charge relief pressure (when

pressure is low)
a If the HSS charge relief pressure is low,
adjust the charge relief valve (8) of the
HSS motor to heighten the HSS charge
relief pressure.
1) Remove the fuel tank.
2)
3)
2)
3)
4)
Fixing adjustment nut (6), loosen locknut

(7).
Turn the adjustment nut (6) to adjust the
pressure.
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. 13.7MPa {Approx. 140kg/cm2}
Fixing adjustment nut (6), tighten locknut
(7).
3 Locknut: 29 39 Nm {3 4 kgm}
4)
5)
5)

(10).
pressure.
q
rises.
q
lowers.
adjustment nut: 1 MPa {10.4 kg/cm2}
(10).
3 Locknut:
58.8 78.5 Nm {6 8 kgm}
After finishing adjustment, check the oil

pressure again according to the procedure
for measurement described above.
After finishing measurement, check the oil

pressure according to the above measuring method.
D275AX-5E0
15
SEN01415-00
3.
Adjusting HSS charge relief pressure (when

pressure is high)
a If the HSS charge relief pressure is high,
adjust the charge safety valve (11) of the
HSS pump to lower the HSS charge relief
pressure.
1) Remove the inspection cover under the
universal joint.
2)
3)
4)
16
5)
After finishing adjustment, check the oil

pressure again according to the procedure
for measurement described above.

(13).
pressure.
q
rises.
q
lowers.
adjustment nut:
1.55 MPa {15.88 kg/cm2}
(13).
3 Locknut:
58.8 78.5 Nm {6 8 kgm}
D275AX-5E0
Adjusting transmission speed

sensor
1.
SEN01415-00
Remove sensor (1) and flange (2) together and

secure them with nut (3).
a Take care not to change the adjustment
angle of the sensor.
3 Nut: 49.0 68.6 Nm {5 7 kgm}
7.
Install flange (2) and sensor to the HSS case

with the mark of "HSS UP" directed to the
upper side of the HSS case.
8.
After finishing adjustment, set the machine

monitor in the "Monitoring display mode" and
check that it displays the transmission speed
normally.
a Monitoring code:
31400 (Transmission output speed)
Remove the undercover of the fuel tank and

then remove transmission speed sensor (1)
and flange together.
a Before adjusting transmission speed sensor (1), remove it and check that its tip is
free from steel chips and flaws, then install
it again.
a Before installing, separate sensor (1),
flange (2), and nut (3).
2.
Install flange (2) to the HSS case temporarily

with the mark of "HSS UP" directed to the
upper side of the HSS case.
3.
Look at bevel gear (4) through the hole of

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
hole, run the engine and move the
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.
D275AX-5E0
6.
17
SEN01415-00
Bleeding air from HSS pump

a
If the HSS pump is removed and installed or its

piping is disconnected and connected, bleed
air from the pump case according to the following procedure.
Before bleeding air, check that the hydraulic oil
level is proper.
1.
Remove the floor inspection cover.
2.
Loosen air bleeder (1) and leave it for 15 minutes.
3.
After 15 minutes, run the engine at low idle.

a After starting the engine, do not move the
PCCS lever from the full neutral position.
4.
After oil flows out of air bleeder (1), tighten air

bleeder (1).
18
Simple method of testing brake

performance
1
a
Carry out the simple test of brake performance

under the following condition.
q
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 FORWARD 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.
stalled, press the brake pedal securely
and keep your right foot on the decelerator pedal for safety until the work is
finished.
D275AX-5E0
Adjusting brake pedal and parking brake lever
SEN01415-00
Brake pedal
Parking lever
D275AX-5E0
19
SEN01415-00
Adjusting brake pedal side

1. Adjusting brake pedal stroke
Adjust stroke (a) of brake pedal (1) by adjusting installed dimension (b) of stopper bolt (2).
a Adjust the brake pedal stroke with the
brake rod disconnected from the pedal.
q
Pedal stroke (a): 74 mm
q
Installed dimension (b) of stopper bolt:
42 mm
2.
Adjusting installed length of brake rod

1) Install brake rod (3) and leave brake pedal
(1) free [Do not press brake pedal (1)].
2) Adjust installed dimensions (c) and (d) of
brake rod (3) with turnbuckle (5) so that
the spool of brake valve (4) will be at the
OFF position.
a The locknut screw of the turnbuckle
o n t h e b r a k e p e d a l s i d e i s l e ft handed.
q
Installed dimension (c): 32 mm
q
Installed dimension (d): 14 mm
3 Locknut:
34.3 58.8 Nm {3.5 6.0 kgm}
3.
Checking brake pedal stroke

1) Press brake pedal (1) and check that its
stroke is as adjusted in step 1 above.
2) Press brake pedal (1) and check that it is
stopped at stopper (6).
3) Press brake pedal (1) and check that
spool stroke (e) of brake valve (4) is in the
normal range at this time.
q
Spool stroke (e): 19 23 mm
4.
Checking brake oil pressure

1) Run the engine and set the machine monitor in the adjustment mode.
a For the method of operating the
adjustment mode, see "Special functions of machine monitor (EMMS)".
a Adjustment code: 9996
(Mechanical brake operation check)
2) Press the brake pedal fully with the parking brake lever in the FREE position and
check that the brake oil pressure on both
right and left sides is 0.
a For the point to measure the brake oil
pressure, see "Testing power train oil
pressure".
20
5.
Setting brake potentiometer to initial position

machine monitor in the adjustment mode and
set the brake potentiometer to the initial position.
a For the method of operating the adjustment mode, see "Special functions of
machine monitor (EMMS)".
a Adjustment code:
0005 (Brake pedal standard value)
Adjusting parking brake lever side

6.
Assembly and installation of lever assembly

1) Assemble lever assembly (7) and adjust
the operation of limit switch (8).
a Assemble the lever assembly with the
parking brake cable (9) disconnected from
the lever.
q
When lever is at upper position: OFF, at
lower position: ON
q
Operating stroke of limit switch: 3 mm
2) Install lever assembly (7).
7.
Adjusting installed length of parking brake

cable
1) Connect parking brake cable (9) to the
lever side and valve side, and then adjust
installed dimensions (f) and (g).
q
Installed dimension (f) of cable:
112.8 mm
q
Installed dimension (g) of cable:
14.0 mm
2) Operate parking brake lever (10) between
the FREE position and LOCK position and
adjust the position of rod end (11) so that
spool stroke (h) of brake valve (4) will be
normal.
q
Spool stroke (h): 23.0 mm
8.
Checking brake oil pressure

Run the engine and set the parking brake lever
in the FREE position and LOCK position and
check that the brake oil pressure will be as follows.
a For the measuring point of the brake oil
pressure, see "Testing power train oil
pressure".
q
LOCK position: 0, FREE position: Specified pressure
D275AX-5E0
9.
SEN01415-00
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 display mode, see "Special functions of
machine monitor (EMMS)".
q
(Steering controller input signal 1)
2) Set the parking brake lever in the FREE
position and LOCK position and check
that the limit switch signals are input normally.
D275AX-5E0
21
SEN01415-00
Adjusting PCCS lever console position
1.
Set operators seat (1) in the forward (dozing)

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

in parallel with operators seat (1).
a If the console is not parallel with the operators seat, adjust dimension (a) of rod (3).
q
Standard dimensions (a): 179mm
a The locknut on the rear side of the turnbuckle is a left-handed (reversing) screw.
22
D275AX-5E0
SEN01415-00
Emergency escape method when

power train has trouble
1
Devices used for emergency escape
Symbol
Part No.
Part name
Since the female side of connector

PL2 is kept disconnected, mask it
with a vinyl sheet, etc.
Put switch assembly [1] in the cab
through the cab window.
19M-06-32820 Switch assembly

Q
Register
17M-06-41530 Wiring harness

2
1.
7824-66-6430
790-190-1600
Pump assembly
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 following procedure. If the engine cannot be
started, see "Emergency escape with
brake releasing device".
1) Connect switch assembly [1] and register
[2] to wiring harness [3] of emergency
escape device Q1.
k Since register [2] controls the drive
voltage of the solenoid, connect it
to the wiring harness before connecting to the machine.
k Set the all gear speed switches of
switch assembly [1] in the OFF
position and the direction switch in
the P position to prevent the
machine from starting suddenly.
2)
3)
Disconnect neutral safety relay (NSF) in

the fuse room and connect pins [3] and [5]
of the connector on the wiring harness
side.
k If the engine is started by this
method, the neutral safety function
does not work. Accordingly, before
starting the engine, set the parking
brake lever in the LOCK position
and set the PCCS lever in the full
neutral position.
k Start the engine by this method
only in an emergency. If the engine
does not start in another case, be
sure to carry out troubleshooting
and repair the trouble.
Open the left fender inspection cover and

connect wiring harness [3] to connectors
PL1 (1) and PL2 (2).
q
Connector PL1 (1):
Connect to male side and female side.
q
Connector PL2 (2):
Connect to male side.
D275AX-5E0
23
SEN01415-00
4)
5)
24
Start the engine and set the parking brake

Operate switch assembly [1] and move
the machine to a safe place.
a The gear speed switch is so made
that the switch on the lower gear
speed will be operated first.
2.
Escape with brake releasing device (Use

Q2)
a If the engine cannot be started and the
parking brake cannot be released, escape
1) Assemble pump assembly Q2.
2)
Install volume pump [4] of pump assembly

Q2 to the outside of the operators cab.
3)
Remove the fuel tank undercover and disconnect supply hose (3) of the pin puller
solenoid valve.
D275AX-5E0
4)
Connect end hose [5] of pump assembly

Q2 to the supply hose.
a Block the solenoid valve side with
plug [6].
5)

parking brake lever in the FREE position.
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 operated 30 50 times to raise the oil
pressure.
a If the oil pressure does not rise above
a certain level, the relief valve may be
set to low pressure. In this case,
adjust the set pressure of the relief
valve.
Tow the machine to a safe place.
a The brake releasing oil pressure lowers gradually because of internal
leakage and the brake is applied
again about 1 minutes after. Accordingly, work quickly.
a If the brake releasing pressure lowers
to about 1.5 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.
6)
7)
D275AX-5E0
SEN01415-00
25
SEN01415-00
Adjusting clearance of idler
If the idler runs out or tilts because of wear of

the side guide, upper and lower guides, and
guide plate, adjust according to the following
procedure.
1.
Drive the machine for 1 2m on a level place,

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

(1) and reduce shims (2).
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 thickness of the shims on each side is 7 mm.
a Reduce the shims on the inside and outside equally.
3 Mounting bolt:
490 608 Nm {50 62 kgm}
26
Inspecting wear of sprocket

a
As the wear measurement gauge for the

sprocket, use the "Full-scale drawing of
sprocket tooth profile" in "Structure, function
and maintenance standard", "Sprocket".
Make a copy of the "Full-scale drawing of
sprocket tooth profile" on a transparent sheet
and apply it to the sprocket directly to see if the
sprocket is serviceable.
D275AX-5E0
SEN01415-00
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
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.
D275AX-5E0
27
SEN01415-00
Testing and adjusting work

a
Testing and adjusting instruments for work

Symbol
1
R
2
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
799-101-5220
07002-11023
O-ring
Measuring
k Stop the machine on level ground, lower
a Test the work equipment oil pressure under the
following condition.
q
1.
Run the engine at high idle and set the

blade lever and ripper lever in neutral and
test the oil pressure.
5)

Testing unload pressure

2) Remove work equipment oil pressure sensor (1).
3)
28
4)
Install nipple R2 and connect oil pressure

gauge [1] of hydraulic tester R1.
{60 kg/cm2}.
D275AX-5E0
2.
Testing main relief pressure

a Test the main relief pressure at the same
point with the unload pressure.
{400 kg/cm2}.
1)
2)
3)
SEN01415-00
a
The unload pressure and main relief pressure

can be tested in the "Pm Clinic auxiliary mode"
of the machine monitor.
Start the engine and set the work iquipment lock lever in the FREE position.
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.

D275AX-5E0
29
SEN01415-00
3.
Testing LS pressure (Load Sensing pressure)

2) Remove oil pressure testing port (2).
6)
3)
Install nipple R2 and connect oil pressure

gauge [1] of hydraulic tester R1.
MPa {400 kg/cm2}.
4)
Start the engine and set the work equipment lock lever in the FREE position.
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.
5)
30

D275AX-5E0
SEN01415-00
Adjusting
a The unload pressure cannot be adjusted.
1.
Adjusting main relief pressure

a If the main relief pressure is abnormal,
adjust LS relief valve (3) of the control
valve according to the following procedure.
a If the LS relief valve is adjusted, the LS
pressure (load sensing pressure) is
changed, too.
1)
2)
3)
4)
2.
After finishing adjustment, check both

main relief pressure and LS pressure
(load sensing pressure) again according
to the procedure for measurement
described above.
Adjusting LS pressure (load sensing pressure)

a If the LS pressure (load sensing pressure)
is abnormal, adjust LS relief valve (3) of
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.

(5).
pressure.
k Do not remove the adjustment nut.
If it is removed, the internal parts
may come off.
q
rises.
q
lowers.
adjustment nut: Approx. 19.6 MPa
{Approx. 200 kg/cm2}
(5).
3 Locknut: 39 49 Nm {4 5 kgm}
D275AX-5E0
31
SEN01415-00
Testing control circuit main

pressure
a
1
S
2
5.
Run the engine at high idle and set the blade

lever and ripper lever in neutral and test the oil
pressure.
6.
a The control circuit basic pressure cannot
be adjusted.
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
799-401-3100
Oil pressure pickup adapter

(Size 02)
02896-11008
O-ring
A nipple (quick coupler) is installed to the control valve outlet hose of the Pm clinic specification machine.
The control circuit main pressure is the pressure lowered by the self-pressure reducing
valve of the fan pump. It is used commonly for
HSS servo charge, work equipment PPC, and
fan pump control.
Test the control circuit main pressure under the
q
1.
Open the right fender inspection cover.
2.
Disconnect hose (1).
3.
Install oil pressure pickup adapter S2 and connect the disconnected hose again.
32
Install nipple [1] of hydraulic tester S1 and connect oil pressure gauge [2].
a Use an oil pressure gauge of 5.9 MPa {60
kg/cm2}.
Testing instrument for control circuit main pressure
Symbol
4.
D275AX-5E0
SEN01415-00
Testing PPC valve output

pressure
a
3
k
a
a
Install nipple [1] of hydraulic tester T1 and connect oil pressure gauge [2].
kg/cm2}.
4.
Start the engine and set the work equipment

lock lever in the FREE position.
5.
Run the engine at high idle and operate the

control lever of the circuit to be tested and test
the oil pressure.
a Test the oil pressure with the lever at a
stroke end.
a When testing the blade circuit, operate the
lever until the blade floats.
6.
Testing instruments for PPC valve output pressure
Symbol
3.
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
799-401-3100

(Size 02)
02896-11008
O-ring
799-401-3200

(Size 03)
02896-11009
O-ring

Before testing the PPC valve output pressure,
check that the control circuit main pressure is
normal.
Test the PPC valve output pressure under the
q
1.
Open the right side cover.
2.
Remove the pressure switch or pressure testing plug (1) of the circuit to be tested.
a For the circuit to be tested, see the drawing 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.
D275AX-5E0
33
SEN01415-00
34
D275AX-5E0
Adjusting play of PPC valve

a
a
q
SEN01415-00
If the end play of the blade lever and ripper

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

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

3 Locknut: 98 127 Nm {10 13 kgm}
4.
Install boot (1).
D275AX-5E0
35
SEN01415-00
Testing outlet pressure of ripper

pin puller solenoid valve
1
a
Testing instruments for outlet pressure of ripper pin puller solenoid valve
Symbol
1
U
2
k
1.
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
799-401-3200

(Size 03)
02896-11009
O-ring

Test the outlet pressure of the ripper pin puller
solenoid valve under the following condition.
q
Run the engine at high idle and operate the ripper pin puller switch and test the oil pressure.
5.
Disconnect pin puller cylinder hose (1) or (2).
2.
Install oil pressure pickup adapter U2 and connect the disconnected hose again.
3.
Install nipple [1] of hydraulic tester U1 and connect oil pressure gauge [2].
kg/cm2}.
36
4.
D275AX-5E0
SEN01415-00
Testing parts which cause

hydraulic drift of blade and ripper1
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 following 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
with a piston valve, do not extend it to
the stroke end.
2)
Blade tilt cylinder

Extract the tilt cylinder to the stroke end
and brace the blade to push up the right
side of the machine body.
3)

Brace the ripper to push up the rear side
of the machine body.
D275AX-5E0
2.
Turn the starting switch ON and set the work

equipment lock lever in the FREE position.
3.
Extend the cylinder to be tested with the corresponding lever and check its movement.
q
If the lowering speed is increased, the cylinder 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:
1. If the machine is set in the above position
(where the holding pressure is applied to the
bottom side), the oil leaks from the bottom side
to the head side. Since the volume on the head
side is less than that on the bottom side by the
volume of the rod, the pressure in the head
side is increased by the oil flowing in from the
bottom side.
2. As the pressure in the head side is 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
unbalanced and the lowering speed is
increased.
37
SEN01415-00
Testing internal leakage of work

equipment cylinder
1
a
3.
Run the engine at high idle and apply the relief

pressure to the cylinder bottom side.
q
Blade tilt cylinder:
Operate to extend the cylinder to
be tested.
q
Ripper lift cylinder:
Operate to lower ripper.
q
Ripper Tilt cylinder:
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.

a Referring to "Bleeding air from work equipment cylinder", bleed air from the cylinder
circuit.
Testing instruments for internal leakage of

work equipment cylinder
Symbol
Part No.
Commercially
available
a
a
Part name
Measuring cylinder

Test the internal leakage of work equipment
cylinder under the following condition.
q
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.
38
D275AX-5E0
SEN01415-00
Releasing residual pressure from

work equipment cylinder
1
Bleeding air from work equipment

cylinder
1
1.
When disconnecting the piping between the

control valve and work equipment cylinder,
release the residual pressure from the circuit
work equipment lock lever in the LOCK
position.
a
1.
Run the engine at low idle for about 5 minutes.
2.
While running the engine at low idle, extend

and retract the cylinder to be bled 4 5 times.
a Move the piston rod to about 100 mm
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.
Loosen oil filler cap (1) of the hydraulic tank

gradually to release the residual pressure from
the tank.
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 seconds to increase the pressure in the accumulator, then stop it.
5.
Repeat steps 2 4 above 2 3 times.
D275AX-5E0
If the work equipment cylinder is removed and

installed or its piping is disconnected and connected, bleed air from its circuit according to
the following procedure.
Before performing the following operation,
check that the hydraulic oil level is normal.
39
SEN01415-00
Adjusting ripper lever position
a
a
Adjust the ripper lever to the best position

The ripper lever can be adjusted forward and
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).
40
5)
6)
7)
Loosen nut (3).

Reverse 180 knob (4).
Tighten nut (3) to secure knob (4).
D275AX-5E0
Adjusting work equipment lock lever
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.
D275AX-5E0
SEN01415-00
41
SEN01415-00
Adjusting blade
1.
If the blade is removed and installed or disassembled and reassemble, adjust it according
Adjusting shims for assembly
1) Adjust the shim of center (1).
Adjusted
point
Adjusted
clearance
Standard
clearance
Standard
shim
thickness
See note.
4.5 mm
2)
Adjust the shim of lift (2).

Adjusted
point
Adjusted
clearance
Standard
clearance
Standard
shim
thickness
Max. 1mm
4.0mm
Note: Adjust the shim so that the play of

the ball in the axial direction will be
less than 1mm and the ball can rotate smoothly.
42
D275AX-5E0
3)
2.
SEN01415-00
Adjust the shim of trunnion (3).
Adjusted
point
Adjusted
clearance
Standard
clearance
Standard
shim
thickness
1.56 0.65mm
(Total
thickness)
12 mm
Adjusting blade tilt distance

1) Adjust dimension (d) of brace (4) with the
handle.
q
Dimension (d) of brace: 1,460 mm
2) Measure right and left tilt distances (e1)
and (e2).
q
Right tilt distance (e1):
Approx. 700 mm
q
Left tilt distance (e2):
Approx. 700 mm
3) If both tilt distances are not the same,
adjust dimension (d) of brace (4) according to the following procedure.
q
(e1) > (e2):
Increase dimension (d) finely.
q
(e1) < (e2):
Decrease dimension (d) finely.
D275AX-5E0
43
SEN01415-00

a
Testing and adjusting operator's

cab
1
a
If the operator's cab is removed and installed

or disassembled and transported and assembled in the field, test and adjust it according to
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 monitor)
q
Air conditioner fan switch: High
q
Air conditioner Fresh/Recirculation switch:
Fresh air position
a If the measured value is lower than the
standard value, check the seals of the
holes for wiring harnesses and optional
parts in the cab.
1)
A simple method of measuring the internal

pressure is as follows.
i) Prepare a transparent vinyl hose.
q
Inside diameter: 6 mm,
Length: 3,000 mm
ii) Secure the inside end of the hose to
the top of the back seat with a tape.
iii) Remove bolt (1) under the left console box. Pass the other end of the
hose through the bolt hole and take it
out of inspection cover (2) on the left
side of the cab.
2.
[a] side: Inside of cab (Pressurized)

[b] side: Out of cab
(Atmospheric pressure)
Check of searing performance

1) Close the all openings of the cab.
2) Splash water around the hatched part of
the cab at the rate of about 19 l/min for 10
minutes.
q
At this time, it is not necessary to
splash pressurized water.
3) Splash water horizontally from a hose over
sealing surface (4).
4) Check around the dashboard carefully.
a If water leaks, caulk the leaking part and
check again.
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 measure water level difference (c).
(Value (c): Pa {mmH2O})
44
D275AX-5E0
SEN01415-00
46
D275AX-5E0
SEN01416-00
BULLDOZER
1SHOP MANUAL
D275AX-5E0
Machine model
Serial number
D275AX-5E0
30001 and up

Special functions of machine monitor (EMMS) ............................................................................................... 2
D275AX-5E0
SEN01416-00
Special functions of machine monitor (EMMS)
Display section of special func- Operation section 1 of special

tions
functions
(Basic operation)
1. Gear speed display section
3. Service switch
2. Multi-information section
Operation section 2 of special

functions
(Changeover operation)
4.
5.
6.
7.
Buzzer cancel switch

Information switch
Shift-up switch
Shift-down switch
EMMS: Equipment Management Monitoring System
D275AX-5E0
SEN01416-00
Normal function and special functions of machine monitor (EMMS)

The machine monitor (EMMS) has the normal function and special functions and displays information of various types at the gear speed display section at its center and the multi-information section.
Some items are displayed automatically according to the internal setting of the monitor panel and the others
are displayed according to the operation of the switches.
1. Normal function: Operation mode
With this function, the operator can display and change the items displayed normally.
2. Special function 1: Service mode
With this function, a serviceman can display and change the displayed items with special switches for
testing, adjusting, and troubleshooting.
Flow of modes and functions
Operator mode
Normal display (Default)
Maintenance mode
Pm clinic auxiliary mode
[U]
(W)
Error code display mode
[T]
Adjustment mode
Maintenance mode
[>]
Travel direction/Gear speed
+
Shift mode/Service meter
[>]
[>]
[>]
(Automatic)
Maintenance item: 12 items
[<]
Auxiliary menu: 11 items
[<]
[<]
Adjustment menu: 5 items
[<]
Action code display function

[ON] & [U](W)
[T]
Service mode
Maintenance interval change

mode
[>]
Maintenance item: 12 items
[<]
Electric system error code

display mode
[>]
[<]
Mechanical system error code

7
display mode
[>]
8
[<]
Adjustment mode
[>]
[<]
9 Load memory display mode

[>]
Adjustment menu: 21 items

Display menu: 3 items
[<]
10 Real-time monitoring mode

[>]
[<]
11 Dual display monitoring mode

[>]
[<]
Maintenance interval change

5
mode
D275AX-5E0
[ON]
[U]:
[T]:
[ > ]:
[ < ]:
(W):
Service switch
Buzzer cancel switch (Left)
Buzzer cancel switch (Right)
Information switch (Right)
Information switch (Left)
Min. 2.5 sec
SEN01416-00
Operation and display in operator mode

(Outline)
a
In this section, only the outline of the operation

mode is described. For the details of the contents and operation method of each function
and mode, see "Operation Manual".
Normal display mode (Default)

The monitor panel displays the following information normally.
Gear speed display section (1):
q
Left side: Travel direction (P N F R)
q
Right side: Gear speed (1 2 3)
q
Graphics: Engine speed
Multi-information section (2):
a Information is displayed in 2 lines of 16 characters each.
q
Left side:
Gear shift mode (F1-R1 F1-R2 F2-R2)
q
Right side:
Service meter (Unit: 0.1h)
a To change the normal display mode to the
operator mode, hold buzzer cancel switch (4)
in the [U] position for 3 seconds.
1.
Maintenance mode
(1-OIL, FILTER MAINTENANCE MODE)
In this mode, the time up to the next replacement of oils and filters is displayed on the
multi-information section (2) and to update the
maintenance history.
a Gear speed display section (1) keeps displaying normally.
Order
Display
Item
01:ENG OIL
Engine oil
02:ENG FILT
Engine oil filter
03:FUEL FILT
Fuel main filter
04:HYD FILT
Hydraulic oil filter
06:CORR RES
Corrosion resistor
07:DAMP OIL
Damper oil
08:FNL OIL
Final drive oil
10:HYD OIL
Hydraulic oil
12:HSS FILT
Charge filter
10
19:POWL OIL
Power train oil
11
20:POWL FILT
12
41:F. PRE-FLT
Fuel pre-filter
The displayed numbers are specific to the

corresponding items. (Some of them may
not be used in some models.)
D275AX-5E0
2.
Pm clinic auxiliary mode

(2-PM CLINIC MODE)
In this mode, the condition of the machine is
displayed on multi-information section (2) as
an auxiliary function of the periodic diagnoses
such as the Pm clinic, even if any measuring
instrument is not connected.
OrDisplay
der
1 01-ENG SPEED
2
3
4
5
6
7
8
9
10
11
SEN01416-00
Item
Engine speed
Engine coolant tempera02-COOLANT TEMP.
ture
03-ENG OIL PRESS Engine oil pressure
05-BOOST PRESS.
Boost pressure
06-BOOST TEMP.
Boost temperature
Torque converter oil tem07-T/C TEMP.
perature
08-HYD TEMP.
09-HYD PRESS.
Hydraulic oil pressure
HSS circuit oil pressure
11-HSS PRESS. A
A
HSS circuit oil pressure
12-HSS PRESS. B
B
13-BATTERY VOLT.
Battery voltage mV
a
a
Unit
rpm
C
kPa
kPa
C
C
C
MPa
MPa
MPa
mV
The displayed numbers are specific to the

corresponding items. (Some of them may
not be used in some models.)
The boost pressure is indicated by the
absolute pressure.
D275AX-5E0
3.
Error code display mode

(3-FAULT CODE DISPLAY MODE)
In this mode, the contents of each fault in the
machine are displayed by a 6-character error
code on the multi-information section (2).
When the user or the operator needs to be
notified of the error code of each fault, this
mode is applied.
a When a serviceman needs to check the
error codes for troubleshooting, the Electric system error code display mode and
the Mechanical system error code display
mode should be used for more detailed
information.
a Method of checking error code:
Turn buzzer cancel switch (4) to the [U]
position on the screen shown at right, and
the all error codes detected currently are
displayed at the interval of about 2 seconds. (To finish displaying, turn the buzzer
cancel switch to the [T] position.)
a For details of the displayed failure code,
see Troubleshooting Volume, "Failure
code table".
SEN01416-00
4.
Adjustment mode (4-USER ADJUST MODE)

In this mode, the display condition of the
machine monitor can be adjusted and the fan
speed (for cleaning the radiator) can be
changed on the multi-information section (2).
Order
Display
01:LCD BRIGHTNES
Adjustment of display
02:DSP BRIGHTNES
brightness
03:DSP CONTRAST
Fan 100% speed

04:FAN 100%SPEED mode (For cleaning
radiator)
05:NO INJECTION
1)
Brightness of LCD
This function is used to adjust the brightness of the back light of the LCD gauge
unit (See the operation manual).
2)
Brightness of display
This function is used to adjust the brightness of the back light of the multi-information unit (See the operation manual).
3)
Contrast of display
This function is used to adjust the contrast
of the LCD of the multi-information unit
(See the operation manual).
4)
Fan 100% mode

This function is to control rotation speed of
the cooling fan forcedly at approximately
100% of the maximum speed.
1] This mode is selected by operating
the information switch.
2] The mode is selected by turning the
buzzer cancel switch to the [U] position.
3] The function is effective under this
condition and the rotation speed of
the cooling fan is controlled to
approximately 100% of the maximum
speed.
a Exiting this mode disables the
function.
Item
Adjustment of LCD
brightness
Adjustment of display
contrast
Non-injection cranking mode
D275AX-5E0
5)
No-injection cranking mode

This function is used to stop fuel injection
into all the cylinders of the engine to lubricate the engine parts simply before starting the engine after a long-time stop.
i) Operate the information switch to
select this mode.
ii) Set the buzzer cancel switch in the
[U] position to settle the mode.
iii)
D275AX-5E0
SEN01416-00
iv) Under this condition, set the starting

switch in the START position to perform non-injection cranking.
v) Return the starting switch to the ON
position and set the buzzer cancel
switch in the [t] position to reset the
mode.
a If the system gets out of 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 indicate that the mode is ineffective.
After about 3 seconds, "WAIT" displayed on the lower line changes to

"ACTIVE" and the mode becomes
effective.
SEN01416-00
Action code display function

If a fault to be notified to the operator occurs during
work, an action code and a phone No. are displayed
on the multi-information section (2).
a The phone No. is displayed only when an action
code of high importance is displayed. The figure 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>
An action code is displayed only when a serious
fault occurs.
Even if an action code is not displayed, a fault may
have occurred. If you feel any abnormality, be sure
to check for a error code in the "Electric system error
code display mode" and "Mechanical system error
code display mode" of the service mode.
Action codes table

Action
code
E01
E02
Indication method of fault
Only action code is displayed.
Action code is displayed.

Caution lamp flashes.
Caution buzzer sounds.
Example of contents of fault
Remedy
Torque converter is not locked

up.
Blade dual tilt mechanism does
not work.
Automatic function stops or normal function stops partially but

machine can work.
Call your Komatsu distributor for
repair.
Gear is not shifted up or down.

Blade tilt is not limited.
Blade pitch mechanism does not
work.
Stop engine and start it again,

and you can operate machine
without limiting function. You
must take care, however.
repair.

CALL E03 Caution lamp flashes.
Engine coolant temperature is

defective.
Usable gear speeds are limited.
Move machine to safe place.
Engine speed does not rise fully.
Gear shifting shocks become
repair.
large.
Steering performance lowers.
Brake shocks become large.

CALL E04 Caution lamp flashes.
Engine cannot be controlled.

Machine cannot travel.
Machine stops.
Stop machine immediately.

repair.
D275AX-5E0
Operation and display in service mode
SEN01416-00
2)
Method of changing to service mode

a When using the service mode, change the
screen by the following special operation.
1)
Special operation of switches

Set the monitor panel in the service mode by
operating service switch (3) and buzzer cancel
switch (4).
a While keeping the service switch in the
ON position (hold it up), keep the buzzer
cancel switch in the [U] position for a minimum of 3 seconds.
a If the multi-information section changes to
the mode display shown below, the system is in the service mode.
a The mode displayed first depends on each
case.
Gear
Order speed
display
3)
D275AX-5E0
Selecting and executing mode to be used

Select the mode to be used with information
switch (5) and execute it with buzzer cancel
switch (4).
q
[ > ]: Next mode No.
q
[ < ]: Previous mode No.
q
[U]: Execute mode.
a For the details of operation in each mode,
see the following pages.
1C
EE
bE
Cb
Ld
5R
dR
Display and item

5-EXCHG, INTVAL INTERVAL MODE
Maintenance interval change mode
6-ELEC. FAULT CODE MODE
Electric system fault code display mode
7-MACHINE CHECK CODE MODE
Mechanical system fault code display mode
8-SERVICE ADJUST MODE

Adjustment mode
9-LOAD MAP DISPLEY MODE
Load memory display mode
10-REAL TIME MONITORING MODE
Real time monitoring mode
11-DUAL DISPLAY MONITORING MODE
Dual display monitoring mode
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.
SEN01416-00
5.
Maintenance interval change mode

(5-EXCHG. INTVAL. INTERVAL MODE)
In this mode, you can check and set the maintenance interval times of various filters and oils
which are the bases of the maintenance display function in the operator mode.
1)
10
2)
Selecting and displaying maintenance

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

The following items are displayed on the
information section.
[1]: Code
[2]: Maintenance item
[3]: Replacement interval time (Set time)
a The items shown at right are examples.
a If the replacement interval does not
need to be changed, finish the operation on this screen.
a If the replacement interval needs to
be changed, go to step 4).
Selecting and executing mode

i) Select "Maintenance interval change
mode" on the mode selection screen.
a If the mode is selected, code
(1C) is displayed on gear speed
display section (1) and the title is
displayed on multi-information
section (2).
ii) Display the maintenance item selection screen by operating buzzer cancel switch (4).
q
[U]: Execute mode.
D275AX-5E0
4)
Changing replacement interval time

i) Change the set time by operating
information switch (5), shift-up switch
(6), and shift-down switch (7).
q
[ > ]: Move cursor to right.
q
[ < ]: Move cursor to left.
q
[UP]: Increase number.
q
[DOWN]: Decrease number.
D275AX-5E0
If you do not use the maintenance function, set the all times
to 0.
SEN01416-00
ii)
If the input time is correct, enter the

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

screen before the change
appears after the screen shown
at right. In this case, execute the
above operation again.
11
SEN01416-00
Maintenance items table

Order
Display
Item
1st time
(Cannot be changed)
2nd time and after

(Can be changed)
01:ENG OIL
Engine oil
0500h
0500h
02:ENG FILT
Engine oil filter
0500h
0500h
03:FUEL FILT
Fuel main filter
1000h
1000h
04:HYD FILT
Hydraulic oil filter
0250h
2000h
06:CORR RES
Corrosion resistor
1000h
1000h
07:DAMP OIL
Damper oil
2000h
2000h
08:FNL OIL
Final drive oil
0250h
2000h
10:HYD OIL
Hydraulic oil
0250h
2000h
12:HSS FILT
Charge filter
1000h
1000h
10
19:POWL OIL
Power train oil
0250h
1000h
11
20:POWL FILT
0250h
0500h
12
41:F. PRE-FLT
Fuel prefilter
0500h
0500h
a
a
12
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.
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.
D275AX-5E0
6.
Electric system error code display mode

(6-ELEC. ERROR CODE MODE)
In this mode, you can check the past electric
system error codes.
1)
SEN01416-00
2)
Display in the case where no codes are

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

are recorded
If any error code has been output up to
shown below.
[1]: Record No. (Up to 20)
[2]: Error code (Code being output currently is flashing)
[3]: Number of past occurrences
[4]: Time measured by service meter after
first occurrence
last occurrence
a The items shown below are examples.
a For the details of displayed error
codes, see the errors code table in
"Troubleshooting when error code is
indicated (Error code)".

i) Select "Electric system error code
display mode" on the mode selection
screen.
(EE) is displayed on gear speed
section (2).
ii) Display the error code display screen
by operating buzzer cancel switch (4).
q
[U]: Execute mode.
D275AX-5E0
13
SEN01416-00
a
14
Flashing and lighting of error code

Flashing:
Code is being output currently.
Lighting:
Code is not being output currently.
Condition for detecting and keeping
error code
If 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
q
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.
D275AX-5E0
7.
Mechanical system error code display mode

(7-MACHINE CHECK CODE MODE)
In this mode, you can check the past mechanical system error codes.
1)
SEN01416-00
2)
Display in the case where no codes are

recorded
If no error codes have been output up to
shown below.
3)
Display in the case where 1 or more codes

are recorded
If any error code has been output up to
shown below.
[1]: Record No. (Up to 15)
[2]: Error code (Code being output currently is flashing)
[3]: Number of past occurrences
first occurrence
last occurrence
a The items shown below are examples.
a For the details of displayed error
codes, see the errors code table in
"Troubleshooting when error code is
indicated (Error code)".

i) Select "Mechanical system error code
display mode" on the mode selection
screen.
(bE) is displayed on gear speed
section (2).
ii) Display the error code display screen
by operating buzzer cancel switch (4).
q
[U]: Execute mode.
D275AX-5E0
15
SEN01416-00
a
16
Flashing and lighting of error code

Flashing:
Code is being output currently.
Lighting:
Code is not being output currently.
Condition for detecting and keeping
error code
If 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
q
5)
Method of deleting error code

The mechanical system error codes cannot be deleted.
D275AX-5E0
8.
Adjustment mode
(8-SERVICE ADJUST MODE)
In this mode, you can adjust the control system
and various devices of the machine.
1)
SEN01416-00
2)
Selecting adjustment items

On the adjustment code input screen,
input the 4-digit code of the item to be
adjusted by operating information switch
(5), shift-up switch (6), and shift-down
switch (7).
q
q
q
q
a Input a 4-digit code and set buzzer
cancel switch (4) to the [U] position,
and the information on that item is
displayed.
3)
Contents of display on adjustment screen

[1]: Code
[2]: Adjustment item
[3]: Related information
a For the detailed information and
adjustment procedure, see "Adjustment mode table and adjustment procedure".

i) Select "Adjustment mode" on the
mode selection screen.
(Cb) is displayed on gear speed
section (2).
ii) Display the adjustment code input
screen by operating buzzer cancel
switch (4).
q
[U]: Execute mode.
D275AX-5E0
17
SEN01416-00
a
4)
18
If an incorrect code is input, the

adjustment code input screen
appears again after the screen shown
below. In this case, execute the
above operation again.
When operating machine in adjustment

mode
If the parking brake lever is set in the
FREE position, gear speed display section
(1) displays normally and the machine can
be operated normally.
a To select another screen, return the
parking brake lever to the LOCK position and perform the necessary procedure.
k Since the operation may be different from the usual, take extreme
care when operating.
5)
Automatic selection of adjustment item

(Limited function)
After one of some adjustment items is
selected, if the information switch is operated, the next adjustment item is selected
automatically, even if the code of the next
adjustment item is not input.
q
[ > ]: Code is increased
q
[ < ]: Code is decreased
a This function is applied to only the
items having numbers in the Automatic selection column of the Adjustment mode table. Those items are
selected in the order of their numbers.
a Note that this operation is not effective while the parking brake lever is in
the RESET position.
a You may return to the screen for
inputting codes and enter a code
without using this function.
D275AX-5E0
SEN01416-00
Adjustment mode table and adjustment procedure

No.
Adjustment
code
[1]
0001
INP TEL NO.
Phone No. input mode
[2]
0002
S/T S. CODE
[3]
0003
[4]
Disassembly/ Automatic
Assembly selection
Displayed data
Unit
Phone No.
(None)
Steering controller model code setting
Code
Character
T/M S. CODE
Transmission controller model code setting
Code
Character
0004
BODY TYPE
Machine specification code setting
Code
Character
[5]
0005
BRAKE BASE
Brake pedal standard value set
Voltage offset
quantity
mV
[6]
0006
PUMP N. AJST
HSS pump neutral adjustment
Pressure
MPa
[7]
0007
ENG. FULL CH
Engine decelerator cut mode
Engine speed
rpm
[8]
0008
INJ->123456
Reduced cylinder mode
Engine speed/Injection quantity
rpm/mg
[9]
0009
PITCH SENS.
Pitch angle sensor standard value set
Voltage offset
quantity
mV
[10]
0010
FAN 70%MODE
Fan 70% mode
Adjustment
quantity
(None)
[11]
0021
KMTRX INST
KOMTRAX specification setting
Setting
condition
Character
[12]
0530
STALL CHECK
Stall speed check mode
Engine speed
rpm
[13]
1005
FAN 100%MODE Fan 100% mode
Adjustment
quantity
(None)
10
[14]
1012
S/T N-SET
Steering lever neutral value set
Steering lever
voltage
mV
[15]
1013
S/T M. L-SET
Steering lever left max. value set
Steering lever
voltage
mV
[16]
1014
S/T M. R-SET
Steering lever right max. value set
Steering lever
voltage
mV
[17]
2222
HSS ADJUST
HSS initial current adjustment mode
Adjustment
quantity
mA
[18]
2223
R SLOW CUT
Reverse slow cut function setting
Setting
condition
Character
[19]
9995
LOCK BRAKE
Sudden stop prevention valve operation

mode
Brake potentiometer voltage
mV
[20]
9996
MECHA BRAKE
Mechanical brake operation check mode
Brake potentiometer voltage
mV
[21]
9997
HI IDLE SET
High idle limit setting
Adjustment
quantity
rpm
[22]
9998
SFT INHIBIT
3rd gear speed cut setting
Setting
condition
Character
Adjustment item
7
9
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".)
D275AX-5E0
19
SEN01416-00
[1] 0001: Phone number input mode

q
This code inputs or changes a phone number
to be displayed simultaneously with when the
user code is displayed.
q
The lower part displays a phone number and
symbols.
q
Available characters: 0 1 2 3 4 5 6 7 8 9 : ; < > ?
q
Instructions for use:
By operating the information switch (5), shift up
switch (6), and shift down switch (7), input a
phone number and symbols.
q
[ > ]: Moves the cursor rightward.
q
[ < ]: Moves the cursor leftward.
q
[UP]: Advance the numeric character or
character (in the order of available
characters).
q
[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 symbols other than numeric characters at digits you will not use.
a 0 (zero) is input at all places of the lower
part before shipment from our factory.
a The setting is enabled even after ending
this code.
20
[2] 0002: Steering controller model code setting

q
This code is used to initialize the model codes
recognized by the steering controller and the
set values of the memory in the controller.
q
The model code is displayed on the lower line.
q
Adjustment method:
1) Set buzzer cancel switch (4) in the [U]
position and check that the caution buzzer
sounds.
2) Check that the displayed model code has
changed from [6*6] to [666].
a If model code [666] is not displayed, the
controller wiring harness or the controller
unit may be defective.
a Even if this code is turned off, the setting
is effective.
D275AX-5E0
[3] 0003:Transmission controller model code setting

q
This code is used to initialize the model codes
recognized by the transmission controller and
the set values of the memory in the controller.
q
The model code is displayed on the lower line.
q
Adjustment method:
sounds.
2) Check that the displayed model code has
changed from [5*5] to [555].
a If model code [555] is not displayed, the
controller wiring harness or the controller
unit may be defective.
is effective.
SEN01416-00
[4] 0004: Machine specification code setting

q
This code is used to have the machine specification recognized by the controllers which
compose the system.
q
The specifications of the work equipment, SSC
and travel lever are set with this code.
a Since setting of this code is reset when "Transmission controller specification setting" is executed, adjust it after that.
q
Adjustment procedure
1) Select code 0004 in the adjustment mode.
(a): Indicates specification of travel lever
(1st place)
(b): Indicates specification of work equipment (2nd place)
(c): Indicates specification of SSC (3rd
place)
2)
D275AX-5E0
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.
21
SEN01416-00
List of specifications of work equipment

and SSC
No.
X00
X01
X02
X10
X11
X12
Specification of
work equipment
Single tilt
Single tilt
Single tilt
Dual tilt
Dual tilt
Dual tilt
Specification of SSC
Without SSC
SSC power setting 1
SSC power setting 2
Without SSC
SSC power setting 1
SSC power setting 2
Note) "X" indicates the travel lever code.

3)
Each time shift-down switch (7) is pressed,

display of the 1st place changes. Select a
proper specification (standard specification
or optional specification) of the travel lever.
q
Example of operation
Upper line: Indicates standard specification of travel lever.
Lower line: Indicates optional specification of travel lever.
a Be sure to select the standard travel
lever specification. (Do not select the
optional travel lever specification.)
[5] 0005: Brake pedal standard value setting

q
This code is used to adjust the zero point of the
brake pedal potentiometer.
q
The deviation from the standard value is indicated by voltage on the lower line (Indication
range: 2,500 2,500).
q
Adjustment method:
1) Check that the brake pedal is in neutral (it
is not pressed).
position and check that the alarm buzzer
sounds.
a This adjustment is performed to have the
zero point of the potentiometer recognized
by the controller. It is not performed to
adjust the effect of the brake.
a Even if this adjustment is performed, the
indication on the lower line does not
change.
is effective.
Travel lever specification table

Code
8XX
9XX
Travel lever specification

Standard travel lever specification
Optional travel lever specification
Note) XX indicates the work equipment and

SSC code.
4)
22
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.
Even if this code is turned OFF, the setting
is effective.
D275AX-5E0
[6] 0006: HSS pump neutral adjustment

(HSS specification)
q
This code is used to solve a problem in the
straight travel performance of the HSS steering.
q
The HSS oil pressure is indicated on the lower
line.
q
Adjustment method 1 (Check of HSS differential pressure and deviation direction):
a Before performing this adjustment, check
the differential pressure of the HSS pump
to see if the straight travel performance
needs to be adjusted.
1) Run the engine at high idle with the parking brake lever in the LOCK position.
2) Set the machine monitor in the real-time
monitoring mode (5R) and set it to the following code.
q
Monitoring code:
50500 (HSS differential oil pressure)
3) Check the indicated differential pressure
to see if the straight travel performance
needs to be adjusted.
a If the differential pressure is 2 MPa or
lower, the straight travel performance
does not need to be adjusted. In this
case, finish the work.
a If the differential pressure is higher
than 2 MPa, perform the following
adjustment step.
4) Run the engine at high idle and tilt the
PCCS lever to the right end and return it
and measure the differential pressure and
tilt it to the left end and return it and measure the differential pressure, and then
judge the deviation direction from the
measured differential pressure.
a The machine deviates during travel in
the lever operation direction in which
the differential pressure is higher.
D275AX-5E0
SEN01416-00
Adjustment method 2 (Adjustment of neutral

position of HSS):
k Since the steering circuit will be
relieved, take care of safety around the
machine and keep pressing the brake
pedal securely during adjustment.
1) Set the machine monitor in the adjustment
mode.
2) Set the parking brake lever in the FREE
position and keep pressing the brake
pedal securely and run the engine at high
idle.
3) Turn the PCCS lever fully in the opposite
direction to the deviating direction and
keep it that position.
4) Set the buzzer cancel switch (4) in the [U]
position and return the PCCS lever to the
neutral position.
a It takes about 1 minutes to complete
the adjustment (The progress of the
adjustment is displayed graphically
on the engine speed display section
of the monitor panel).
5) When the adjustment is completed, the all
segments of the engine speed display
section of the monitor panel light up and
start flashing.
23
SEN01416-00
24
Adjustment procedure 3 (Check of adjustment):

Check that the differential pressure in the HSS
pump is in the normal range according to
Adjustment method 1 above.
q
Monitoring code:
50500 (HSS differential pressure)
q
Normal range: Max. 2 MPa
is effective.
[7] 0007: Engine deceleration-cut mode

q
This code is used to stop the auto-deceleration
function of the engine and check the high idle
speed of the engine singly.
q
The engine speed is displayed on the lower
line (Display range: 0 3000).
q
Using method:
While this code is displayed, its function is
turned on and the auto-deceleration function is
turned off.
a If this code is turned off, its function is
turned off.
D275AX-5E0
[8] 0008: Reduced cylinder mode

a When the engine common rail system seems
to be faulty, this code is used to stop injecting
fuel into 1 or more cylinders (reduce the number of effective cylinders) while the engine is
running and find out a faulty cylinder from the
change of the engine speed and fuel injection
quantity.
a Since a fault is detected by the difference of
the engine speed and fuel injection quantity in
the reduced cylinder mode operation from that
in the normal mode operation, use this function
while the engine is running.
q
Engine speed (A) and fuel injection quantity
(B) are displayed on the lower line.
D275AX-5E0
SEN01416-00
Using method:
Select the cylinders to be turned off for the
reduced cylinder mode operation by operating
information switch (5) and buzzer cancel
switch (4).
Use this method to turn on the selected cylinders again, too.
q
q
q
[U]: Execute or stop reduced cylinder mode
operation.
a The figure at below is an example that No.
2 cylinder is turned off for reduced cylinder
mode operation and turned on again (The
cylinder No. lamp is turned off in the
reduced cylinder mode operation and on
in the normal mode operation).
a Only one or more cylinders can be turned
off for the reduced cylinder mode operation.
turned off.
k Since this mode is for troubleshooting,
do not carry out work in this mode.
25
SEN01416-00
[9] 0009: Pitch angle sensor standard value set

q
This code is used to adjust the zero point and
correct the installation error of the pitch angle
sensor.
q
The deviation from the standard neutral position is displayed by voltage on the lower line
(Display range: 2500 2500).
q
Adjustment method:
i) Stop the machine on level ground.
ii) Buzzer cancel switch (4) in the [U] position and check that the caution buzzer
sounds.
a Even after adjustment, the display of the
lower line does not change.
is effective.
[11] 0021: KOMTRAX specification setting

q
This code is used to select installation condition of the KOMTRAX terminal.
a Set this specification before starting the
operation of the KOMTRAX.
q
The installation condition of the KOMTRAX terminal is displayed on the lower line.
q
ACTIVE: KOMTRAX is installed.
q
DEACTIVE: KOMTRAX is not installed.
q
Setting method
1) Select installation condition of the
KOMTRAX terminal with shift-up switch
(6) and shift-down switch (7).
2) After selecting the installation condition of
the terminal correctly, set buzzer cancel
switch (4) in the [U] position and check
that the alarm buzzer sounds.
a Even if this code is turned OFF, the setting
is effective.
a After replacing the controller, be sure to
perform (check) the setting.
[10] 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
The function is enabled with this code displayed to control the rpm of cooling fan to
approximately 70% of the maximum speed.
a Ending this code disables the function.
26
D275AX-5E0
[12] 0530: Stall speed check mode

q
This code is used to obtain the torque converter stall speed while keeping the cooling fan
speed to the maximum.
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 the protective function
does not work while this mode is used,
warm up the engine fully before using this
mode.
k 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.
q
The engine speed is displayed on the lower
line. (Display range: 0 3,000)
q
Using method
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 adjustment mode (ID: 1005).
a After this code is turned OFF, its function
becomes ineffective.
D275AX-5E0
SEN01416-00
[13] 1005: Fan 100% mode

q
This code forcedly sets the rpm of cooling fan
at approximately 100% of the maximum speed.
It is also used to set the adjustment value of
the maximum speed.
q
The lower part displays data for adjustment.
q
a The function is enabled with this code displayed to control the rpm of cooling fan to
approximately 100% of the maximum
speed.
i) Change the adjustment value of the maximum speed by operating shift-up switch
(6) and shift-down switch (7).
q
[UP]: Increase the adjustment value.
q
[DOWN]: Decrease the adjustment
value.
ii) To settle the adjustment value, set buzzer
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 adjustment value is effective.
27
SEN01416-00
[14] 1012: Steering lever neutral value setting

q
This code is used to adjust the steering potentiometer neutral position of the PCCS lever.
q
The output signal of steering potentiometer
from displayed by voltage on the lower line
q
Adjustment method:
i) Shift the PCCS lever in the steering neutral position.
ii) Set buzzer cancel switch (4) in the [U]
sounds.
is effective.
a This code is not for adjustment of the
steering performance, etc.
28
[15] 1013: Steering lever left maximum value se

q
This code is used to adjust the maximum left
steering potentiometer position of the PCCS
lever.
q
The output signal of the steering potentiometer
from displayed by voltage on the lower line
q
Adjustment method:
i) Set the PCCS lever to the left steering
stroke end.
sounds.
is effective.
D275AX-5E0
[16] 1014: Steering lever right maximum value set

q
This code is used to adjust the maximum right
steering potentiometer position of the PCCS
lever.
q
The output signal of steering potentiometer from
displayed by voltage on the lower line (Display
range: 0 5000).
q
Adjustment method:
i) Set the PCCS lever to the right steering
stroke end.
sounds.
is effective.
SEN01416-00
[17] 2222: HSS initial current adjustment mode

q
When the steering start feeling is different by
the steering direction, this code is used to
adjust the turning radius at the start of steering.
q
The current to drive the HSS pump solenoid is
displayed on the lower line [Display range:
350 (Left end) 0 350 (Right end)].
D275AX-5E0
Adjustment method:
1) Turning the PCCS lever to the left or right,
display and keep the current to be set.
q
If the lever is turned to the left, the
current becomes negative.
q
If the lever is turned to the right, the
current becomes positive.
sounds.
a As the set current is increased in the positive or negative direction, the turning
radius at the start of steering is decreased
(the machine turns more quickly).
a The figure is an example that the set current for steering to the left is reduced to
increase the turning radius.
a: Max. steering point
b: Steering start point
c: Steering start point
d: Max. steering point
is effective.
29
SEN01416-00
[18] 2223: Reverse slow cut function setting

q
This code is used to forcibly stop the reverse
slow function in the R1 gear speed, regardless
of the switch operations of the machine monitor.
q
This code does not affect the reverse slow
function in the R2 and R3 gear speeds.
q
Whether the reverse slow cut function is turned
on is displayed by letters on the lower line.
q
Adjustment method:
Change the setting by operating information
switch (5).
q
[ < ], [ > ]: Change setting.
q
[DEACTIVE]: Turn off reverse slow cut function.
q
[ACTIVE]: Turn on reverse slow cut function.
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.
is effective.
[19] 9995: Operation mode of emergency stop prevention valve

q
This code is used to check that the sudden
stop prevention valve works normally.
q
The voltage of the brake potentiometer is displayed on the lower line.
q
Using method:
effective and the emergency stop prevention
valve keeps operating.
Under this condition, operate the brake pedal
or parking brake lever and check the brake oil
pressure.
turned off.
[20] 9996: Mechanical brake operation check mode

This code is used to check the operation of the
mechanical brake.
q
The voltage of the brake potentiometer is displayed on the lower line.
q
Using method:
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.
turned off.
q
30
D275AX-5E0
[21] 9997: High idle limit setting

q
This code is used to limit the use high idle
speed.
q
The engine speed limit adjustment value is displayed on the lower line.
q
Limit range: High idle speed 400rpm
q
Using method:
1) Select a limit speed by setting information
switch (5) in the [ > ] position or [ < ] position.
sounds.
a If the high idle speed is limited, the engine
speed is not set to the normal high idle
even if the fuel control dial is set to the
maximum position.
is effective.
D275AX-5E0
SEN01416-00
[22] 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.
31
SEN01416-00
9.
Load memory display mode

(9-LOAD MAP DISPLAY MODE)
In this mode, you can check the load on the
machine, forward odometer, and reverse
odometer.
1)

i) Select "Load memory display mode"
on the mode selection screen.
a If the mode is selected, code (Ld)
is displayed on gear speed display section (1) and the title is
section (2).
ii) Display the information screen by
operating buzzer cancel switch (4).
q
[U]: Execute mode.
2)
No.
3)
32
Changing information screen

Change the information screen by operating information switch (5).
q
[ > ]: Next screen.
q
[ < ]: Previous screen.
Display
Item
01-1000 rpm SMR
1000 rpm service

meter
02-FOWARD ODO M
Forward travel
distance
03-REVERSE ODO M
Reverse travel
distance
04-F1 ODO Meter
F1 travel distance
05-F2 ODO Meter
F2 travel distance
06-F3 ODO Meter
F3 travel distance
07-R1 ODO Meter
R1 travel distance
08-R2 ODO Meter
R2 travel distance
09-R3 ODO Meter
R3 travel distance
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.
D275AX-5E0
SEN01416-00
4)
Displayed information of forward odometer (02)

On this screen, the integrated forward
travel distance is displayed.
7)
Display of F2 odometer (05)

On this screen, the integrated F2 (forward
2nd gear speed) travel distance is displayed.
5)
Display of reverse odometer (03)

On this screen, the integrated reverse
travel distance is displayed.
8)

3rd gear speed) travel distance is displayed.
6)

1st gear speed) travel distance is displayed.
9)
Display of R1 odometer (07)

On this screen, the integrated R1 (reverse
1st gear speed) travel distance is displayed.
D275AX-5E0
33
SEN01416-00
10) Display of R2 odometer (08)

2nd gear speed) travel distance is displayed.
12) When operating machine in load memory

display mode
If the parking brake lever is set in the FREE
position, gear speed display section (1) displays normally and the machine can be
operated normally.
parking brake lever to the LOCK position and perform the necessary procedure.
11) Display of R3 odometer (09)

3rd gear speed) travel distance is displayed.
34
D275AX-5E0
10. Real-time monitoring mode

(10-REAL TIME MONITORING MODE)
In this mode, the speeds, oil pressures, oil
temperatures, currents, voltages, etc. can be
monitored by using the signals from sensors,
switches, and solenoids installed various parts
of the machine.
a This mode is used to monitor 1 item.
When monitoring 2 items simultaneously,
use the "Dual display monitoring mode".
1)
SEN01416-00
2)
Selecting and entering monitored items

i) On the code input screen, input the 5digit code of the item to be monitored
by operating information switch (5),
shift-up switch (6), and shift-down
switch (7).
q
q
q
q
[DOWN]:Decrease number.

i) Select "Real-time monitoring mode"
a If the mode is selected, the title is
section (2).
ii) Display the monitoring code input
switch (4).
q
[U]: Execute mode.
ii)
D275AX-5E0
After inputting the code, display the

m o n ito ring scree n by op erating
q
[U]: Enter input code.
a If the input code is correct, the
monitoring screen shown at right
appears.
35
SEN01416-00
a
3)
36
If the input code is abnormal, the

code input screen appears again
after the screen shown.
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 "Monitoring mode table".
4)
Function of holding monitoring information

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

mode
parking brake lever to the FREE position and perform the necessary procedure.
D275AX-5E0
6)
SEN01416-00
Automatic selection of monitoring item

(Limited function)
After one of some monitoring items is
selected, if the information switch is operated, the next monitoring item is selected
automatically, even if the code of the next
monitoring item is not input.
q
[ > ]: Code is increased
q
[ < ]: Code is decreased
a This function is applied to only the
items having numbers in the Automatic selection column of the Monitoring mode table. Those items are
selected in the order of their numbers.
a Note that this operation is not effective while the parking brake lever is in
the RESET position.
a You may return to the screen for
inputting codes and enter a code
without using this function.
D275AX-5E0
37
SEN01416-00
Monitoring mode table

No.
Code
Monitoring item
Unit
Remarks
Automatic
selection
00201 ENG M ID
Engine controller model name
01000 ENG REV
Engine speed
01603 Remote Th
2nd throttle position
03000 FUEL DIAL
Fuel control dial voltage
mV
25
03200 BATTERY
Battery voltage
mV
39
03201 S/T ACC
Steering controller ACC input voltage
mV
03202 S/T PWR2
Steering controller load power supply

voltage
mV
03203 E-ECM PW
Engine controller power supply voltage
mV
03207 S/T PWR1
Steering controller unswitched power

supply voltage
mV
10
03208 T/M PWR1
Transmission controller unswitched

power supply voltage
mV
11
03212 T/M ACC
Transmission controller ACC input

voltage
mV
12
03216 T/M PWR2
Transmission controller load power

supply voltage
mV
13
04104 COOLANT TP
Engine coolant temperature
04105 COOLANT TP
Engine coolant temperature sensor

voltage
mV
14
Character
rpm
15
04200 FUEL SENS
Fuel level sensor voltage
mV
37
16
04401 HYD. TEMP.
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
22
10500 S/T 5V PW1
Steering controller sensor 5V power

supply voltage (for potentiometer)
mV
23
10501 T/M 5V PW1
Transmission controller sensor 5V power

supply voltage (for potentiometer)
mV
24
10505 S/T 5V PW2

supply voltage 2
mV
25
10506 T/M 5V PW2
Transmission controller sensor 5V power

supply voltage 2
mV
26
10700 S/T 24V PW

supply voltage
mV
27
10701 T/M 24V PW
Transmission controller sensor 24V

power supply voltage
mV
28
14200 FUEL TMP
Fuel temperature
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
18000 EGR IN PRS
EGR valve inlet pressure
MPa
33
18001 EGR IN PRS
EGR valve inlet pressure sensor voltage
mV
34
18100 EGR VALVE
EGR valve position
mm
35
18101 EGR VALVE
EGR valve position sensor voltage
mV
38
D275AX-5E0
SEN01416-00
Monitoring item
Unit
Remarks
Automatic
selection
No.
Code
36
18200 BPS VALVE
BYPAS valve position
mm
37
18201 BPS VALVE
BYPAS valve position sensor voltage
mV
38
18300 ENG IVSW 1
Engine controller idle validation switch 1
bit
See detailed information
39
18301 ENG IVSW 2
Engine controller idle validation switch 2
bit
40
18500 BOOST TMP
Boost temperature
41
18501 BOOST TMP
Boost temperature sensor voltage
mV
42
18600 INJECT CMD
Final injection quantity command
mg/st
43
18700 ENG TRUQUE Engine output torque
Nm
44
18900 E-ECM TP
45
20201 T/M. PROGRM Transmission controller program version Character
46
20202 S/T. PROGRM
Steering controller program version
Character
47
20216 ENG BLD
Engine controller build version
Character
48
20217 ENG CAL
Engine controller calibration data version Character
49
20300 KOMTRAX
KOMTRAX LED monitor
LED
40
50
20400 E-ECM SN
Engine controller ECM serial No.
Character
51
30100 T/C TEMP.
Torque converter oil temperature
52
31400 T/M OUT
Transmission controller output speed
rpm
53
31520 T/M-FILL
Transmission controller fill switch input

condition
bit
54
31521 S/T FILL
Steering controller fill switch input

condition
bit
55
31602 1st CLUTCH
1st clutch ECMV current command value
mA
56
31603 2nd CLUTCH
2nd clutch ECMV current command

value
mA
57
31604 3rd CLUTCH
3rd clutch ECMV current command value
mA
58
31606 Rev CLUTCH
Reverse clutch ECMV current command

value
mA
59
31608 Frd CLUTCH
Forward clutch ECMV current command

value
mA
60
31612 1 CLUTCH F
1st clutch ECMV output current

(Feedback value)
mA
33
61
31613 2 CLUTCH F
2nd clutch ECMV output current

(Feedback value)
mA
34
62
31614 3 CLUTCH F
3rd clutch ECMV output current

(Feedback value)
mA
35
63
31616 R CLUTCH F
Reverse clutch ECMV output current

(Feedback value)
mA
32
64
31618 BRAKE R. H.
Right brake ECMV output current

(Feedback value)
mA
27
65
31619 BRAKE L. H.
Left brake ECMV output current

(Feedback value)
mA
26
66
31620 BRAKE R. H.
Right brake ECMV current command

value
mA
67
31621 BRAKE L. H.
Left brake ECMV current command

value
mA
68
31622 F CLUTCH F
Forward clutch ECMV output current

(Feedback value)
mA
31
69
31623 FAN PUMP. O
Fan pump EPC current command value
mA
D275AX-5E0
Engine controller engine internal

temperature
39
SEN01416-00
Monitoring item
Unit
Automatic
selection
No.
Code
Remarks
70
31624 FAN PUMP. F
Fan pump EPC output current

(Feedback value)
mA
71
31625 PITCH SOL.
Pitch solenoid current
mA
72
31626 HSS M. FREE
Motor free solenoid voltage
mV
73
31627 L/U SOL
Lockup solenoid current
mA
36
74
31628 E. BRAKE SL
Emergency stop prevention solenoid

current
mA
28
75
31701 DECEL
Decelerator position
76
31703 DECEL
Decelerator pedal potentiometer voltage
mV
24
77
31706 F THROTTLE
Final accelerator position
78
32900 BODY ANGLE
Machine pitch angle
deg
18
79
36001 Accel Adj
Throttle correction value
MPa
CA
80
36200 PRESS CMD
Final common rail command
81
36300 INJECT CMD
Final injection timing command
82
36400 RAIL PR
Common rail pressure
MPa
11
83
36401 RAIL PR
Common rail pressure sensor voltage
mV
84
36500 BOOST PRS
Boost pressure
kPa
85
36501 BOOST PRS
Boost pressure sensor voltage
mV
86
36700 ENG TORQUE Engine conversion torque
13
87
37200 EG OIL PRS
Engine oil pressure
kPa
10
88
37201 EG OIL PRS
Engine oil pressure sensor voltage
mV
89
37301 FUEL RATE
Momentary fuel consumption
L/h
90
37400 AMB PRESS
Ambient pressure
kPa
91
37401 AMB PRESS
Ambient pressure sensor voltage
mV
92
40001 VEHICLE SP
Theoretical travel speed
km/h
93
40905 T/M-SW1
Transmission controller switch input

signal 1
bit
94
40906 T/M-SW2
Transmission controller switch input

signal 2
bit
95
40907 T/M OP SIG
Transmission controller operation input

signal
bit
96
40908 T/M HYD SW
Transmission controller blade lever oil

pressure switch input signal
bit
97
40909 T/M SOL. 2
Transmission controller ON/OFF output

signal 2
bit
98
40910 S/T-SW1
Steering controller switch input signal 1
bit
99
40911 S/T-SW2
bit
100 40913 S/T-SW5
bit
101 40914 S/T SOL. 1
Steering controller ON/OFF output

signal 1
bit
102 40915 S/T SOL. 2
Steering controller ON/OFF output

signal 2
bit
103 43502 IdleCancel
Warm-up operation cancel flag
bit
104 44202 Accel Up
Throttle upper limit value data
105 44203 Accel Low
Throttle lower limit value data
106 50200 T/M LEVR 1
FR lever potentiometer 1 voltage
mV
19
107 50201 T/M LEVR 2
FR lever potentiometer 2 voltage
mV
20
108 50300 S/T LEVR 1
Steering lever potentiometer 1 voltage
mV
21
40
(Absolute pressure)
12
D275AX-5E0
No.
Code
SEN01416-00
Monitoring item
Unit
Remarks
Automatic
selection
109 50301 S/T LEVR 2
Steering lever potentiometer 2 voltage
mV
22
110 50400 BRAKE PEDL
Brake pedal potentiometer voltage
mV
23
111 50500 HSS PUMP D
HSS differential oil pressure
MPa
15
112 50501 HSS PUMP A
HSS oil pressure A
MPa
16
113 50502 HSS PUMP B
HSS oil pressure B
MPa
17
114 50503 HSS PUMP A
HSS oil pressure A sensor voltage
mV
115 50504 HSS PUMP B
HSS oil pressure B sensor voltage
mV
116 50600 HSS L. H. F
Left HSS pump EPC output current

(Feedback value)
mA
29
117 50601 HSS R. H. F
Right HSS pump EPC output current

(Feedback value)
mA
30
118 50602 HSS L. H. O
Left HSS pump EPC current command

value
mA
119 50603 HSS R. H. O
Right HSS pump EPC current command

value
mA
120 50900 N-SAFTY
Neutral safety relay drive voltage
mV
38
121 51000 ENG REG
Regulation circuit command value
rpm
122 51100 FUEL DIAL
Fuel control dial command speed
rpm
123 60000 TRACTION
Theoretical traction force
124 60100 BODY ANGLE
Pitch angle sensor voltage
mV
125 60200 ACCELERATN Acceleration sensor voltage
mV
126 60300 SSC ORDER
SSC command value
rpm
127 60400 S/T-SW6
Steering controller SW input signal 6
bit
Engine controller ACC cut relay drive

128 60500 ENG. CON. PW
voltage
mV
129 60600 BR HOLD
Steering controller battery relay drive

voltage
mV
130 60700 S/T MODE
Steering condition variable
Character
131 60800 FILL MODE
Fill condition setting variable
Character
132 60909 MOD. MODE
Modulation condition setting variable
Character
133 70000 CHG. P. MODE Gearshift point condition setting variable Character
134 70200 T/M OUT
Transmission output speed sensor

voltage
mV
135 70300 B. KNOB SW
Transmission controller blade lever knob

switch input signal
bit
136 70304 T/M SOL. 1
Transmission controller ON/OFF output

signal 1
bit
137 70305 T/M RIPER2
Ripper lever oil pressure switch input
bit
138 70400 BACK ALARM
Backup alarm relay drive voltage
mV
139 70600 DUAL SOL.
Dual tilt solenoid current
mA
140 70700 HYD. PUMP 1
Work equipment oil pressure 1
MPa
14
141 70701 HYD. PUMP 1
Work equipment oil pressure 1 sensor

voltage
mV
142 92100 F1 SMR
F1 travel integrated time
143 92101 F2 SMR
144 92102 F3 SMR
145 92200 R1 SMR
R1 travel integrated time
146 92201 R2 SMR
D275AX-5E0
41
SEN01416-00
No.
Code
Automatic
selection
Monitoring item
Unit
Remarks
147 92202 R3 SMR
148 99901 TRIG T F
Trigger time F
msec
149 99902 TRIG T R
Trigger time R
msec
150 99903 TRIG T 1
Trigger time 1
msec
151 99904 TRIG T 2
Trigger time 2
msec
152 99905 TRIG T 3
Trigger time 3
msec
153 99906 TM SFT
Transmission shift condition
154 99907 LU
Lockup condition
bit
155 99908 TM IN TRQ
Transmission input torque
Nm
156 99909 DOZING h
Dozing time
157 99910 RIPPING h
Ripping time
158 99911 PATH NUM
Number of path
path
159 99913 TC IN TRQ
Torque converter input torque
Nm
160 99914 H. P 1 TRQ
Work equipment pump 1 input torque
Nm
161 99917 BR L PRESS
Left brake command pressure
MPa
162 99918 BR R PRESS
Right brake command pressure
MPa
42
Character
D275AX-5E0
SEN01416-00
Detailed information on bit display codes

Examples of display of bit information
a The display position of the bit information in the
"Real-time monitoring mode (Display of only 1
item)" is different from that in the "Dual display
monitoring mode (Simultaneous display of 2
items)".
a The bit information is displayed by [ _ ] for OFF
and [ o ] for ON in the places 1 8.
a The state of each item shown below is the condition for turning on the bit.
18300: Engine controller idle validation switch 1

1: Idle validation switch: When detected
2: (Unused)
3: (Unused)
4: (Unused)
5: (Unused)
6: (Unused)
7: (Unused)
8: (Unused)
D275AX-5E0
18301: Engine controller idle validation switch 2

1: Idle validation switch: When detected
2: (Unused)
3: (Unused)
4: (Unused)
5: (Unused)
6: (Unused)
7: (Unused)
8: (Unused)
31520: Input state of transmission controller related

fill switch
1: Forward clutch fill switch: ON
2: Reverse clutch fill switch: ON
3: 1st clutch fill switch: ON
4: 2nd clutch fill switch: ON
5: 3rd clutch fill switch: ON
6: (Unused)
7: (Unused)
8: (Unused)
43
SEN01416-00
31521: Input state of steering controller fill switch

1: Left brake fill switch: ON
2: (Unused)
3: (Unused)
4: (Unused)
5: (Unused)
6: Right brake fill switch: ON
7: (Unused)
8: (Unused)
40905: Transmission controller input signal 1

1: Gear shift-up switch: OFF
2: Gear shift-up switch: ON
3: Gear shift-down switch: OFF
4: Gear shift-down switch: ON
5: Parking brake switch: FREE
6: Parking brake switch: LOCK
7: (Unused)
8: (Unused)
44
40906: Transmission controller input signal 2

1: Automatic gear shift-down switch: ON
2: Neutral switch: ON
3: Neutral switch: OFF
4: Shift mode switch: ON
5: Shift mode switch: OFF
6: (Unused)
7: (Unused)
8: (Unused)
a Items 2 and 5 are for optional specifications.
40907: Transmission controller operation input signal

1: ACC signal
2: (Unused)
3: R signal
4: (Unused)
5: (Unused)
6: (Unused)
7: (Unused)
8: (Unused)
D275AX-5E0
40908: Input signal of transmission controller blade

lever oil pressure switch
1: Blade raise switch: ON
2: Blade lower switch: ON
3: (Unused)
4: (Unused)
5: Blade left tilt switch: ON
6: Blade right tilt switch: ON
7: (Unused)
8: (Unused)
a This item is for optional specifications.
40909: Transmission controller ON/OFF output

signal 2
1: (Unused)
2: (Unused)
3: (Unused)
4: Back-up alarm relay: ON
5: Neutral safety relay: ON
6: Lockup solenoid: ON
7: (Unused)
8: (Unused)
D275AX-5E0
SEN01416-00
40910: Steering controller switch input signal 1

1: (Unused)
2: (Unused)
3: (Unused)
4: (Unused)
5: Parking brake lever switch: FREE
6: Parking brake lever switch: LOCK
7: (Unused)
8: (Unused)

1: Buzzer cancel switch: T position (Right)
2: Buzzer cancel switch: U position (Left)
3: Information switch: > position (Right)
4: Information switch: < position (Left)
5: Service switch: ON
6: Pivot turn mode switch: ON
7: (Unused)
8: (Unused)
45
SEN01416-00

1: ACC signal: ON
2: Pre-lubricating oil pressure switch: ON
3: R signal
4: (Unused)
5: Fan reverse mode switch: ON
6: Fan clean mode switch: ON
7: (Unused)
8: (Unused)
40915: Steering controller ON/OFF output signal 2

1: Pre-lubrication motor relay drive: ON
2: Engine ACC cut relay drive: (ON)
3: (Unused)
4: (Unused)
5: (Unused)
6: (Unused)
7: (Unused)
8: (Unused)
a This item is for optional specifications.
40914: Output signal of steering controller ON/OFF

1: HSS MOTOR FREE solenoid: ON
2: Snap shot signal: ON
3: Fan reverse solenoid: ON
4: (Unused)
5: Battery relay drive output: ON
6: Sudden stop prevention valve: ON
7: (Unused)
8: (Unused)
a Item 2 is for optional specifications.
43502: Warm-up operation cancel flag

1: Warm-up operation cancel flag: ON
2: (Unused)
3: (Unused)
4: (Unused)
5: (Unused)
6: (Unused)
7: (Unused)
8: (Unused)
46
D275AX-5E0

1: (Unused)
2: C-signal: ON
3: Engine low idle: ON
4: Engine stop signal: ON
5: Hydraulic oil level switch signal: ON
6: Pre-lubrication motor drive signal: ON
7: (Unused)
8: (Unused)
70300: Input signal of transmission controller blade

lever knob switch
1: Blade lever tilt switch: Single tilt
2: Blade lever tilt switch: Dual tilt
3: Blade lever pitch switch: When ON
4: Blade lever pitch switch: When OFF
5: (Unused)
6: (Unused)
7: (Unused)
8: (Unused)
D275AX-5E0
SEN01416-00
70304: Transmission controller ON/OFF output signal

1: Dual tilt solenoid: ON
2: Pitch solenoid: ON
3: (Unused)
4: (Unused)
5: (Unused)
6: (Unused)
7: (Unused)
8: (Unused)
70305: Input signal of ripper lever oil pressur

switch
1: (Unused)
2: Ripper lift RAISE oil pressure switch:
ON (Operated)
3: Ripper lift LOWER oil pressure switch:
ON (Operated)
4: Ripper lift TILT-IN oil pressure switch:
ON (Operated)
5: Ripper lift TILT-OUT oil pressure switch:
ON (Operated)
6: (Unused)
7: (Unused)
8: (Unused)
a Item 5 is for the optional specification.
47
SEN01416-00
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
48
D275AX-5E0
11. Dual display monitoring mode

(11-DUAL DISPLAY MONITORING MODE)
In this mode, 2 monitored items can be displayed simultaneously.
a Note that only codes and monitoring information are displayed in this mode since
the usable display columns are limited.
(Item names and units cannot be displayed.)
1)

i) Select "Dual display monitoring mode"
(dR) is displayed on gear speed
displayed.
ii) Display the monitoring code input
switch (4).
q
[U]: Execute mode.
SEN01416-00
2)
Selecting and entering monitored items

i) On the code input screen, input the 5digit codes of the items to be monitored to the upper and lower lines by
operating information switch (5), shiftup switch (6), and shift-down switch
(7).
q
q
q
q
ii) After inputting the codes, display the
m o n ito ring scree n by op erating
q
[U]: Enter input code.
D275AX-5E0
If the input codes are normal, the

mo nito ring s cree n sh own a t
appears.
49
SEN01416-00
a
3)
50
If the input codes are abnormal,

the code input screen appears
again after the screen shown at
right.
4)
When operating machine in monitoring

mode
parking brake lever to the FREE position and perform the necessary procedure.
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".
D275AX-5E0
SEN01416-00
52
D275AX-5E0
SEN01417-00
BULLDOZER
1SHOP MANUAL
D275AX-5E0
Machine model
Serial number
D275AX-5E0
30001 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....................................................................................................................................................... 14
D275AX-5E0
SEN01417-00
Adjustment method when

controller has been replaced
a
1.
2.
3.
After the machine is assembled or transmission controller or steering controller is

replaced, adjust the system according to the
If the system is not adjusted, the machine
may not operate normally and may move
suddenly. Accordingly, be sure to adjust it.
Precautions for replacing a controller:
If a controller is replaced, the memory of the oil
and filter maintenance mode is reset. Accordingly, take a record of the next replacement
periods of the oils and filters.
Precautions for replacing a controller:
Stop the machine on a save place, turn the
starting switch OFF, check that the battery relay
is turned OFF, wait for about 1 minute, and then
replace the controller.
The control is still operating for a while after
the starting switch is turned OFF and the battery relay is turned OFF. Accordingly, do not
remove the controller just after the battery
relay is turned OFF.
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
displayed. You may continue the work,
however.
Setting system in service mode
After step 1, turn the starting switch ON again
and set the monitor panel in the "Adjustment
mode" of the service mode.
a For details of the operation in the service
mode, see the special functions section of
machine monitor (EMMS).
4.
Adjusting transmission controller

Select Transmission controller specification set
(0003) and adjust the transmission controller.
a Execute this code only when the steering
controller is also replaced.
5.
Turning power on again

Turn the starting switch off (battery relay off)
and leave it for 1 minute. Then turn the starting
switch on, then reset the monitor panel in the
"Adjustment Mode" of the service mode.
6.
Adjusting machine specification

Select Machine specification set (0004) and
adjust the machine specification.
Adjusting steering controller

Select Steering controller specification set
(0002) and adjust the steering controller.
a Execute this code only when the transmission controller is also replaced.
D275AX-5E0
7.
Adjusting brake potentiometer

Select Brake potentiometer initial set (0005)
and adjust the brake potentiometer.
8.
Adjusting pitch angle sensor

Select the initial setting (0009) of the pitch
angle sensor and adjust the pitch angle sensor.
9.
KOMTRAX system set

Set KOMTRAX system using Adjustment
mode (0021).
(If not, take care that default is not-equipped
set.)
D275AX-5E0
SEN01417-00
10. Turning power on again

Turn the starting switch OFF (battery relay off)
and after leaving it for 1 minute, turn it ON
again.
11. Checking failure codes
1) Set the monitor panel in the Electrical
system failure code display mode of the
service mode.
2) Check if any active failure codes exist. If
not, delete all the failure codes recorded.
a If any active failure codes exist, eliminate the cause of the incident by troubleshooting, then carry out steps 10
and 11 again.
a Precautions after replacing controller:
If any controller is replaced, the service meter in the oil and filter maintenance mode is reset to 0.
As a result, the replacement period
displayed on the monitor panel may
be different from the actual operating
hours. To solve this problem, determine the first replacement periods of
the oils and filters after the replacement of the controller according to the
replacement periods recorded before
the replacement of the controller.
SEN01417-00
Method of starting use of

KOMTRAX terminal
4)
If KOMTRAX terminal is installed when machine

is delivered:
a If the KOMTRAX terminal is installed (as standard) 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 computer, 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.
5)
6)
7)
8)
Turn the starting switch ON and wait for 5

seconds.
Disconnect inspection connector 2 and
wait for 5 seconds.
Reconnect inspection connector 1 and
wait for 5 seconds.
Reconnect inspection connector 2 and
wait for 5 seconds.
Check that the 7-segment lamp of the
KOMTRAX terminal indicates normally.
a If the inspection result is normal, the
7-segment lamp indicates for 30 seconds after step 7). (It indicates "d",
"0" and "" repeatedly.)
If KOMTRAX terminal is installed after machine

is delivered:
a If the KOMTRAX terminal is installed (retrofitted) after the machine is delivered, carry out
1.
Inspection of machine for starting use of

KOMTRAX
a Perform steps 4) to 7) in 30 seconds.
1) Turn the starting switch OFF and wait for
at least 5 seconds, and then go to the next
step.
2) 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)
a
a
3)
If the 7-segment lamp indicates "Normal", go to the next step.

If the 7-segment lamp indicates
"Abnormal", repeat the above procedure from step 1).
Disconnect inspection connector 1 and

wait for 5 seconds.
D275AX-5E0
SEN01417-00
a
If the 7-segment lamp indicates "Network trouble", check for "LED-C4",

referring to "Display of KOMTRAX
terminal lamp" (If CAN is not recognized, check the CAN wiring harness
of the KOMTRAX terminal. If there is
any defect, repair and repeat the
above procedure from step 1).
9)
Turn the starting switch to the START

position and hold it for at least 5 seconds
and check that the engine does not start.
a If the engine starts, repeat the above
procedure from step 1).
10) Return the starting switch to the ON position and hold it for at least 5 seconds.
a Do not return the starting switch to
the OFF position.
11) Turn the starting switch to the START
position again and check that the engine
starts.
12) Check that the 7-segment lamp of the
KOMTRAX terminal indicates normally.
a If the 7-segment lamp of the
KOMTRAX terminal indicates "Normal", go to the next step (It takes 90
seconds 15 minutes for the system
to indicate "Normal").
a If the 7-segment lamp indicates "GPS
data detection trouble", check the
GPS antenna and cable for a defect.
If there is any defect, repair and
repeat the above procedure from step
1).
a If the 7-segment lamp indicates
"Communication receiving trouble",
check the communication antenna
and cable for a defect. If there is any
defect, repair and repeat the above
procedure from step 1).
a If the 7-segment lamp indicates "GPS
data detection trouble and Communication receiving trouble", check the
GPS antenna and cable and the communication antenna and cable for a
defect. If there is any defect, repair
and repeat the above procedure from
step 1).
D275AX-5E0
SEN01417-00
13) Turn the starting switch to the OFF position.

14) After 5 seconds, check that the 7-segment
lamp indicates "Normal".
a If "Normal" is indicated, the inspection
for starting use is finished.
a If "Abnormal" is indicated, the inspection for starting use is not finished
normally. In this case, repeat the
above procedure from step 1).
2.
Application for start of use

a Before applying for start of use, be sure to
finish the inspection of the machine for
starting use.
1) Notify the following data of the machine
inspected for start of use to the responsible person for use of KOMTRAX.
(1) Data of machine inspected for start of
use (Machine name, machine monitor, 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)
The condition of the indicator lamp can also be

checked in the monitoring mode (ID: 20300) of
the machine monitor.
2)
Using the KOMTRAX client personal computer, 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.
D275AX-5E0
SEN01417-00
Indication by KOMTRAX terminal lamps
LEDs for CPU

1. LED-C1 (R signal and ACC signal)
2. LED-C2 (Condition of starting output)
3. LED-C3 (Condition of S-NET and C signal)
4. LED-C4 (Condition of CAN)
5. LED-C5 (Download writing condition)
6. LED-C6 (Download writing condition)
D275AX-5E0
7-segment lamp and dot for CPU

7. 7-segment lamp (Number of males which are
not sent yet)
8. Dot (Measuring condition of GPS)
SEN01417-00
The KOMTRAX system indicates the information in the system and contents of processing with the LED display 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
Starting switch ACC

LED-C1 signal and alternator
R signal
Condition of engine
control signal
LED-C2
Condition of S-NET
LED-C3 connection and starting switch C signal
LED-C4
Condition of CAN
connection
Indication (*1)
ON
Starting switch ACC signal: ON, Alternator R signal: ON
Quick blink
Starting switch ACC signal: OFF, Alternator R signal: ON
Slow blink
Starting switch ACC signal: ON, Alternator R signal: OFF
OFF
Starting switch ACC signal: OFF, Alternator R signal: OFF
ON
Engine control signal: ON
OFF
Engine control signal: OFF
ON
S-NET: Connected, Starting switch C signal: OFF
Quick blink
Starting switch C signal: ON
Slow blink
(Unused)
OFF
S-NET: Disconnected, Starting switch C signal: OFF
ON
CAN: Installed, (Fuel sensor: Not installed)
Quick blink
CAN: Installed, (Fuel sensor: Installed)
Slow blink
CAN: Not installed, (Fuel sensor: Installed)
OFF
5
6
LED-C5 Condition of
download writing
LED-C6
Contents of indication
Either is ON
CAN: Not installed, (Fuel sensor: Not installed)

Download writing mode (Special function of system
administrator)
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.
D275AX-5E0
2.
a
Contents of indication of 7-segment lamp and dot for CPU

When checking the indication of the LEDs, turn the starting switch to the ON position.
No. Indicator
SEN01417-00
7-segment
lamp
Dot
Name/Function
Indication (*2)
Lighting of 0 9
Number of mails
which are not sent yet
and satellite capturQuick blink of
ing condition
09
Measuring condition
of GPS
Contents of indication
Figure indicates number of mails which are not sent yet (When
10 or more mails are not sent yet, 9 is indicated).
Lighting indicates that satellite is captured.
Figure indicates number of mails which are not sent yet (When
10 or more mails are not sent yet, 9 is indicated).
Quick blink indicates that satellite is not captured.
ON
GPS has completed measuring (Position is recognized. See

*3.)
OFF
GPS has not completed measuring (Position is not recognized.

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.
D275AX-5E0
SEN01417-00
Preparation work for

troubleshooting for electric
system
2.
When carrying out troubleshooting for an electric circuit related to the machine monitor,
engine controller, transmission controller, or
steering controller, expose the related connectors 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 operators
seat.
Engine controller
1) Open left engine side cover (3) and
remove cover (4).
2)
3)
10
Insert or connect T-adapters in or to conne ctors S01, S02, S 0 3 , a n d S 0 4 o f

machine monitor (2).
Remove the cover (5).
3)
Insert or connect troubleshooting T-adapters in or to connectors EGC1, EGC2 and

EGC3 of engine controller (6).
a Since connectors EGC1 and EGC2 are
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}
D275AX-5E0
3.
1) Slide the operator's seat to the front end
and fold the seat back forward.
3)
Insert or connect T-adapters in or to connectors TMCN1, TMCN2, and TMCN3 of

transmission controller (8).
a If the connectors cannot be disconnected and connected easily, remove
the controller from the floor frame.
a Since the connectors are secured
with screws, loosen those screws
a When connecting the connectors,
tighten the screws to the specified
torque.
3 Screw: 2.82 Nm {0.288 kgm}
D275AX-5E0
SEN01417-00
4.
Steering controller
3)
Insert or connect T-adapters in or to connectors STCN1, STCN2, and STCN3 of

transmission controller (9).
a If the connectors cannot be disconnected and connected easily, remove
the controller from the floor frame.
a Since the connectors are secured
with screws, loosen those screws
a When connecting the connectors,
torque.
3 Screw: 2.82 Nm {0.288 kgm}
11
SEN01417-00
5.
KOMTRAX terminal
2) Remove cover (10) from the right rear of
the operator's seat.
3)
12
Insert or connect a troubleshooting Tadapter in or to connector KOM1 of

KOMTRAX terminal (11).
a If it is difficult to disconnect and connect the connector, remove the terminal from the floor frame.
a Since the connector is fixed with
screws, loosen those screws before
disconnecting.
a When connecting the connector,
torque.
3 Screw: 2.82 Nm {0.288 kgm}
D275AX-5E0
Handling of optional devices
SEN01417-00
This machine has connectors to install optional

devices in its fuse box. When installing any
optional device, receive the necessary signals
and power through those connectors without
modifying the wiring harness.
1.
Taking out ACC signal of starting switch

If the ACC signal (ON signal) of the starting
switch is necessary to an optional device such
as the turbocharger timer, take it out through
the following connector pin.
q
Pin (B) of CN-ESD (3-pole heavy duty wire
connector)
a A 20-A fuse is installed on the upstream
side of this connector pin.
2.
Inputting engine stop signal

When it is required to stop the engine with an
optional engine emergency stop function etc.
while the starting switch is in the ON position,
utilize the circuit of the following connectors
and pins.
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.
D275AX-5E0
4.
Taking out C signal of starting switch

If the C signal (starting signal) of the starting
switch is necessary to an optional device such
as the pre-lubricator, take it out through the following connector pin.
q
CN-PRS (2-pole heavy duty wire connector)
a Remove the connector installed when the
machine is shipped and connect pin (1) to
the starting signal to be output finally by
the optional device and connect pin (2) to
the starting switch signal to be input to the
optional device.
5.
Taking out external power source

If an external power source is necessary, take
it through the following connectors.
q
CN-800, CN-810 (Plug connectors)
q
CN-801, CN-811 (Plug connectors)
a A 20-A fuse is installed on the upstream
side of each of these connectors.
a CN-800 and CN-801 are prepared in the
fuse box and CN-810 and CN-811 are prepared on the outside of the floor.
13
Pm Clinic
1
Model
Serial No.
Service meter
D275AX-5E0
User name
Date of clinic
Blade
Specifications
Rear attachment
Semi-U blade
U-blade
Dual tilt blade
Multi-shank ripper
Variable giant ripper
Counterweight (
Serviceman
kg)
Shoe width
610 mm
710 mm
760 mm
Operating conditions
Quarry, mine
Coal
Gold
Limestone
Construction
Construction,
civil engineering
Roads
Tunnels
Type of soil (specific gravity )

Rock
Gravel
Sand
Clay
Type of work
Dozing
Side cutting
Ripping
Travel
%
%
%
%
Existence of abnormalities
Oil, water level check
Engine coolant level
Engine oil level
Hydraulic oil level
Engine coolant temperature Max. range
When necessary
Damper case
(
Power train
Final drive
Ambient temperature
Power train oil temperature Max. range
Max.
Min.
Height above sea level

m
Operator's opinion
Visual check results
Service code history

h
Content:
h
Content:
h
Content:
14
h
Content:
D275AX-5E0
Check positions/Method 1
D275AX-5E0
15
16
D275AX-5E0
D275AX-5E0
17
Pm Clinic check sheet
D275AX-5E0
Date
Work order No.
Serial No
Serviceman
Service meter
h
Item
Engine speed
Low idle
Deceleration pedal depressed
High idle
Unit
High idle (Deceleration cut-off mode)
rpm
Torque converter stall

Torque converter stall + work equipment relief
Engine
Blow-by pressure

High idle
Engine oil
pressure
Low idle
Boost pressure
SAE0W30E0S
SAE5W40E0S
SAE10W30DH
SAE15W40DH
SAE30DH Oil
Oil temperature:
Min. 80
kPa
{mmH2O}
Standard value for new machine Service limit value
650 - 750
850 - 950
2,125 - 2,175
1,570 - 1,670
Test results
Pass Fail
650 - 750
850 - 950
2,125 - 2,175
1,530 - 1,630
Max. 2.94
{Max. 300}
Min. 1,510
Min. 1,450
3.92
{400}
Min. 0.34
{Min. 3.5}
0.21
{2.1}
Min. 0.10
{Min. 1.0}
0.08
{0.8}
Min. 169
{Min. 1,270}
144
{1,080}
Max. 620
670
MPa
{kg/cm2}
kPa
{mmHg}
Exhaust temperature Torque converter stall
When measuring the oil pressure of the torque converter and transmission, use the adjustment mode of the monitor and set to "Both steering clutches release mode (Co mode)".
(Check that the left and right steering clutches are released.) When measuring the pressure of each transmission clutch, check only with the engine at low idling to ensure safety.
Item
Unit
Standard value for new machine
Service limit value
MPa
{kg/cm2}
Max. 0.2
{Max. 2}
Max. 0.2
{Max. 2}
1.08 - 1.47
{11 - 15}
2.45 - 2.85
{25 - 29}
0.49 - 1.0
{5 - 10}
0.39 - 0.59
{4 - 6}
1.08 - 1.47
{11 - 15}
2.45 - 2.85
{25 - 29}
1.07 - 1.47
{11.0 - 15.0}
0-0
{0 - 0}
Max. 0.2
{Max. 2}
Max. 0.2
{Max. 2}
1.08 - 1.47
{11 - 15}
2.45 - 2.85
{25 - 29}
0.49 - 1.0
{5 - 10}
0.39 - 0.59
{4 - 6}
1.08 - 1.47
{11 - 15}
2.45 - 2.85
{25 - 29}
1.07 - 1.47
{11.0 - 15.0}
0-0
{0 - 0}
Unit
Standard value for new machine
Service limit value
2.74 - 3.06
{28 - 31.2}
3.04 - 3.30
{31 - 33.7}
Min. 2.65
{Min. 27}
Min. 2.94
{Min. 30}
0.05 - 0.29
{0.5 - 3.0}
2.84 - 3.14
{29 - 32}
2.84 - 3.14
{29 - 32}
2.84 - 3.14
{29 - 32}
2.84 - 3.14
{29 - 32}
2.84 - 3.14
{29 - 32}
0.05 - 0.29
{0.5 - 3.0}
Min. 2.65
{Min. 27}
Min. 2.65
{Min. 27}
Min. 2.65
{Min. 27}
Min. 2.65
{Min. 27}
Min. 2.65
{Min. 27}
Inlet oil pressure

Outlet oil pressure
Low idle
Torque converter
Lock-up clutch pressure

Stator clutch pressure
Inlet oil pressure
Transmission:
Neutral
Oil temperature:
70-90
Outlet oil pressure

High idle
Raise engine speed,

Transmission: F1 when lock-up lamp
lights up
Item
Low idle
Transmission
Lubricating oil
pressure (Reference)
Steering brake
High idle
High idle
Transmission: F3
R clutch pressure
Transmission: R3 Low idle
1st clutch pressure
Transmission: F1
Low idle
2nd clutch pressure
Transmission: F2
Low idle
3rd clutch pressure
Transmission: F3
Low idle
Left brake pressure
Pass Fail
Test results
Pass Fail
Low idle
F clutch pressure
Item
18
Transmission:
Neutral
Test results
Low idle
Transmission: Low idle
Neutral High idle
Low idle
Right brake pressure
Transmission:
Neutral High idle
Brake performance
High idle, F2, brake actuated
MPa
{kg/cm2}
Unit
MPa
{kg/cm2}
2.84 - 3.14
{29 - 32}
3.14 - 3.43
{32 - 35}
2.84 - 3.14
{29 - 32}
3.14 - 3.43
{32 - 35}
Test results Pass Fail
Min. 2.26
{Min. 23}
Min. 2.45
{Min. 25}
Min. 2.26
{Min. 23}
Min. 2.45
{Min. 25}
Machine must not move
D275AX-5E0
Pm Clinic check sheet
D275AX-5E0
Date
Work order No.
Serial No
Serviceman
Service meter
h
HSS oil pressure
Item
HSS main relief pressure
HSS charge relief pressure
HSS servo charge pressure
PCCS lever (for travel)

right FULL
High idle
left FULL
NEUTRAL
Unit
MPa
{kg/cm2}
Unit
Hydraulic components
Ripper lift
relief
26.1 - 28.8
{266 - 294}
Pass Fail
Test results
Pass Fail
26.1 - 28.8
{266 - 294}
26.1 - 28.8
{266 - 294}
26.1 - 28.8
{266 - 294}
26.1 - 28.8
{266 - 294}
Blade tilt relief

High idle
(single tilt only)
26.1 - 28.8
{266 - 294}
26.1 - 28.8
{266 - 294}
Lever: Neutral
3.43 - 3.92
{35 - 40}
3.23 - 3.92
{33 - 40}
Test results
Pass Fail
Test results
Pass Fail
Test results
Pass Fail
Test results
Pass Fail
Low idle
Work equipment pump

MPa
{kg/cm2}
Ripper lift
relief
Item
Test results
38.2 - 41.7
{390 - 425}
38.2 - 41.7
{390 - 425}
2.6 - 3.4
{27 - 35}
26.1 - 28.8
{266 - 294}
Blade tilt relief

(single tilt only)
Control circuit basic

pressure
Blade RAISE
Single tilt (left
Dual tilt (left
Ripper tilt (in
right)
right)
out)
Unit
Low idle
8 - 15
20
High idle
3-5
Low idle
3-5
2.3 - 3.3
3.5
Low idle
5-8
10
High idle
2.3 - 3.3
3.5
Low idle
8 - 14
17
High idle
3-4
4.5
High idle
Item
Hydraulic drift
38.2 - 41.7
{390 - 425}
38.2 - 41.7
{390 - 425}
2.6 - 3.4
{27 - 35}
Common use with work equipment PPC and fan pump control
at control initial pressure
Item
Sec.
Unit

Blade lift drift level
Engine stopped
Max. 100
Max. 150
Max. 15
Max. 30
mm/5 min.
Ripper lift drift level
Item
Fan
Fan speed
Fan oil pressure
Max rotation speed
Fan 100%
Min rotation speed
speed mode
High idle
Item
Visual inspection of final drive drain plug
Unit
420 - 480
rpm
MPa
{kg/cm2}
Unit
Engine stopped
400
1,400 - 1,500
1,350
16.17 - 19.11
{165 - 195}
16.17 - 19.11
{165 - 195}

There must be no excessive metal particles
Always fill in the record when repairing, adjusting, or replacing main parts.
Date
D275AX-5E0
Service meter
Repair record
Date
Service meter
Repair record
19
Pm Clinic undercarriage check sheet
Work order No.
Date
D275AX-5E0
Serial No
Serviceman
Service meter
h
Measure the bushing temperature immediately after operations

Left side of machine
Measurement
results
Pass Fail
Measurement
results
Pass Fail
Right side of machine
Opening of track link
20
Left track
A: Clearance between links
Pin No.
1.4
Right track
A: Clearance between links
Pin No.
1.4
D275AX-5E0
Undercarriage troubleshooting report (Normal)

(Program form No.: SELA195001)
Komatsu
Undercarriage Inspection
Customer name:
Address:
D275AX-5E0
Model
Location
Soil condition
Dealer
Shoe width (mm)

Shoe type
(yyyy/m/d)
Wear
%
New
SMR
Hours on
Rebuilt Parts:
Wet
SINGLE
Wear type
NORMAL
Comments/Observation
L=l/4
RH 1042.4 1054.4
LH
master pin
Work Order No
Wet,AR,HD or Dry
Insp.Date(yy/mm/dd)
New 100% Measured
Wear
mm
LH 1042.4 1054.4
LINK PITCH
Equip#
SMR
Inspector
Working condition
Serial#
260.60 263.60
1.3
RH 260.60 263.60
LINK HEIGHT1.3
BUSHING
d1
d
D is the smallest
of d1,d2 and,d3
LH
166.0
148.0
RH
166.0
148.0
LH
90.5
82.0
RH
90.5
82.0
LH
88.0
30.0
RH
88.0
200.0
30.0
175.0
200.0
200.0
175.0
175.0
200.0
21.0
175.0
33.5
21.0
21.0
33.5
33.5
LH
21.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
0.0
33.5
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
8.0
RH
0.0
8.0
New
Turned
New
Turned
GROUSER HIGHT
H
LH
CARRIER
CARRIER
Front
RH
LH
D
Rear
1.3
RH
LH
IDLER
IDLER
Front
RH
LH
Rear
1.3
TRACK ROLLER
D
h2
h1
D=2(h1-h2)
1.3
SPROCKET
h1
H is the smallest of
h1,h2,h3
h3
h2
1.3
RH
1
LH
LH
LH
LH
LH
LH
LH
LH
LH
10
LH
RH
RH
RH
RH
RH
RH
RH
RH
RH
10
RH
Remarks:
D275AX-5E0
21
Undercarriage troubleshooting report (Impact)

(Program form No.: SELA195001)
Komatsu
Undercarriage Inspection
Customer name:
Address:
D275AX-5E0
Model
Location
Soil condition
Dealer
Shoe width (mm)

Shoe type
(yyyy/m/d)
Wear
%
New
SMR
Hours on
Rebuilt Parts:
Wet
SINGLE
Wear type
IMPACT
Comments/Observation
L=l/4
RH 1042.4 1054.4
LH
master pin
Work Order No
Wet,AR,HD or Dry
Insp.Date(yy/mm/dd)
New 100% Measured
Wear
mm
LH 1042.4 1054.4
LINK PITCH
Equip#
SMR
Inspector
Working condition
Serial#
260.60 263.60
1.3
RH 260.60 263.60
LINK HEIGHT1.3
BUSHING
d1
d
D is the smallest
of d1,d2 and,d3
LH
166.0
148.0
RH
166.0
148.0
LH
90.5
84.5
RH
90.5
84.5
LH
88.0
30.0
RH
88.0
200.0
30.0
175.0
200.0
200.0
175.0
175.0
200.0
21.0
175.0
33.5
21.0
21.0
33.5
33.5
LH
21.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
0.0
33.5
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
8.0
RH
0.0
8.0
New
Turned
New
Turned
GROUSER HIGHT
H
LH
CARRIER
CARRIER
Front
RH
LH
D
Rear
1.3
RH
LH
IDLER
IDLER
Front
RH
LH
Rear
1.3
TRACK ROLLER
D
h2
h1
D=2(h1-h2)
1.3
SPROCKET
H is the smallest of
h1,h2,h3
h3
h1
h2
1.3
RH
1
LH
LH
LH
LH
LH
LH
LH
LH
LH
10
LH
RH
RH
RH
RH
RH
RH
RH
RH
RH
10
RH
Remarks:
22
D275AX-5E0
SEN01417-00
24
D275AX-5E0
SEN01767-00
BULLDOZER
1SHOP MANUAL
D275AX-5E0
Machine model
Serial number
D275AX-5E0
30001 and up
40 Troubleshooting

Failure codes table.......................................................................................................................................... 2
Fuse locations............................................................................................................................................... 10
D275AX-5E0
SEN01767-00
40 Troubleshooting
Failure codes table

Failure
code
1
Applicable
equipment
Action
code
TM
CALL E03
15SAL1 Forward clutch oil pressure 1
TM
CALL E03
15SALH Forward clutch oil pressure 2
TM
CALL E03
15SBL1 Reverse clutch oil pressure 1
TM
CALL E03
15SBLH Reverse clutch oil pressure 2
TM
CALL E03
15SEL1 1st clutch oil pressure 1
TM
CALL E03
15SELH 1st clutch oil pressure 2
TM
CALL E03
15SFL1
2nd clutch oil pressure 1
TM
CALL E03
15SFLH 2nd clutch oil pressure 2
TM
CALL E03
15SGL1 3rd clutch oil pressure 1
TM
CALL E03
15SGLH 3rd clutch oil pressure 2
TM
CALL E03
1800MW Power train clutch slip
TM
E02
2300NR Brake thermal load
ST
2301L1
Right steering brake oil pressure 1
ST
CALL E04
2301LH
Right steering brake oil pressure 2
ST
CALL E04
2301NR Right steering brake thermal load
ST
2302L1
Left steering brake oil pressure 1
ST
CALL E04
2302LH
Left steering brake oil pressure 2
ST
CALL E04
2302NR Left steering brake thermal load
ST
A000NS Engine overheat
AA10NX Air cleaner clogging
MON
AB00MA Battery charge abnormal
MON
B@BAZG Eng oil press low
ENG
B@BAZK Eng oil level low
B@BCNS Eng coolant overheat
ENG
B@BCZK Radiator coolant level low
MON
B@BEBF Water gets mixed with fuel
B@BFZK Fuel level abnormal reduction
MON
B@CENS Torque converter oil overheat
MON
B@CHZG HSS charge oil pressure reduction
MON
1500L0
Trouble
Transmission clutch dual engagement
History
classification
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Mechanical
system
Mechanical
system
Mechanical
system
Mechanical
system
Mechanical
system
Mechanical
system
Mechanical
system
Mechanical
system
Mechanical
system
Mechanical
system
Mechanical
system
Reference
manual
Troubleshooting
by failure code,
Part 1
SEN01655-00
D275AX-5E0
40 Troubleshooting
Failure
code
SEN01767-00
Applicable
equipment
Action
code
B@CHZK Power train oil level reduction
B@GAZK Battery electrolyte level reduction
MON
Trouble
B@HANS Hyd oil overheat

B@HAZK Hydraulic oil level reduction
CA111
EMC critical internal failure
ENG
CALL E04
CA115
Eng Ne and Bkup speed sens error
ENG
CALL E04
CA122
Chg air press sensor high error
ENG
CALL E03
CA123
Chg air press sensor low error
ENG
CALL E03
CA131
Throttle sensor high error
ENG
CALL E03
CA132
Throttle sensor low error
ENG
CALL E03
CA135
Eng oil press sensor high error
ENG
E02
CA141
Eng oil press sensor low error
ENG
E02
CA144
Coolant temp sens high error
ENG
E02
CA145
Coolant temp sens low error
ENG
E02
CA153
Chg air temp sensor high error
ENG
E01
CA154
Chg air temp sensor low error
ENG
E01
CA187
Sens supply 2 volt low error
ENG
CALL E03
CA221
Ambient press sens high error
ENG
CALL E03
CA222
Ambient press sens low error
ENG
CALL E03
CA227
Sens supply 2 volt high error
ENG
CALL E03
CA234
Eng overspeed
ENG
CA238
Ne speed sens supply volt error
ENG
CALL E03
CA263
Fuel temp sensor high error
ENG
E01
CA265
Fuel temp sensor low error
ENG
E01
CA271
PCV1 short error
ENG
CALL E03
CA272
PCV1 open error
ENG
CALL E03
CA273
PCV2 short error
ENG
CALL E03
CA274
PCV2 open error
ENG
CALL E03
CA322
Inj #1 (L#1) open/short error
ENG
CALL E03
CA323
ENG
CALL E03
CA324
ENG
CALL E03
D275AX-5E0
History
classification
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system
Mechanical
system
Mechanical
system
Mechanical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Reference
manual
Troubleshooting
by failure code,
Part 1
SEN01655-00
Troubleshooting
by failure code,
Part 2
SEN01656-00
SEN01767-00
Failure
code
40 Troubleshooting
Trouble
Applicable
equipment
Action
code
CA325
ENG
CALL E03
CA331
ENG
CALL E03
CA332
ENG
CALL E03
CA342
Calibration code incompatibility
ENG
CALL E04
CA351
Injectors drive circuit error
ENG
CALL E03
CA352
ENG
CALL E03
CA386
ENG
CALL E03
CA441
Battery voltage low error
ENG
CALL E04
CA442
Battery voltage high error
ENG
CALL E04
CA449
Rail press very high error
ENG
CALL E03
CA451
Rail press sensor high error
ENG
CALL E03
CA452
Rail press sensor low error
ENG
CALL E03
CA553
Rail press high error
ENG
E02
CA554
Rail press sensor in range error
ENG
CALL E03
CA559
Rail press low error
ENG
E02
CA689
Eng Ne speed sensor error
ENG
CALL E03
CA731
Eng Bkup speed sens phase error
ENG
CALL E03
CA757
All continuous data lost error
ENG
CALL E04
CA778
Eng Bkup speed sensor error
ENG
CALL E03
CA1228 EGR valve servo error 1
ENG
E02
CA1625 EGR valve servo error 2
ENG
CALL E03
CA1626 BP valve sol current high error
ENG
CALL E03
CA1627 BP valve sol current low error
ENG
CALL E03
CA1628 Bypass valve servo error 1
ENG
E02
CA1629 Bypass valve servo error 2
ENG
CALL E03
CA1631 BP valve pos sens high error
ENG
CALL E03
CA1632 BP valve pos sens low error
ENG
CALL E03
CA1633 KOMNET datalink timeout error
ENG
CALL E03
CA1642 EGR inlet press sens low error
ENG
E01
CA1653 EGR inlet press sens high error
ENG
E01
CA2185 Throt sens sup volt high error
ENG
CALL E03
History
classification
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Reference
manual
Troubleshooting
by failure code,
Part 2
SEN01656-00
Troubleshooting
by failure code,
Part 3
SEN01657-00
D275AX-5E0
40 Troubleshooting
Failure
code
SEN01767-00
Applicable
equipment
Action
code
CA2186 Throt sens sup volt low error
ENG
CALL E03
CA2249 Rail press very low error
ENG
CALL E03
CA2271 EGR valve pos sens high error
ENG
CALL E03
CA2272 EGR valve pos sens low error
ENG
CALL E03
CA2351 EGR valve sol current high error
ENG
CALL E03
CA2352 EGR valve sol current low error
ENG
CALL E03
CA2555 Grid htr relay volt low error
ENG
E01
CA2556 Grid htr relay volt high error
ENG
E01
D110KA Battery relay holding disconnection
ST
D110KB Battery relay drive short circuit
ST
D130KA Neutral safety relay disconnection
TM
E02
D130KB Neutral safety relay short circuit
TM
E02
D161KA Back-up alarm relay disconnection
TM
E01
D161KB Back-up alarm relay short circuit
TM
E01
D190KA Engine controller ACC signal cut relay
ST
D190KB Engine controller ACC signal cut relay short
ST
D811KR KOMTRAX controller CAN defective communication
ST
MON
CALL E03
DAQ0KT Transmission controller internal abnormality
TM
E01
controller main source voltage reducDAQ1KK Transmission

tion
TM
CALL E04
DAQ2KK Transmission controller load voltage reduction
TM
CALL E04
controller sensor 5 V power source

DAQ5KK Transmission
(1) power supply source voltage reduction
controller sensor 24 V power supply
DAQ6KK Transmission
source voltage reduction
DAQ7KK Transmission
source (2) power source voltage reduction
Transmission controller type collation (Type select
DAQ9KQ signal
inconsistency)
controller CAN defective communicaDAQRKR Transmission
tion (Abnormality in objective component system)
controller S-NET defective communiDAQSKR Transmission
cation (Abnormality in objective component system)
TM
CALL E03
TM
E01
TM
CALL E03
TM
CALL E04
ST
CALL E03
TM
E01
DB2RKR Engine controller CAN defective communication
ST
CALL E03
DB30KT Steering controller abnormality in controller
ST
E01
controller main power supply source voltDB31KK Steering

age reduction
power source of steering controller power
DB32KK Load
source voltage drop
ST
CALL E04
ST
CALL E04
Trouble
monitor CAN communication defective

DAFRKR Machine
communication
D275AX-5E0
History
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Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Reference
manual
Troubleshooting
by failure code,
Part 3
SEN01657-00
Troubleshooting
by failure code,
Part 4
SEN01658-00
SEN01767-00
Failure
code
40 Troubleshooting
Applicable
equipment
Action
code
ST
CALL E03
ST
CALL E03
ST
CALL E03
ST
CALL E04
TM
CALL E03
ST
E01
DD12KA Shift up switch disconnection
TM
E02
DD12KB Shift up switch short circuit
TM
E02
DD13KA Shift down switch disconnection
TM
E02
DD13KB Shift down switch short circuit
TM
E02
DD14KA Parking brake lever switch disconnection
TM
CALL E03
DD14KB Parking brake lever switch short circuit
TM
E03
DDB9L4 Reverse switch disagreement
TM
CALL E03
DDK3L4 Forward switch disagreement
TM
CALL E03
DDK5KA Gearshift switch disconnection
TM
CALL E03
DDK5KB Gearshift switch short circuit
TM
CALL E03
DDN7KA Blade pitch switch disconnection
TM
E02
DDN7KB Blade pitch switch short circuit
TM
E02
DDN9KA Blade tilt switch disconnection
TM
E01
DDN9KB Blade tilt switch short circuit
TM
E01
lift raise oil pressure switch is kept ON for

DDNBLD Ripper
long time
lift lower oil pressure switch is kept ON for
DDNCLD Ripper
long time
lift tilt-in oil pressure switch is kept ON for
DDNDLD Ripper
long time
TM
TM
TM
DDQ2KA Parking brake lever switch disconnection
TM
CALL E03
DDQ2KB Parking brake lever switch short circuit
ST
CALL E03
DDQ2L4 Parking brake lever switch disagreement
ST
CALL E03
DDT5KA Neutral switch disconnection
TM
CALL E04
DDT5KB Neutral switch short circuit
TM
CALL E04
specification selection (Model selection signal

DDT5KQ Lever
disagreement)
oil temperature sensor input signal is out
DGS1KX Hydraulic
of normal range
TM
CALL E04
TM
Trouble
controller sensor 5 V power source (1)

DB35KK Steering
power source voltage drop
DB36KK Steering
controller sensor 5 V power source (2)
DB37KK Steering
controller type collation (Type select signal
DB39KQ Steering
inconsistency)
controller CAN defective communication
DB3RKR Steering
(Abnormality in objective component system)
Steering controller S-NET defective communication
DB3SKR (Abnormality
in objective component system)
History
classification
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Reference
manual
Troubleshooting
by failure code,
Part 4
SEN01658-00
D275AX-5E0
40 Troubleshooting
Failure
code
SEN01767-00
Trouble
DGT1KA Power train oil temp sensor disconnection

DGT1KX Power train oil temp sensor out of signal range
Applicable
equipment
Action
code
TM
E01
MON
E01
equipment pump oil pressure sensor short cirDH21KB Work

cuit
equipment pump oil pressure sensor disconDH22KA Work
nection
equipment pump oil pressure sensor short cirDH22KB Work
cuit
ST
E01
TM
TM
DHH3KA HSS pump oil pressure sensor A disconnection
ST
CALL E03
DHH3KB HSS pump oil pressure sensor A short circuit
ST
CALL E03
DHH4KA HSS pump oil pressure sensor B disconnection
ST
CALL E03
DHH4KB HSS pump oil pressure sensor B short circuit
ST
CALL E03
DK10KA Fuel control dial disconnection
ST
CALL E03
DK10KB Fuel control dial short circuit
ST
CALL E03
DK30KA Steering potentiometer (1) disconnection
ST
CALL E03
DK30KB Steering potentiometer (1) short circuit
ST
CALL E03
DK30KX Steering potentiometer (1) out of input signal range
ST
CALL E04
potentiometer (1) disconnection or short

DK30KZ Steering
circuit
potentiometer (1) analog signals do not
DK30L8 Steering
agree
ST
CALL E04
ST
CALL E03
DK31KA Steering potentiometer (2) disconnection
ST
CALL E03
DK31KB Steering potentiometer (2) short circuit
ST
CALL E03
DK40KA Brake potentiometer disconnection
ST
CALL E03
DK40KB Brake potentiometer short circuit
ST
CALL E03
DK55KX Directional potentiometer out of input signal range
TM
CALL E04
Directional potentiometer disconnection or short cirDK55KZ cuit

potentiometer analog signals do not
DK55L8 Directional
agree
TM
CALL E04
TM
CALL E03
DK56KA F-R potentiometer (1) disconnection
TM
CALL E03
DK56KB F-R potentiometer (1) short circuit
TM
CALL E03
DK57KA F-R potentiometer (2) disconnection
TM
CALL E03
DK57KB F-R potentiometer (2) short circuit
TM
CALL E03
DK60KA Acceleration sensor disconnection
ST
E01
DK60KB Acceleration sensor short circuit
ST
E01
DKH1KA Pitch angle sensor disconnection
ST
CALL E03
DKH1KB Pitch angle sensor short circuit
ST
CALL E03
D275AX-5E0
History
classification
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Reference
manual
Troubleshooting
by failure code,
Part 5
SEN01659-00
SEN01767-00
Failure
code
40 Troubleshooting
Applicable
equipment
Action
code
DKH1KX Pitch angle sensor out of input signal range
TM
E01
DLT3KA Transmission out-speed sensor disconnection
TM
E01
DLT3KB Transmission out-speed sensor abnormal
TM
E01
MON
DW59KA Blade dual selector solenoid disconnection
TM
E01
DW59KB Blade dual selector solenoid short circuit
TM
E01
DW59KY Blade dual selector solenoid hot short
TM
E01
DW5AKA Blade pitch selector solenoid disconnection
TM
E02
DW5AKB Blade pitch selector solenoid short circuit
TM
E02
DW5AKY Blade pitch selection solenoid hot short circuit
TM
E02
DW7BKA Fan rev EPC disconnection
ST
E01
DW7BKB Fan rev EPC short circuit
ST
E01
DW7BKY Fan reverse solenoid hot short circuit
ST
E02
DWN1KA HSS pump solenoid right disconnection
ST
CALL E03
DWN1KB HSS pump solenoid right short circuit
ST
CALL E03
DWN1KY HSS pump solenoid right hot short
ST
CALL E04
DWN2KA HSS pump solenoid left disconnection
ST
CALL E03
DWN2KB HSS pump solenoid left short circuit
ST
CALL E03
DWN2KY HSS pump solenoid left short circuit
ST
CALL E03
DWN3KA Sudden stop prevention solenoid disconnection
ST
CALL E04
DWN3KB Sudden stop prevention solenoid short circuit
ST
CALL E04
DWN3KY Sudden stop prevention solenoid hot short circuit
ST
CALL E04
DWN4KA HSS motor free solenoid disconnection
ST
E01
DWN4KB HSS motor free solenoid short circuit
ST
E01
DWN5KA Fan pump solenoid disconnection
TM
E01
DWN5KB Fan pump solenoid short circuit
TM
E01
DWN5KY Fan pump solenoid hot short circuit
TM
E02
DXH1KA Lock-up solenoid disconnection
TM
E01
DXH1KB Lock-up solenoid short circuit
TM
E01
DXH1KY Lock-up solenoid hot short
TM
E03
DXH4KA 1st clutch ECMV disconnection
TM
CALL E03
Trouble
DV00KB Caution buzzer short circuit
History
classification
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Reference
manual
Troubleshooting
by failure code,
Part 5
SEN01659-00
Troubleshooting
by failure code,
Part 6
SEN01878-00
D275AX-5E0
40 Troubleshooting
Failure
code
SEN01767-00
Applicable
equipment
Action
code
DXH4KB 1st clutch ECMV short circuit
TM
CALL E03
DXH4KY 1st clutch ECMV hot short circuit
TM
CALL E03
DXH5KA 2nd clutch ECMV disconnection
TM
CALL E03
DXH5KB 2nd clutch ECMV short circuit
TM
CALL E03
DXH5KY 2nd clutch ECMV hot short circuit
TM
CALL E03
DXH6KA 3rd clutch ECMV disconnection
TM
CALL E03
DXH6KB 3rd clutch ECMV short circuit
TM
CALL E03
DXH6KY 3rd clutch ECMV hot short circuit
TM
E03
DXH7KA Reverse clutch ECMV disconnection
TM
CALL E03
DXH7KB Reverse clutch ECMV short circuit
TM
CALL E03
DXH7KY R clutch ECMV hot short circuit
TM
CALL E03
DXH8KA Forward clutch ECMV disconnection
TM
CALL E03
DXH8KB Forward clutch ECMV short circuit
TM
CALL E03
DXH8KY F clutch ECMV hot short circuit
TM
CALL E03
DXHBKA Right brake ECMV disconnection
ST
CALL E04
DXHBKB Right brake ECMV short circuit
ST
CALL E04
DXHBKY Right brake ECMV hot short circuit
ST
CALL E04
DXHCKA Left brake ECMV disconnection
ST
CALL E04
DXHCKB Left brake ECMV short circuit
ST
CALL E04
DXHCKY Left brake ECMV hot short circuit
ST
CALL E04
a
a
a
a
a
Trouble
History
classification
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Reference
manual
Troubleshooting
by failure code,
Part 6
SEN01878-00
The items in this table are arranged in the order of the failure codes.
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
The failure codes having no numbers in the action code column are not displayed on the ordinary
screen when abnormality related to them occurs. They are simply recorded in the fault history of the
service menu (Electrical equipment system or mechanical equipment system).
The history classification column shows in which system each failure is classified, the electrical equipment system or mechanical equipment system, when it is recorded in the failure history.
Blinking and lighting of failure code
q
Blinking : The trouble has not been repaired.
q
Lighting : The trouble has been repaired.
D275AX-5E0
SEN01767-00
40 Troubleshooting
Fuse locations
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.
Circuit breakers
Breaker No.
Conector No.
Breaker capacity
(A)
CB105H
105
Electrical intake air heater relay
B7L
30
Engine controller
F96
105
Main power supply
F32
30
Unswitched power supply
CB1
20
Steering controller
CB2
20
Machine monitor
CB3
20
CB4
20
Air conditioner
CB5
20
Head lamp
10
CB6
20
Unswitched power supply of starting switch
Destination of power
Fuse box FS11, FS12

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

Fuse No.
Power source
Backup alarm
20
Pin puller, Pre-heat, Air suspension seat
20
Additional heater
20
Working lamp
20
Rear lamp
2
3
10
Fuse capacity
(A)
D275AX-5E0
40 Troubleshooting
SEN01767-00
Fuse box FS31, FS32

Fuse No.
Power source
Fuse capacity
(A)
Engine controller ACC
20
Horn
20
Spare power supply 1
20
Spare power supply 2
20
Spare ACC signal
D275AX-5E0
11
SEN01767-00
40 Troubleshooting
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
D275AX-5E0
40 Troubleshooting
SEN01767-00
Fuse box
Fuse No.
Power source
Fuse capacity
(A)
10
Radio, Cigarette lighter, Room lamp
10
Rear wiper
10
Right wiper
10
Front wiper
10
Left wiper
20
Additional rear lamp
20
Additional head lamp, Revolving warning lamp
Spare
Spare
10
Radio memory
10
Location of fuse box
D275AX-5E0
(In operator's cab)
13
SEN01767-00
Reset method for main power supply circuit

breaker
Turn the starting switch to the OFF position to turn
the electric circuit OFF, wait for 5 10 minutes, and
press reset buttons (1) (4).
a Check by the operating effort of each reset button that the circuit is reset.
a If the electric circuit is turned OFF, the operating 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.
14
40 Troubleshooting
Reset method for circuit breaker

Turn the starting switch to the OFF position and
push in reset button (5) which was pushed out
when the electric circuit was turned OFF.
a If the reset button is pushed out again soon
after it is pushed in, carry out troubleshooting
and repair the faulty part.
D275AX-5E0
SEN01767-00
40 Troubleshooting
16
D275AX-5E0
SEN01768-00
BULLDOZER
1SHOP MANUAL
D275AX-5E0
Machine model
Serial number
D275AX-5E0
30001 and up
40 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-adapter box and T-adapter table................................................................................................................ 39
D275AX-5E0
SEN01768-00
40 Troubleshooting
Points to remember when troubleshooting

k
k
k
k
k
k
Stop the machine in a level place, and check that the lock pin, blocks, and parking brake are
securely fitted.
When carrying out the operation with 2 or more workers, keep strictly to the agreed signals, and
do not allow any unauthorized person to come near.
If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause
burns, so wait for the engine to cool down before starting troubleshooting.
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
When disconnecting wiring, always disconnect the negative () terminal of the battery first.
When removing the plug or cap from a location which is under pressure from oil, water, or air,
always release the internal pressure first. When installing 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 prevent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to
understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator
various questions to form some idea of possible causes of the failure that would produce the reported symptoms.
1.
2.
3.
When carrying out troubleshooting, do not

hurry to disassemble the components.
If components are disassembled immediately
any failure occurs:
q
Parts that have no connection with the failure or other unnecessary parts will be disassembled.
q
It will become impossible to find the cause
of the failure.
It will also cause a waste of manhours, parts,
or oil or grease, and at the same time, will also
lose the confidence of the user or operator. For
this reason, when carrying out troubleshooting,
it is necessary to carry out thorough prior
investigation and to carry out troubleshooting
in accordance with the fixed procedure.
Points to ask user or operator
1) Have any other problems occurred apart
from the problem that has been reported?
2) Was there anything strange about the
machine before the failure occurred?
3) Did the failure occur suddenly, or were
there problems with the machine condition
before this?
4) Under what conditions did the failure
occur?
5) Had any repairs been carried out before
the failure? When were these repairs carried out?
6) Has the same kind of failure occurred
before?
4)
Other maintenance items can be checked

externally, so check any item that is considered to be necessary.
4.
Confirming failure
Confirm the extent of the failure yourself, and
judge whether to handle it as a real failure or
as a problem with the method of operation, etc.
a When operating the machine to reenact
the troubleshooting symptoms, do not
carry out any investigation or measurement that may make the problem worse.
5.
Troubleshooting
Use the results of the investigation and inspection in Items 2 4 to narrow down the causes
of failure, then use the troubleshooting table or
troubleshooting flowchart to locate the position
of the the failure exactly.
a The basic procedure for troubleshooting is
as follows.
1] Start from the simple points.
2] Start from the most likely points.
3] Investigate other related parts or
information.
6.
Measures to remove root cause of failure

Even if the failure is repaired, if the root cause
of the failure is not repaired, the same failure
will occur again.To prevent this, always investigate why the problem occurred. Then, remove
the root cause.
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.
D275AX-5E0
40 Troubleshooting
SEN01768-00
Sequence of events in troubleshooting
D275AX-5E0
SEN01768-00
40 Troubleshooting
Check before troubleshooting

Item
Criterion
Remedy
1. Check of level and type of fuel
Add fuel
2. Check of fuel for foreign matter
Clean and drain
Between H L
Add oil
3. Check of hydraulic oil level

Lubricating
oil/Coolant
Hydraulic/
Mechanical
equipment
4. Check of damper case oil level
Between H L
Add oil
5. Check of power train oil level
Between H L
Add oil
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
1. Check for abnormal noise/smell
Repair
2. Check for oil leakage
Repair
3. Bleeding air
Bleed air
1. Check of battery terminals and wiring for looseness and corrosion
Retighten or replace
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

Electrical
equipment
Between H L
Add or replace
6. Check of wires for discoloration, burn, and

removal of cover
Repair or replace
7. Check for released wire clamp and drooping wire
Repair
8. Check of wires for wetness (Check connectors

and terminals for wetness, in particular)
Dry
9. Check circuit breaker for turning OFF and fuse

for disconnection and corrosion
Replace
10. Check of alternator voltage

(while engine speed is at middle or higher)
After operating for several

minutes: 27.5 29.5 V
Replace
11. Check of battery relay for operating sound

(when starting switch is turned ON or OFF)
Replace
D275AX-5E0
40 Troubleshooting
SEN01768-00
Classification and procedures for troubleshooting
Classification for troubleshooting

Type
Display of code
Contents
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 history:
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" according 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 troubleshooting corresponding to that phenomenon in the "E mode", "H mode", or "S mode".
D275AX-5E0
SEN01768-00
40 Troubleshooting
Phenomena looking like troubles and troubleshooting Nos.

Troubleshooting
No.
Phenomena looking like troubles
Display
of code
E mode
H mode
S mode
Phenomena related to action code/failure code

1 Action code and failure code are displayed on machine monitor
2
When fault history is checked, failure code is displayed in mechanical

system fault history
When fault history is checked, failure code is displayed in electrical

system fault history
When fault history is checked, failure code is displayed in air conditioner

or heater fault history
According to displayed
code
E-28
Phenomena related to engine

5 Starting performance of engine is poor
6 Engine does not start
S-1
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 The preheater does not operate (Manual preheating function)
E-2
Phenomena related to power train

22 No travel power (No drawbar pull)
H-1
23 Machine does not move (At 2nd or 3rd speed)
H-2
24 Machine does not move in any speed range
H-3
25 Machine travels only in one direction forward or in reverse
H-4
26
When gear is shifted or travel direction is changed, large time lag is

made
H-5
27 Machine does not turn (Not turned rightward or leftward)
H-6
28 Steering speed or power is low
H-7
29 Brake does not work
H-8
30 Torque converter does not lock-up
H-9
31 Overheat of power train oil temperature
H-10
32 Abnormal sound around HSS pump or HSS motor
H-11
Phenomena related to work equipment

33 All work equipment speeds are slow
H-12
34 Work equipment does not move
H-13
35 Blade lift speed is slow or lacks power
H-14
36 Blade tilt speed is slow or lacks power
H-15
37 Ripper lift speed is slow or lacks power
H-16
38 Ripper tilt speed is slow or lacks power
H-17
D275AX-5E0
40 Troubleshooting
SEN01768-00
Troubleshooting
No.
Phenomena looking like troubles
Display
of code
E mode
39 Excessive hydraulic drift of blade lift
H mode
H-18
40 Excessive hydraulic drift of blade tilt
H-19
41 Excessive hydraulic drift of ripper lift
H-20
42
S mode
Ripper pin puller cylinder does not work (Giant ripper attachment
machine)
H-21
43 Blade pitch does not work (Dual tilt attachment machine)
H-22
44 Abnormal sound comes out from around work equipment pump
H-23
Fan speed is abnormal (Sound and/or vibration of fan are/is abnormally

45
large or engine overheats)
H-24
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
turned ON
E-4
When the starting switch is turned ON, the machine monitor completely
remains lighted and does not go out
E-5
48
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
come on
E-9
53
At the selecting time of dual tilt, the dual/single tilt selector lamp does
not come on (Dual tilt-mounted machine)
E-10
54
At the locking-up of the torque converter, the torque converter lock-up

display lamp does not come on
E-11
55 The engine coolant temperature gauge does not indicate normally
E-12
56 Indication of the torque converter temperature gauge is abnormal
E-13
57 The hydraulic oil temperature gauge does not indicate normally
E-14
58 Indication of the fuel gauge is abnormal
E-15
59 Indications of gear speed and engine speed are abnormal
E-16
60 Indication of the shift mode service meter is abnormal
E-17
61 The switch module cannot be operated
E-18
62 The warning lamp does not flash or does not go out
E-19
63 The alarm buzzer does not sound or does not stop
E-20
64 Auto shift down is not possible or is not released
E-21
65 Pivot turn is not possible or is not released
E-22
66 The alarm buzzer cannot be cancelled
E-23
67 The operator mode cannot be operated
E-24
68 The service mode cannot be operated
E-25
69 The back-up alarm does not sound
E-26
70
The night light, the headlamp, the working lamp and the rear lamp on
the panel do not come on
71 The air conditioner does not operate
E-27
E-28
Other phenomena
72 KOMTRAX system does not operate normally
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Contents of troubleshooting table

a
The following information is summarized in the troubleshooting table and the related electrical circuit
diagram. Before carrying out troubleshooting, understand that information fully.
Action code
Failure code
Machine
monitor
display
Machine monitor
display
Contents of
trouble
Trouble
Names of the failure symptoms displayed in the failure history

on the machine monitor
State where the machine monitor or controller detects the trouble
Action of
Action to be taken to protect the system and equipment when the machine monitor or controlmachine moniler detects a trouble
tor or controller
Problem that
appears on
machine
Related
information
Problem that appears as an abnormality in the machine by the action (above) taken by monitor
or controller
Information related to troubles occurred or troubleshooting
Cause
2
Possible causes
and standard
value in normal
state
Standard value in normal state/Remarks on troubleshooting

<Described contents>
Standard value when normal required to judge the possible cause
Remarks required to judge whether any cause is right or
not
<Symptoms of defective harness>
Disconnection in wiring
The connector connection is defective or the wiring harness 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
(24V) circuit comes into contact with the electric power
supply (24V) circuit.
Short circuit
A harness abnormally comes into contact with a harness
of separate circuit.
Cause by which a trouble is

assumed to be detected
(The order number indicates
a serial number, not a priority <Points to remember when troubleshooting>
sequence.)
(1) Method of indicating connector numbers and handling Tadapter
For troubleshooting, insert or connect the T- adapter as
described below unless especially specified.
3
When maleor female is not indicated for a connector number, disconnect the connector, and insert the Tadapter in both the male and female.
When maleor female is indicated for a connector
number, disconnect the connector, and insert the Tadapter in only either the male or female.
(2) Pin number description sequence and tester lead handling
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.
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Circuit diagram related
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 ( ): Roughly shows the location on the machine.
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Connection table for connector pin numbers

a
10
40 Troubleshooting
The terms male and female refer to the pins, while the terms male housing and female housing refer to
the mating portion of the housing.
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T-adapter box and T-adapter table
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.
Out of kit
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7000
799-601-7100
799-601-2800
Identification
symbol
799-601-2700
Part name
T-adapter kit
799-601-2500
Part No.
Number of pins
799-601-2600
T-box (for ECONO)
21
799-601-3100
T-box (for MS)
37
799-601-3200
T-box (for MS)
37
799-601-3380
Plate for MS (14-pin)
799-601-3410
Adapter for BENDIX (MS)
24
MS-24P
799-601-3420
24
MS-24P
799-601-3430
17
MS-17P
799-601-3440
17
MS-17P
799-601-3450
MS-5P
799-601-3460
10
MS-10P
799-601-3510
MS-5S
799-601-3520
17
MS-17P
799-601-3530
19
MS-19P
799-601-2910
14
MS-14P
799-601-3470
Case
799-601-2710
Adapter for MIC
MIC-5P
799-601-2720
Adapter for MIC
13
MIC-13P
799-601-2730
Adapter for MIC
17
MIC-17P
799-601-2740
Adapter for MIC
21
MIC-21P
799-601-2950
Adapter for MIC
MIC-9P
799-601-2750
Adapter for ECONO
ECONO2P
799-601-2760
Adapter for ECONO
ECONO3P
799-601-2770
Adapter for ECONO
ECONO4P
799-601-2780
Adapter for ECONO
ECONO8P
799-601-2790
Adapter for ECONO
12
ECONO12P
799-601-2810
Adapter for DLI
DLI-8P
799-601-2820
Adapter for DLI
12
DLI-12P
799-601-2830
Adapter for DLI
16
DLI-16P
799-601-2840
Extension cable (ECONO type)
12
ECONO12P
799-601-2850
Case
799-601-4210
Adapter for DRC
50
799-601-7010
Adapter for X (T-adapter)
799-601-7020
Adapter for X
X2P
799-601-7030
Adapter for X
X3P
799-601-7040
Adapter for X
X4P
799-601-7050
Adapter for SWP
SW6P
799-601-7060
Adapter for SWP
SW8P
799-601-7310
Adapter for SWP
12
SW12P
799-601-7070
Adapter for SWP
14
SW14P
799-601-7320
Adapter for SWP
16
SW16P
799-601-7080
Adapter for M (T-adapter)
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q
q
q
q
DRC50
q
q
q
q
q
q
39
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40 Troubleshooting
799-601-7120
Adapter for M
M4P
799-601-7130
Adapter for M
M6P
Out of kit
799-601-9300
799-601-9200
799-601-9100
M3P
799-601-9000
799-601-7400
M2P
799-601-8000
799-601-7100
Adapter for M
799-601-7500
799-601-7000
Adapter for M
799-601-7110
799-601-2800
799-601-7090
Part name
799-601-2700
Identification
symbol
Part No.
799-601-2500
Number of pins
T-adapter kit
799-601-7340
Adapter for M
M8P
799-601-7140
Adapter for S
S8P
799-601-7150
Adapter for S (White)
10
S10P
799-601-7160
Adapter for S (Blue)
12
S12P
799-601-7170
Adapter for S (Blue)
16
S16P
799-601-7330
16
S16PW
799-601-7350
12
S12PW
799-601-7180
Adapter for AMP040
A8P
799-601-7190
Adapter for AMP040
12
A12P
799-601-7210
Adapter for AMP040
16
A16P
799-601-7220
Adapter for AMP040
20
A20P
799-601-7230
Short connector for X
799-601-7240
Case
799-601-7270
Case
799-601-7510
Adapter for 070
10
07-10
799-601-7520
Adapter for 070
12
07-12
799-601-7530
Adapter for 070
14
07-14
799-601-7540
Adapter for 070
18
07-18
799-601-7550
Adapter for 070
20
07-20
799-601-7360
Adapter for relay
REL-5P
799-601-7370
Adapter for relay
REL-6P
799-601-7380
Adapter for JFC
q
q
q
799-601-9010
Adapter for DTM
DTM2
799-601-9020
Adapter for DT
DT2
799-601-9030
Adapter for DT
DT3
799-601-9040
Adapter for DT
DT4
799-601-9050
Adapter for DT
DT6
799-601-9060
Adapter for DT (Gray)
DT8GR
799-601-9070
Adapter for DT (Black)
DT8B
799-601-9080
Adapter for DT (Green)
DT8G
799-601-9090
Adapter for DT (Brown)
DT8BR
799-601-9110
Adapter for DT (Gray)
12
DT12GR
799-601-9120
Adapter for DT (Black)
12
DT12B
799-601-9130
Adapter for DT (Green)
12
DT12G
799-601-9140
Adapter for DT
12
DT12BR
799-601-9210
Adapter for HD30-18
D18-8
799-601-9220
Adapter for HD30-18
14
D18-14
799-601-9230
Adapter for HD30-18
20
D18-20
799-601-9240
Adapter for HD30-18
21
D18-21
799-601-9250
Adapter for HD30-24
D24-9
799-601-9260
Adapter for HD30-24
16
D24-16
40
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D24-31
Plate for HD30 (24-pin)
799-601-9320
T-box (for DT/HD)
799-601-9330
Case
12
Out of kit
Adapter for HD30-24
799-601-9310
799-601-9300
799-601-9100
799-601-9290
799-601-9200
799-601-9000
799-601-8000
799-601-7500
D24-23
799-601-7400
D24-21
23
799-601-7100
21
Adapter for HD30-24
799-601-7000
Adapter for HD30-24
799-601-9280
799-601-2800
799-601-9270
Part name
799-601-2700
Identification
symbol
Part No.
799-601-2500
Number of pins
T-adapter kit
q
q
799-601-9340
Case
799-601-9350
Adapter for DRC
40
DRC-40
799-601-9360
Adapter for DRC
24
DRC-24
799-601-9410
Adapter for engine (CRI-T2)
799-601-9420

A3
799-601-9430

799-601-9440
1,2,3
795-799-5520
Adapter for engine (HPI-T2)
795-799-5530

795-799-5540

795-799-5460
Cable for engine (HPI-T2)
795-799-5470
795-799-5480
799-601-4160
q
OIL
799-601-4340
1,2,3
799-601-4130
FCIN
799-601-4140
FCIG
799-601-4150
FCIB
799-601-4180
FCIP3
799-601-4190
1,2,3
799-601-4240
1,2,3
799-601-4250
1,2,3
799-601-4330
1,2,3
799-601-4230
1,2,3,4
799-601-4260
Adapter for controller (ENG)
DTP4
799-601-4210
50
DRC50
799-601-4220
60
DRC60
799-601-4280
Box for controller (PUMP)
121
799-601-9720
Adapter for controller (HST)
16
HST16A
799-601-9710
16
HST16B
799-601-9370
26
HST26A
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BULLDOZER
1SHOP MANUAL
D275AX-5E0
Machine model
Serial number
D275AX-5E0
30001 and up
40 Troubleshooting
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 [1800MW] Power train clutch slip............................................................................................. 18
Failure code [2300NR] Brake thermal load................................................................................................... 19
Failure code [2301L1] Right steering brake oil pressure 1 ........................................................................... 20
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Failure code [2301LH] Right steering brake oil pressure 2 ........................................................................... 22

Failure code [2301NR] Right steering brake thermal load ............................................................................ 24
Failure code [2302L1] Left steering brake oil pressure 1 .............................................................................. 26
Failure code [2302LH] Left steering brake oil pressure 2 ............................................................................. 28
Failure code [2302NR] Left steering brake thermal load............................................................................... 30
Failure code [A000NS] Engine overheat....................................................................................................... 30
Failure code [AA10NX] Air cleaner clogging ................................................................................................. 32
Failure code [AB00MA] Battery charge abnormal......................................................................................... 34
Failure code [B@BAZG] Eng oil press low ................................................................................................... 36
Failure code [B@BAZK] Eng oil level low ..................................................................................................... 37
Failure code [B@BCNS] Eng coolant overheat ............................................................................................ 38
Failure code [B@BCZK] Radiator coolant level low...................................................................................... 38
Failure code [B@BEBF] Water gets mixed with fuel ..................................................................................... 39
Failure code [B@BFZK] Fuel level abnormal reduction ................................................................................ 39
Failure code [B@CENS] Torque converter oil overheat................................................................................ 40
Failure code [B@CHZG] HSS charge oil pressure reduction ....................................................................... 41
Failure code [B@CHZK] Power train oil oil level reduction ........................................................................... 41
Failure code [B@GAZK] Battery electrolyte level reduction.......................................................................... 42
Failure code [B@HANS] Hyd oil overheat .................................................................................................... 42
Failure code [B@HAZK] Hydraulic oil level reduction ................................................................................... 43
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Failure code [1500L0] Transmission clutch dual engagement

Action code
Failure code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
1500L0
D275AX-5E0
Transmission clutch dual engagement

(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]
(3) Either of [DXH6KA] or [DXH6KB] and (1) above
(4) [15SALH] and [15SBLH]
(5) Either [15SAL1] or [DXH8KY] and either [15SBL1] or [DXH7KY]
(6) [15SELH], [15SFLH], and [15SGLH]
(7) Either [15SEL1] or [DXH4KY] and either [15SFL1] or [DXH5KY]
(8) Either [15SEL1] or [DXH4KY] and either [15SGL1] or [DXH6KY]
(9) Either [15SFL1] or [DXH5KY] and either [15SGL1] or [DXH6KY]
Flashes warning lamp and turns on alarm buzzer.
Limits operation of engine and transmission.
The auto shift down function does not start.

Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, traveling is limited to specific gear speeds.
Machine cannot travel.
Duplication of failure code: Engine start + travel
Cause
Possible causes
and standard
value in normal
state
Trouble
Confirm the failure codes displayed at the same time, then carry out troubleshooting for the codes.
[15SAL1], [15SALH ], [15SBL1], [15SBLH], [15SEL1], [15SELH], [15SFL1], [15SFLH], [15SGL1],
[15SGLH]
[DXH4KA], [DXH4KB], [DXH4KY], [DXH5KA], [DXH5KB], [DXH5KY], [DXH6KA], [DXH6KB],
[DXH6KY], [DXH7KA], [DXH7KB], [DXH7KY], [DXH8KA], [DXH8KB], [DXH8KY]
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40 Troubleshooting
Failure code [15SAL1] Forward clutch oil pressure 1

Action code
Failure code
CALL E03
15SAL1
Trouble
Forward clutch oil pressure 1 (Command current is OFF but fill signal is ON)
Contents of
trouble
The fill switch signal is not set off at output stop of the transmission forward clutch solenoid circuit.
Action of
controller
Flashes caution lamp and turns on caution buzzer.

Decides that engine speed is neutral (N) at reverse operation. (Prevention of double engagement)
Problem that
appears on
machine
Related
information

Once machine is stopped, running is limited to F1.
The input state (ON/OFF) from the forward clutch fill switch can be checked in real-time monitoring
mode. (Code 31520: Transmission fill switch input state)
Method of reproducing failure code: Engine start + Neutral running
Cause

a Prepare with starting switch OFF, then start the engine for troubleshooting.
Possible causes
and standard
value in normal
state
Defective forward clutch fill

switch (Internal short)
FFT (male)
PCCS lever
Resistance
Between (1)
chassis ground
Min. 1 Mz
F (Forward)
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootDefective harness grounding without turning starting switch ON.
2 ing (Contact with ground cirWiring harness between TMCN1 (female)
Resiscuit)
Max. 1 Mz
(5) FFT (female) (1) with chassis ground
tance
3
Defective transmission controller
TMCN1
PCCS lever
Voltage
Between (5)
chassis ground
5 11 V
F (Forward)
Max. 1 V
When no fault is detected in the electric system, the hydraulic presDefective hydraulic pressure
sure system is assumed to be abnormal. Carry out the related trou4
system
bleshooting (H mode).
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Failure code [15SALH] Forward clutch oil pressure 2

Action code
Failure code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
15SALH
Trouble
Forward clutch oil pressure 2 (Command current is ON but fill signal is OFF)
The fill switch signal is not set off at output to the transmission forward clutch solenoid circuit.
Decides that engine speed is neutral (N) at forward operation. (Prevention of double engagement)
Once machine is stopped, running is limited to R1.
The input state (ON/OFF) from the forward clutch fill switch can be checked in real-time monitoring
Method of reproducing failure code: Engine start + Forward running
Cause
Defective forward clutch fill
1 switch (Internal disconnection in wiring)
Possible causes
and standard
value in normal
state

FFT (male)
PCCS lever
Resistance
Between (1)
chassis ground
Min. 1 Mz
F (Forward)
Max. 1 z
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
ness (Disconnection in wiring
2
or defective contact in con- Wiring harness between TMCN1 (female)
ResisMax. 1 z
nector)
(5) FFT (female) (1)
tance
3
TMCN1
PCCS lever
Voltage
Between (5)
chassis ground
5 11 V
F (Forward)
Max. 1 V
system
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Failure code [15SBL1] Reverse clutch oil pressure 1

Action code
Failure code
CALL E03
15SBL1
Trouble
Reverse clutch oil pressure 1 (Command current is OFF but fill signal is ON)
Contents of
trouble
The fill switch signal is not set off at output stop of the transmission reverse clutch solenoid circuit.
Action of
controller

Decides that engine speed is neutral (N) at forward operation. (Prevention of double engagement)
Problem that
appears on
machine
Related
information

Once machine is stopped, running is limited to R1.
The input state (ON/OFF) from the reverse clutch fill switch can be checked in real-time monitoring
Cause

Possible causes
and standard
value in normal
state
Defective reverse clutch fill

FRT (male)
PCCS lever
Resistance
Between (1)
chassis ground
Min. 1 Mz
R (Reverse)
Max. 1 z
2 ing (Contact with ground cirWiring harness between TMCN1 (female)
Resiscuit)
Min. 1 Mz
(24) FFT (female) (1) with chassis ground
tance
3
TMCN1
PCCS lever
Voltage
Between (24)
chassis ground
5 11 V
R (Reverse)
Max. 1V
system
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Failure code [15SBLH] Reverse clutch oil pressure 2

Action code
Failure code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
15SBLH
Trouble
Reverse clutch oil pressure 2 (Command current is ON but fill signal is OFF)
The fill switch signal is not set on at output to the transmission reverse clutch solenoid circuit.
Decides that engine speed is neutral (N) at reverse operation. (Prevention of double engagement)
Once machine is stopped, running is limited to F1.
The input state (ON/OFF) from the reverse clutch fill switch can be checked in real-time monitoring
Method of reproducing failure code: Engine start + Reverse running
Cause
Defective reverse clutch fill
1 switch (Internal disconnection in wiring)
Possible causes
and standard
value in normal
state

FRT (male)
PCCS lever
Resistance
Between (1)
chassis ground
Min. 1 Mz
R (Reverse)
Max. 1 z
2
ResisMax. 1 z
nector)
(24) FRT (female) (1)
tance
3
TMCN1
PCCS lever
Voltage
Between (24)
chassis ground
5 11 V
R (Reverse)
Max. 1 V
system
10
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40 Troubleshooting
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D275AX-5E0
11
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40 Troubleshooting
Failure code [15SEL1] 1st clutch oil pressure 1

Action code
Failure code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
15SEL1
Trouble
1st clutch oil pressure 1 (Command current is OFF but fill signal is
ON)
The fill switch signal is not set off at output stop of the transmission level 1 clutch solenoid circuit.
Once machine is stopped, running is limited to F1 and R1.
The input state (ON/OFF) from the level 1 clutch fill switch can be checked in real-time monitoring
Method of reproducing failure code: Engine start + F2 or R2 running
Cause

Possible causes
and standard
value in normal
state
Defective 1st clutch fill switch

(Internal short)
F1T (male)
PCCS lever
Resistance
Between (1)
chassis ground
Other than F1/R1
Min. 1 Mz
F1 R1
Max. 1 z
2 ing (Contact with ground cirWiring
harness between TMCN1 (female)
Resiscuit)
Min. 1 Mz
(23) F1T (female) (1) with chassis ground
tance
3
TMCN1
PCCS lever
Voltage
Between (23)
chassis ground
Other than F1/R1
5 11 V
F1 R1
Max. 1 V
sure system is assumed to be abnormal. Carry out the related trousystem
12
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40 Troubleshooting
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Failure code [15SELH] 1st clutch oil pressure 2

Action code
Failure code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
15SELH
Trouble
1st clutch oil pressure 2 (Command current is ON but fill signal is

OFF)
The fill switch signal is not set off at output to the transmission 1st clutch solenoid circuit.
The auto shift down function does not start.
The input state (ON/OFF) from the 1st clutch fill switch can be checked in real-time monitoring
Cause
Defective 1st clutch fill switch
1 (Internal disconnection in
wiring)
Possible causes
and standard
value in normal
state

F1T (male)
PCCS lever
Resistance
Between (1)
chassis ground
Other than F1/R1
Min. 1 Mz
F1 R1
Max. 1 z
2
ResisMin. 1 Mz
nector)
(23) F1T (female) (1)
tance
3
TMCN1
PCCS lever
Voltage
Between (23)
chassis ground
Other than F1/R1
5 11 V
F1 R1
Max. 1 V
D275AX-5E0
13
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40 Troubleshooting
Failure code [15SFL1] 2nd clutch oil pressure 1

Action code
Failure code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
15SFL1
Trouble
2nd clutch oil pressure 1 (Command current is OFF but fill signal is
ON)
The fill switch signal is not set off at stop of output of the transmission 2nd clutch solenoid circuit.
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
Cause

Possible causes
and standard
value in normal
state
Defective 2nd clutch fill

F2T (male)
PCCS lever
Resistance
Between (1)
chassis ground
Other than F2/R2
Min. 1 Mz
F2 R2
Max. 1 z
Resiscuit)
Min. 1 Mz
tance
3
TMCN1
PCCS lever
Voltage
Between (17)
chassis ground
Other than F2/R2
5 11 V
F2 R2
Max. 1 V
14
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40 Troubleshooting
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Failure code [15SFLH] 2nd clutch oil pressure 2

Action code
Failure code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
15SFLH
Trouble
2nd clutch oil pressure 2 (Command current is ON but fill signal is

OFF)
The fill switch signal is not set on at output to the transmission level 2 clutch solenoid circuit.
The input state (ON/OFF) from the 2nd clutch fill switch can be checked in real-time monitoring
Cause

Possible causes
and standard
value in normal
state
Defective 2nd clutch fill

F2T (male)
PCCS lever
Resistance
Between (1)
chassis ground
Other than F2/R2
Min. 1 Mz
F2 R2
Max. 1 z
2
ResisMax. 1 Mz
nector)
(17) F2T (female) (1)
tance
3
TMCN1
PCCS lever
Voltage
Between (17)
chassis ground
Other than F2/R2
5 11 V
F2 R2
Max. 1 V
D275AX-5E0
15
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Failure code [15SGL1] 3rd clutch oil pressure 1

Action code
Failure code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
15SGL1
Trouble
3rd clutch oil pressure 1 (Command current is OFF but fill signal is
ON)
The fill switch signal is not set off at output stop of the transmission 3rd clutch solenoid circuit.
The input state (ON/OFF) from the 3rd clutch fill switch can be checked in real-time monitoring
Cause

Possible causes
and standard
value in normal
state
Defective 3rd clutch fill

F3T (male)
PCCS lever
Resistance
Between (1)
chassis ground
Other than F3/R3
Min. 1 Mz
F3 R3
Max. 1 z
Resiscuit)
Max. 1 Mz
tance
3
TMCN1
PCCS lever
Voltage
Between (11)
chassis ground
Other than F3/R3
5 11 V
F3 R3
Max. 1 V
16
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40 Troubleshooting
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Failure code [15SGLH] 3rd clutch oil pressure 2

Action code
Failure code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
15SGLH
Trouble
3rd clutch oil pressure 2 (Command current is ON but fill signal is

OFF)
The fill switch signal is not set off at output to the transmission 3rd clutch solenoid circuit.
The input state (ON/OFF) from the 3rd clutch fill switch can be checked in real-time monitoring
Cause

Possible causes
and standard
value in normal
state
Defective 3rd clutch fill

F3T (male)
PCCS lever
Resistance
Between (1)
chassis ground
Other than F3/R3
Min. 1 Mz
F3 R3
Max. 1 z
2
ResisMax. 1 z
nector)
(11) F3T (female) (1)
tance
3
TMCN1
PCCS lever
Voltage
Between (11)
chassis ground
Other than F3/R3
5 11 V
F3 R3
Max. 1 V
D275AX-5E0
17
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40 Troubleshooting
Failure code [1800MW] Power train clutch slip

Action code
Failure code
E02
1800MW
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
18
Power train clutch slip

When torque converter is locked up, engine speed does not match transmission speed data.
The number of engine rotations and the number of transmission rotations can be checked in realtime monitoring mode.
(Code 01000: Number of engine rotations, code 31400: Transmission output speed)
Method of reproducing failure code: Engine start + Lock-up switch ON + Actual running
Cause
Possible causes
and standard
value in normal
state
Power train clutch slip

a Clutch slip was detected; check the cause and machine dam(When the system is normal)
age state, then repair the machine.
Defective engine rotation

sensor
Defective transmission rota- Check whether failure codes [DLT3KA] and [DLT3KB] are distion sensor system
played. If it is displayed, carry out the troubleshooting.
Check whether failure codes [CA115] and [CA238] are displayed.

If they are displayed, carry out the troubleshooting.
Internally trouble; troubleshooting is impossible.
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40 Troubleshooting
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Failure code [2300NR] Brake thermal load

Action code
Failure code
Contents of
trouble
Action of
controller
2300NR
Trouble
Brake thermal load

(Steering controller system)
Steering controller judged from pitch angle, travel speed, continuous pedal brake operation time,
etc. that brake was heating abnormally.
None in particular.
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
D275AX-5E0
Cause
1
Improper braking during downslope travel (e.g. Continous downhill travel with brake pedal
pressed)
2 Defective steering controller When the operation in cause 1 is not performed
19
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40 Troubleshooting
Failure code [2301L1] Right steering brake oil pressure 1

Action code
Failure code
CALL E04
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
2301L1
Trouble
Right steering brake oil pressure 1 (Command current is OFF but

fill signal is ON)
The fill switch signal is not set off at output stop of the right steering brake solenoid circuit.
Limits operation of engine, transmission, and brake.
Once machine is stopped, it never runs.
The input state (ON/OFF) from the right steering brake fill switch can be checked in real-time monitoring mode. (Code 31521: Steering fill switch input state)
Method of reproducing failure code: Engine start
Cause

a Prepare with starting switch OFF. Engine start + Pivot turn
switch ON + Forward for troubleshooting.
Defective right steering

1 brake fill switch
(Internal short)
Possible causes
and standard
value in normal
state
FRB (male)
Between (1)
chassis ground
Resistance
N (Neutral)
Max. 1 z
Right steering stroke

end
Min. 1 Mz
2 ing (Contact with ground cirWiring harness between STCN2 (female)
Resiscuit)
Max. 1 Mz
(25) FRB (female) (1) with chassis ground
tance
3 Defective steering controller
STCN2
Between (25)
chassis ground
20
PCCS lever
PCCS lever
Voltage
N (Neutral)
Max. 1 V

end
5 11 V
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21
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Failure code [2301LH] Right steering brake oil pressure 2

Action code
Failure code
CALL E04
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
2301LH
Trouble
Right steering brake oil pressure 2 (Command current is ON but fill

signal is OFF)
The fill switch signal is not set off at output to the right steering brake solenoid circuit.
The input state (ON/OFF) from the right steering brake fill switch can be checked in real-time monitoring mode. (Code 31521: Steering fill switch input state)
Method of reproducing failure code: Engine start + Parking brake release
Cause


1 clutch fill switch
(Internal short)
Possible causes
and standard
value in normal
state
FRB (male)
Between (1)
chassis ground
Resistance
N (Neutral)
Max. 1 z

end
Min. 1 Mz
2
or defective contact in con- Wiring harness between STCN2 (female)
ResisMax. 1 Mz
nector)
(25) FRB (female) (1)
tance
STCN2
Between (25)
chassis ground
22
PCCS lever
PCCS lever
Voltage
N (Neutral)
Max. 1 V

end
5 11 V
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23
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Failure code [2301NR] Right steering brake thermal load

Action code
Contents of
trouble
Action of
controller
Failure code
2301NR
Trouble
Right steering brake thermal load (Abnormal heating)

Steering controller judged from pitch angle, travel speed and continuous right steering operation
time that right steering brake was heating abnormally.
None in particular.
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
24
Cause
1 Improper steering during downslope travel (e.g. Continuous downhill travel with right steering ON)
D275AX-5E0
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Failure code [2302L1] Left steering brake oil pressure 1

Action code
Failure code
CALL E04
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
2302L1
Trouble
Left steering brake oil pressure 1 (Command current is OFF but fill
signal is ON)
The fill switch signal is not set off at output stop of the left steering brake solenoid circuit.
The input state (ON/OFF) from the left steering brake fill switch can be checked in real-time monitoring mode. (Code 31521: Steering fill switch input state)
Method of reproducing failure code: Engine start
Cause

Defective left steering clutch

1 fill switch
(Internal short)
Possible causes
and standard
value in normal
state
FRB (male)
Between (1)
chassis ground
Resistance
N (Neutral)
Max. 1 z
Left steering stroke

end
Min. 1 Mz
2 ing (Contact with ground cirWiring harness between STCN2 (female)
Resiscuit)
Max. 1 Mz
(35) FLB (female) (1) with chassis ground
tance
STCN2
Between (35)
chassis ground
26
PCCS lever
PCCS lever
Voltage
N (Neutral)
Max. 1 V

end
5 11 V
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40 Troubleshooting
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27
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Failure code [2302LH] Left steering brake oil pressure 2

Action code
Failure code
CALL E04
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
2302LH
Trouble
Left steering brake oil pressure 2 (Command current is ON but fill

signal is OFF)
The fill switch signal is not set on at output stop of the left steering brake solenoid circuit.
The input state (ON/OFF) from the left steering brake fill switch can be checked in real-time monitoring mode. (Code 31521: Steering fill switch input state)
Method of reproducing failure code: Engine start + Parking brake release
Cause

Defective left steering brake

1 fill switch
(Internal short)
Possible causes
and standard
value in normal
state
FLB (male)
Between (1)
chassis ground
Resistance
N (Neutral)
Max. 1 z

end
Min. 1 Mz
2
ResisMax. 1 Mz
nector)
(35) FLB (female) (1)
tance
STCN2
Between (35)
chassis ground
28
PCCS lever
PCCS lever
Voltage
N (Neutral)
Max. 1 V

end
5 11 V
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D275AX-5E0
29
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Failure code [2302NR] Left steering brake thermal load

Action code
Contents of
trouble
Action of
controller
Failure code
2302NR
Trouble
Left steering brake thermal load (Abnormal heating)

Steering controller judged from pitch angle, travel speed and continuous left steering operation time
that left steering brake was heating abnormally.
None in particular.
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Cause
1 Improper steering during downslope travel (e.g. Continuous downhill travel with left steering ON)
Failure code [A000NS] Engine overheat

Action code
Failure code
A000NS
Contents of
trouble
Trouble
Engine overheat
(Mechanical system)
Engine overheat caution lamp turned on during engine is running.
Action of
None in particular.
machine monitor
Problem that
appears on
machine
Related
information
30
None in particular.
This failure code is not displayed since caution lamp related above item is not set on this machine.
It is listed in the mechanical system failure code table, however.
D275AX-5E0
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Failure code [AA10NX] Air cleaner clogging

Action code
Failure code
AA10NX
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Air cleaner clogging

(Mechanical system)
While engine was running, clogging of air cleaner was detected.

None in particular.
If machine is used as it is, engine output may lower or engine may be damaged.
Method of reproducing failure code: Start engine.
Air cleaner clogging caution symbol on machine monitor blinks and this failure code is recorded.
Cause
1
Clogged air cleaner

(When system is normal)
Defective air cleaner clog2 ging switch (Internal disconnection)

Possible causes
and standard
value in normal
state

a Air cleaner may be clogged. Check and clean or replace it.
a Prepare with starting switch OFF, then start engine and carry
out troubleshooting.
AF1 (male)
Between (1) (2)
Air cleaner
Resistance
Normal
Max. 1 z
Clogged
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between S03 (female) (13)
3
or defective contact in con- AF1 (female) (1)
nector)
Wiring harness between AF1 (female) (2)
chassis ground
Resistance
Max. 1 z
Resistance
Max. 1 z
4 Defective machine monitor
32
S03
Air cleaner
Voltage
Between (13)
chassis ground
Normal
Max. 1 V
Clogged
20 30 V
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33
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Failure code [AB00MA] Battery charge abnormal

Action code
Failure code
AB00MA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
34
Battery charge abnormal

(Mechanical system)
While engine was running, charge circuit from alternator detected voltage reduction.
Blinks warning lamp.
If machine is used as it is, battery may not be charged.
Battery voltage can be checked with real-time monitoring mode.
(Code: 03200 Battery power supply)
Charge level caution symbol on machine monitor blinks and this failure code is recorded.
Cause
Possible causes
and standard
value in normal
state
Defective charge by battery

Phenomenon seems to have caused battery charge trouble. Find

and stop it and repair damaged part.
If cause 1 is not detected, charge level monitor system may be

Defective charge level monidefective. Carry out "E-7 Caution item blinks while engine is runtor system
ning" in E mode.
D275AX-5E0
40 Troubleshooting
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D275AX-5E0
35
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Failure code [B@BAZG] Eng oil press low

Action code
Failure code
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
36
B@BAZG
Trouble
Eng oil press low

(Engine controller system)
While engine was running, engine oil pressure sensor signal circuit detected that engine oil pressure was abnormally low.
Limits engine operation.
After alarm is made, engine speed is limited to medium (half) at certain rate.
Engine oil pressure sensor signal is input to engine controller and then transmitted to machine monitor through communication system.
Engine oil pressure can be checked with real-time monitoring mode.
(Code: 37200 Engine oil pressure)
Engine oil pressure caution symbol on machine monitor blinks and this failure code is recorded.
Cause
Low engine oil pressure

Phenomenon seems to have caused engine oil pressure reduction.

Find and stop it and repair damaged part.
Defective engine oil caution

lamp system
Carry out troubleshooting for engine oil pressure caution lamp system in "E-8 Emergency item blinks while engine is running" in E
mode.
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40 Troubleshooting
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Failure code [B@BAZK] Eng oil level low

Action code
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Failure code
B@BAZK
Trouble
Eng oil level low

(Mechanical system)
The signal circuit of the engine oil level switch is opened (disconnected from grounding) while the
engine is stopped.
None in particular.
If machine is operated as it is, engine may be damaged.
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 error code table, however.
D275AX-5E0
37
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Failure code [B@BCNS] Eng coolant overheat

Action code
Failure code
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
B@BCNS
Trouble
Eng coolant overheat

While engine was running, engine coolant temperature sensor signal circuit detected that engine
coolant was overheated.
Limits engine operation.
After alarm is made, engine speed is limited to medium (half) at certain rate.
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.
(Code: 04104 Coolant temperature)
Engine coolant temperature caution symbol on machine monitor blinks and this failure code is
recorded.
Cause
Overheated engine coolant

1
Check engine coolant for overheating. If it is overheated, remove

cause.
Defective engine coolant

temperature sensor system
If cause 1 is not detected, engine coolant temperature sensor may

be defective. Carry out troubleshooting for failure codes [CA144]
and [CA145].
Failure code [B@BCZK] Radiator coolant level low

Action code
Failure code
B@BCZK
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
38
Radiator coolant level low

(Machine controller system)
While starting switch was ON (and engine was stopped) or engine was running, radiator coolant
level switch signal circuit detected that radiator coolant level was low (sensor contact was open).
Displays radiator coolant level monitor red on machine monitor.
Engine radiator coolant level caution symbol on machine monitor blinks and this failure code is
recorded.
Cause
Possible causes
and standard
value in normal
state
Low coolant level

Phenomenon seems to have caused radiator sub tank coolant

level reduction. Find and stop it and repair damaged part.
Defective radiator coolant

level monitor system
If cause 1 is not detected, radiator coolant level monitor may be

defective. Carry out "E-6 Caution item blinks while starting switch
is ON" in E mode.
D275AX-5E0
40 Troubleshooting
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Failure code [B@BEBF] Water gets mixed with fuel

Action code
Failure code
B@BEBF
Contents of
trouble
Water gets mixed with fuel

(Mechanical system)
Water gets mixed with fuel and water separator caution lamp turned on.
Action of
controller
None in particular.
Problem that
appears on
machine
None in particular.
Related
information
Trouble
Failure code [B@BFZK] Fuel level abnormal reduction

Action code
Failure code
B@BFZK
Contents of
trouble
None in particular.
Problem that
appears on
machine
None in particular.
D275AX-5E0
Trouble
Fuel level abnormal reduction

(Mechanical system)
Displayed fuel level is abnormally low (while there is sufficient oil actually).
Action of
controller
Related
information
39
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40 Troubleshooting
Failure code [B@CENS] Torque converter oil overheat

Action code
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Failure code
B@CENS
Trouble
40
Torque converter oil overheat

(Mechanical system)
While engine was running, torque converter oil overheated and torque converter oil temperature
caution lamp blinked.
If machine is used as it is, power train components may be damaged.
Torque converter oil temperature can be checked with real-time monitoring mode.
(Code: 30100 Torque converter oil temperature)
Torque converter oil temperature caution lamp on machine monitor blinks and this failure code is
recorded.
Cause
Possible causes
and standard
value in normal
state
Overheated torque con1 verter oil (When system is

normal)
Check torque converter oil for overheating. If it is overheated,

remove cause.
Defective torque converter

2 oil temperature sensor system
If cause 1 is not detected, torque converter oil temperature sensor

system may be defective. Carry out troubleshooting for failure
code [DGT1KA] or [DGT1KX].
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40 Troubleshooting
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Failure code [B@CHZG] HSS charge oil pressure reduction

Action code
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Failure code
B@CHZG
Trouble
HSS charge oil pressure reduction

(Mechanical system)
While engine was running, HSS charge oil pressure decreased and HSS charge oil pressure caution lamp blinked.
If machine is operated as it is, HSS pump or motor may be damaged.
HSS charge oil pressure caution lamp on machine monitor blinks and this failure code is recorded.
Cause
Possible causes
and standard
value in normal
state
HSS charge oil pressure

It is suspected that problem causing HSS charge oil pressure
1 reduction (When system is in reduction is occurring at present or occurred in past. Investigate
normal state)
cause and damage condition, and correct it.
Defective HSS charge oil
2 pressure caution lamp system
Carry out troubleshooting of HSS charge oil pressure caution lamp

system in accordance with "E-8 During running of engine, emergency caution item flashes" in E mode.
Failure code [B@CHZK] Power train oil oil level reduction

Action code
Failure code
B@CHZK
Contents of
trouble
None in particular.
Problem that
appears on
machine
None in particular.
D275AX-5E0
Trouble
Power train oil level reduction

(Mechanical system)
Engine overheat caution lamp turned on during engine is running.
Action of
controller
Related
information
41
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40 Troubleshooting
Failure code [B@GAZK] Battery electrolyte level reduction

Action code
Failure code
B@GAZK
Contents of
trouble
Battery electrolyte level reduction

(Mechanical system)
Battery electrolyte level reduce and battery electrolyte level reduction lamp blinked.
Action of
controller
None in particular.
Problem that
appears on
machine
None in particular.
Related
information
Trouble
Failure code [B@HANS] Hyd oil overheat

Action code
Failure code
B@HANS
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
42
Hyd oil overheat

(Mechanical system)
While engine was running, hydraulic oil overheated and hydraulic oil temperature caution lamp
blinked.
If machine is used as it is, work equipment and HSS circuit components may be damaged.
Hydraulic oil temperature can be checked with real-time monitoring mode.
(Code: 04401 Hyd oil temperature)
Hydraulic oil temperature caution lamp on machine monitor blinks and this failure code is recorded.
Cause
Possible causes
and standard
value in normal
state
Overheated hydraulic oil

1
2
Defective hydraulic oil temperature gauge system

Check hydraulic oil for overheating. If it is overheated, remove
cause.
If cause 1 is not detected, hydraulic oil temperature gauge system
may be defective. Carry out troubleshooting for "E-14 Hydraulic oil
temperature gauge does not display normally" in E mode.
D275AX-5E0
40 Troubleshooting
SEN01655-00
Failure code [B@HAZK] Hydraulic oil level reduction

Action code
Failure code
B@HAZK
Contents of
trouble
None in particular.
Problem that
appears on
machine
None in particular.
D275AX-5E0
Hydraulic oil level reduction

(Mechanical system)
Hydraulic oil level reduce during rotation of engine, hydraulic oil caution lamp flashes.
Action of
controller
Related
information
Trouble
43
SEN01655-00
40 Troubleshooting
44
D275AX-5E0
SEN01656-00
BULLDOZER
1SHOP MANUAL
D275AX-5E0
Machine model
Serial number
D275AX-5E0
30001 and up
40 Troubleshooting

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 press sensor high error.................................................................................... 8
Failure code [CA123] Chg air press sensor low error ................................................................................... 10
Failure code [CA131] Throttle sensor high error........................................................................................... 12
Failure code [CA132] Throttle sensor low error ............................................................................................ 14
Failure code [CA135] Eng 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 temp sensor high error .................................................................................. 24
Failure code [CA154] Chg air temp sensor low error.................................................................................... 26
Failure code [CA187] Sens supply 2 volt low error ....................................................................................... 26
Failure code [CA221] Ambient press sens high error ................................................................................... 28
D275AX-5E0
SEN01656-00
40 Troubleshooting
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......................................................................................... 39
Failure code [CA271] PCV1 short error ........................................................................................................ 40
Failure code [CA272] PCV1 open error ........................................................................................................ 41
Failure code [CA273] PCV2 short error ........................................................................................................ 42
Failure code [CA274] PCV2 open error ........................................................................................................ 43
Failure code [CA322] Inj #1 (L#1) open/short error....................................................................................... 44
Failure code [CA342] Calibration code incompatibility.................................................................................. 50
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] Rail press low error .................................................................................................... 64
Failure code [CA689] Eng Ne speed sensor error ........................................................................................ 68
D275AX-5E0
SEN01656-00
40 Troubleshooting
Failure code [CA111] EMC critical internal failure

Action code
Failure code
CALL E04
CA111
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
EMC critical internal failure

Trouble occurred in engine controller.

None in particular.
Engine runs normally but may stop during operation or may not be able to start.
Source voltage of engine controller can be checked with real-time monitoring mode.
(Code: 03203 Engine controller power supply voltage)
Cause
1
Defective circuit breaker

(CB7)

If circuit breaker is turned OFF, circuit probably has ground fault.
(See cause 3.)
Disconnection in wiring harness (Disconnection in wiring

2
or defective contact in connector)
Possible causes
and standard
value in normal
state
Wiring harness between EGC3 (female) (3),

(4) CB7 (B7L)
Resistance
Max. 1 z
Wiring harness between CB7 (B7S) terminal BRB
Resistance
Max. 1 z

(2) chassis ground (GND8)
Resistance
Max. 1 z
Ground fault in wiring har3 ness (Contact with ground
circuit)

(4) CB7 (B7L) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between CB7 (B7S) terminal BRB and chassis ground
Resistance
Min. 1 Mz

(2) chassis ground (GND20) and chassis
ground
Resistance
Min. 1 Mz
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)

(1), (2)
ON
20 30 V
D275AX-5E0
40 Troubleshooting
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D275AX-5E0
SEN01656-00
40 Troubleshooting
Failure code [CA115] Eng Ne and Bkup speed sens error

Action code
Failure code
CALL E04
CA115
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Eng Ne and Bkup speed sens error

Trouble occurred in Ne speed sensor circuit and Bkup speed sensor circuit simultaneously.
None in particular.
Engine cannot be started (if engine has been stopped).
Engine stops (if engine has been running).
Related
information
Cause
Possible causes
and standard
value in normal
state
Defective Ne speed sensor

system
Ne speed sensor system may be defective. Carry out troubleshooting for code [CA689].
Defective Bkup speed sensor system
Bkup speed sensor system may be defective. Carry out troubleshooting for code [CA778].
Defective mount of Ne speed Check mount of Ne speed sensor directly for defect (defective
sensor
installation of sensor, internal trouble of flywheel, etc.)
Defective mount of Bkup

speed sensor
Defective connection (Wrong Check Ne speed sensor and Bkup speed sensor directly for defecconnection) of sensor
tive connection (wrong connection).
Check mount of Bkup speed sensor directly for defect (defective

installation of sensor, internal trouble of supply pump, etc.)
If causes 1 5 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried
out.)
D275AX-5E0
SEN01656-00
40 Troubleshooting
Failure code [CA122] Chg air press sensor high error

Action code
Failure code
CALL E03
CA122
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Chg air press sensor high error

Signal voltage in charge pressure sensor circuit is abnormally high.

Fixes charge pressure (400 kPa {4.08 kg/cm2}) and continues operation.
Acceleration performance of engine lowers or black smoke is produced more during acceleration.
State of charge pressure sensor can be checked with real-time monitoring mode.
(Code: 36500 Charge pressure-abs)
Cause
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.
2
Defective charge pressure

sensor (Internal trouble)
PIM
Between (1) (2)
Voltage
Power supply
4.75 5.25 V
Pressure sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness
and controller, too, for another cause of trouble, and then judge.
3
Possible causes
and standard
value in normal
state
Wiring harness between EGC1 (female)

(37) PIM (female) (1)
Resistance
Max. 1 z

Resistance
Max. 1 z

Resistance
Max. 1 z
circuit)

(37) PIM (female) (1) and chassis ground
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
Short circuit in wiring har5 ness (with another wiring

harness)

(37) PIM (female) (1) and between EGC1
(female) (47) PIM (female) (2)
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
Chassis ground between EGC1 (female)

Resistance
Min. 1 Mz

EGC1
Between (37) (47)
Voltage
Power supply
4.75 5.25 V
D275AX-5E0
40 Troubleshooting
SEN01656-00
D275AX-5E0
SEN01656-00
40 Troubleshooting
Failure code [CA123] Chg air press sensor low error

Action code
Failure code
CALL E03
CA123
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
10
Trouble
Chg air press sensor low error

Signal voltage in charge pressure sensor circuit is abnormally low.

Fixes charge pressure (400 kPa {4.08 kg/cm2}) and continues operation.
Acceleration performance of engine lowers or black smoke is produced more during acceleration.
State of charge pressure sensor can be checked with real-time monitoring mode.
(Code: 36500 Charge pressure-abs)
Cause

Carry out troubleshooting for failure code [CA122].
D275AX-5E0
SEN01656-00
40 Troubleshooting
Failure code [CA131] Throttle sensor high error

Action code
Failure code
CALL E03
CA131
Contents of
trouble
Action of
controller
Trouble
Throttle sensor high error

Signal voltage in decelerator pedal potentiometer circuit is abnormally high.

Sets throttle position with fuel control dial signal and continues operation.
Problem that
appears on
machine
Related
information
State of decelerator pedal optimum operation range signal can be checked with real-time monitoring mode. (Code: 31703 Decelerator potentiometer voltage)
Cause
1
Defective sensor power sup- If code [CA2185] or [CA2186] is indicated, carry out troubleshootply system
ing for it first.
Defective fuel control dial

(Internal trouble)
DCL (male)
Resistance
Between (B) (C)
1.5 2.5 kz
Between (A) (B)
0 3 kz
Between (A) (C)
0 3 kz
Possible causes
and standard
value in normal
state

3
Wiring harness between EGC2 (female) (9)

DCL (female) (A)
Resistance
Max. 1 z

(22) DCL (female) (B)
Resistance
Max. 1 z

(23) DCL (female) (C)
Resistance
Max. 1 z
circuit)

DCL (female) (A) and chassis ground
Resistance
Min. 1 Mz

(22) DCL (female) (B) and chassis ground
Resistance
Min. 1 Mz

(23) DCL (female) (C) and chassis ground
Resistance
Min. 1 Mz

12
EGC2
Voltage
Between (22) (23)
Power supply
4.75 5.25 V
Between (9) (23)
Signal
0.5 4.5 V
D275AX-5E0
40 Troubleshooting
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D275AX-5E0
13
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40 Troubleshooting
Failure code [CA132] Throttle sensor low error

Action code
Failure code
CALL E03
CA132
Trouble
Throttle sensor low error

Contents of
trouble
Signal voltage in decelerator pedal potentiometer circuit is abnormally low.
Action of
controller
Sets throttle position with fuel control dial signal and continues operation.
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
14
State of decelerator pedal optimum operation range signal can be checked with real-time monitoring mode. (Code: 31703 Decelerator potentiometer voltage)
Cause

D275AX-5E0
SEN01656-00
40 Troubleshooting
Failure code [CA135] Eng oil press sensor high error

Action code
Failure code
E02
CA135
Contents of
trouble
Action of
controller
Trouble
Eng oil press sensor high error

Signal voltage in engine oil pressure sensor circuit is abnormally high.

Sets engine oil pressure to default value (250 kPa {2.55 kg/cm2}) and continues operation.
Problem that
appears on
machine
Related
information
State of engine oil pressure sensor can be checked with real-time monitoring mode.
(Code: 37201 Eng oil press sens volt)
Cause
1
ply system
for it first.
Defective engine oil pressure

POIL
Between (1) (2)
Voltage
Power supply
4.75 5.25 V
Sensor voltage is measured with wiring harness connected.

Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge.
3
Possible causes
and standard
value in normal
state

(37) POIL (female) (1)
Resistance
Max. 1 z

Resistance
Max. 1 z

Resistance
Max. 1 z
circuit)

(37) POIL (female) (1) and chassis ground
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

harness)

(37) POIL (female) (1) and between EGC1
(female) (47) POIL (female) (2)
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

EGC1
Between (37) (47)
16
Voltage
Power supply
4.75 5.25 V
D275AX-5E0
40 Troubleshooting
SEN01656-00
D275AX-5E0
17
SEN01656-00
40 Troubleshooting
Failure code [CA141] Eng oil press sensor low error

Action code
Failure code
E02
CA141
Contents of
trouble
Action of
controller
Trouble
Eng oil press sensor low error

Signal voltage in engine oil pressure sensor circuit is abnormally low.

Sets engine oil pressure to default value (250 kPa {2.55 kg/cm2}) and continues operation.
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
18
State of engine oil pressure sensor can be checked with real-time monitoring mode.
(Code: 37201 Eng oil press sens volt)
Cause

D275AX-5E0
SEN01656-00
40 Troubleshooting
Failure code [CA144] Coolant temp sens high error

Action code
Failure code
E02
CA144
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Fixes engine coolant temperature (90C) and continues operation.

Startability of engine lowers at low temperature.
State of engine coolant temperature sensor can be checked with real-time monitoring mode.
(Code: 04105 Coolant temp sens volt)

1 temperature sensor (Internal
trouble)

TWTR (male)
Coolant temperature
Resistance
Between (A) (B)
10 100C
0.6 20 kz
Disconnection in wiring harness (Disconnection in wiring Wiring harness between EGC1 (female)
Resis2
Max. 1 z
or defective contact in con- (15) TWTR (female) (A)
tance
nector)
ResisMax. 1 z
(38) TWTR (female) (B)
tance
circuit)
20
Coolant temp sens high error

Signal voltage in engine coolant temperature sensor circuit is abnormally high.
Cause
Possible causes
and standard
value in normal
state
(15) TWTR (female) (A) and chassis
ground
Resistance
Min. 1 Mz
EGC1 (female)
Coolant temperature
Resistance
Between (15) (38)
10 100C
0.6 20 kz
D275AX-5E0
40 Troubleshooting
SEN01656-00
D275AX-5E0
21
SEN01656-00
40 Troubleshooting
Failure code [CA145] Coolant temp sens low error

Action code
Failure code
E02
CA145
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
22
Trouble
Coolant temp sens low error

Signal voltage in engine coolant temperature sensor circuit is abnormally low.

Fixes engine coolant temperature (90C) and continues operation.
State of engine coolant temperature sensor can be checked with real-time monitoring mode.
(Code: 04105 Coolant temp sens volt)
Cause

D275AX-5E0
SEN01656-00
40 Troubleshooting
Failure code [CA153] Chg air temp sensor high error

Action code
Failure code
E01
CA153
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Chg air temp sensor high error

Signal voltage in charge temperature sensor circuit is abnormally high.

Fixes charge temperature (intake air temperature) (70C) and continues operation.
State of charge temperature sensor signal can be checked with real-time monitoring mode.
(Code: 18501 Charge temp sens volt)
Cause

Possible causes
and standard
value in normal
state
Defective charge temperature sensor (Internal trouble)
TIM (male)
Intake air
temperature
Resistance
Between (A) (B)
10 100C
0.5 20 kz
Between (A)
chassis ground
All range
Min. 1 Mz
2
or defective contact in con- (23) TIM (female) (A)
nector)
(47) TIM (female) (B)
circuit)
Resistance
Max. 1 z
Resistance
Max. 1 z
(23) TIM (female) (A) and chassis ground
Resistance
Min. 1 Mz
24
EGC1 (female)
Intake air
temperature
Resistance
Between (23) (47)
10 100C
0.5 20 kz
D275AX-5E0
40 Troubleshooting
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D275AX-5E0
25
SEN01656-00
40 Troubleshooting
Failure code [CA154] Chg air temp sensor low error

Action code
Failure code
E01
CA154
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Chg air temp sensor low error

Signal voltage in charge temperature sensor circuit is abnormally low.

Fixes charge temperature (intake air temperature) (70C) and continues operation.
State of charge temperature sensor signal can be checked with real-time monitoring mode.
(Code: 18501 Charge temp sens volt)
Possible causes
and standard
value in normal
state
Cause

Failure code [CA187] Sens supply 2 volt low error

Action code
Failure code
CALL E03
CA187
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble

Signal voltage in sensor power supply 2 (5 V) circuit is abnormally low.
Operates Bkup speed sensor with signals of Ne speed sensor.

Sets oil pressure sensor to default value (250 kPa {2.55 kg/cm2}) and continues operation.
Sets ambient pressure sensor to default value (52.44 kPa {0.53 kg/cm2}) and continues operation.
Fixes charge pressure sensor value (400 kPa {4.08 kg/cm2}) and continues operation.
Sets EGR inlet pressure sensor to default value (102 kPa {1.05 kg/cm2}) and continues operation.
Limits output of EGR valve lift sensor and closes EGR valve and bypass valve.
Limits output of bypass valve lift sensor and closes EGR valve and bypass valve.
Engine output drops.
Related
information
Possible causes
and standard
value in normal
state
26
Cause

D275AX-5E0
SEN01656-00
40 Troubleshooting
Failure code [CA221] Ambient press sens high error

Action code
Failure code
CALL E03
CA221
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Ambient press sens high error

Signal voltage in ambient pressure sensor circuit is abnormally high.

Sets ambient pressure to default value (52.44 kPa {0.53 kg/cm2}) and continues operation.
State of ambient pressure sensor signal can be checked with real-time monitoring mode.
(Code: 37401 Ambient press sens volt)
Cause
1
ply system
for it first.
PAMB
2
Defective ambient pressure

Voltage
Between (1) (2)
Power supply
Between (3) (2)
Signal
4.75 5.25 V

3
Possible causes
and standard
value in normal
state

(37) PAMB (female) (1)
Resistance
Max. 1 z

(38) PAMB (female) (2)
Resistance
Max. 1 z

PAMB (female) (3)
Resistance
Max. 1 z
circuit)

PAMB (female) (1) and chassis ground
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

harness)

(37) PAMB (female) (1) and between
EGC1 (female) (38) - PAMB (female) (2)
Resistance
Min. 1 Mz

EGC1 (female) (3) PAMB (female) (3)
Resistance
Min. 1 Mz

EGC1 (female) (3) PAMB (female) (3)
Resistance
Min. 1 Mz
a repare with starting switch OFF, then turn starting switch ON or

start engine and carry out troubleshooting.
28
EGC1
Voltage
Between (37) (38)
4.75 5.25 V
Between (3) (38)
0.3 4.7 V
D275AX-5E0
40 Troubleshooting
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D275AX-5E0
29
SEN01656-00
40 Troubleshooting
Failure code [CA222] Ambient press sens low error

Action code
Failure code
CALL E03
CA222
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
30
Trouble
Ambient press sens low error

Signal voltage in ambient pressure sensor circuit is abnormally low.

State of ambient pressure sensor signal can be checked with real-time monitoring mode.
(Code: 37401 Ambient press sens volt)
Cause

D275AX-5E0
SEN01656-00
40 Troubleshooting
Failure code [CA227] Sens supply 2 volt high error

Action code
Failure code
CALL E03
CA227
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble

Signal voltage in sensor power supply 2 (5 V) circuit is abnormally high.
Operates Bkup speed sensor with signals of Ne speed sensor.

Sets oil pressure sensor to default value (250 kPa [2.55 kg/cm2}) and continues operation.
Fixes charge pressure sensor value (400 kPa [4.08 kg/cm2}) and continues operation.
Sets EGR inlet pressure sensor to default value (102 kPa {1.05 kg/cm2}) and continues operation.
Limits output of EGR valve lift sensor and closes EGR valve and bypass valve.
Limits output of bypass valve lift sensor and closes EGR valve and bypass valve.
Related
information
Cause
1 Defective related system

If another failure code is indicated, carry out troubleshooting for it.
Defective sensor (Internal

2
trouble)
Possible causes
and standard
value in normal
state
Disconnect devices
at right in order. If
"E" of failure code
disappears when a
device is disconnected, that device
has trouble in it.
Bkup speed sensor
G connector
Oil pressure sensor
POIL connector
Ambient pressure
sensor
PAMB connector
Charge pressure
sensor
PIM connector
EGR inlet pressure

sensor
PEVA connector
EGR valve lift sensor
SEGR connector
Bypass valve lift sensor
SBP connector
Resis3
Max. 1 z
or defective contact in con- (37) each sensor (female)
tance
nector)
ResisMax. 1 z
(47) each sensor (female)
tance
circuit)

harness)
32

(37) each sensor (female) and chassis
ground
Resistance
Min. 1 Mz

(47) each sensor (female) and chassis
ground
Resistance
Min. 1 Mz
(37) each sensor (female) and between
EGC1 (female) (47) each sensor (female)
Resistance
Min. 1 Mz

EGC1
Voltage
Between (37) (47)
4.75 5.25 V
D275AX-5E0
40 Troubleshooting
SEN01656-00
D275AX-5E0
33
SEN01656-00
40 Troubleshooting
Failure code [CA234] Eng overspeed

Action code
Failure code
CA234
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
34
Eng overspeed
Engine speed is above operating range.

Limits fuel injection rate until engine speed lowers to operating range.
Engine speed fluctuates.
Engine speed can be checked with real-time monitoring mode.
(Code: 01000 Engine speed)
Cause
Possible causes
and standard
value in normal
state
2 Improper way of use
Way of use of machine may be improper. Teach proper way of use

to operator.
out.)
D275AX-5E0
SEN01656-00
40 Troubleshooting
Failure code [CA238] Ne speed sens supply volt error

Action code
Failure code
CALL E03
CA238
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Ne speed sens supply volt error

Trouble occurred in Ne speed sensor power supply (5 V) circuit.

Controls Ne speed sensor with signals of Bkup speed sensor.
Running engine stops (when Bkup speed sensor is also abnormal).
Stopped engine cannot be started (when Bkup speed sensor is also abnormal).
Related
information
Cause

Defective Ne speed sensor

(Internal trouble)
Disconnect devices
"E" of failure code
disappears when a
has trouble in it.
Engine Ne
speed sensor
NE connector
Possible causes
and standard
value in normal
state
2
or defective contact in con- (16) NE (female) (1)
nector)
(48) NE (female) (2)

circuit)

harness)
36
Resistance
Max. 1 z
Resistance
Max. 1 z
(16) NE (female) (1) and chassis ground
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
(16) NE (female) (1) and between EGC1
(female) (48) NE (female) (2)
Resistance
Min. 1 Mz

EGC1
Voltage
Between (16) (48)
4.75 5.25 V
D275AX-5E0
40 Troubleshooting
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D275AX-5E0
37
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40 Troubleshooting
Failure code [CA263] Fuel temp sensor high error

Action code
Failure code
E01
CA263
Contents of
trouble
Action of
controller
Trouble
Fuel temp sensor high error

Signal voltage in fuel temperature sensor circuit is abnormally high.

Fixes fuel temperature (90 C) and continues operation.
Problem that
appears on
machine
Related
information
State of fuel temperature sensor signal can be checked with real-time monitoring mode.
(Code: 14201 Fuel temp sens volt)
Cause
Defective fuel temperature
1
Possible causes
and standard
value in normal
state

TFUEL (male)
Fuel temperature
Resistance
Between (A) (B)
10 100C
0.6 20 kz
Resis2
Max. 1 z
or defective contact in con- (30) TFUEL (female) (A)
tance
nector)
ResisMax. 1 z
(47) TFUEL (female) (B)
tance
circuit)
TFUEL (female) (A) and chassis ground
Resistance
Min. 1 Mz
EGC1 (female)
Fuel temperature
Resistance
Between (30) (47)
10 100C
0.6 20 kz
38
D275AX-5E0
40 Troubleshooting
SEN01656-00
Failure code [CA265] Fuel temp sensor low error

Action code
Failure code
E01
CA265
Contents of
trouble
Action of
controller
Trouble
Fuel temp sensor low error

Signal voltage in fuel temperature sensor circuit is abnormally low.

Fixes fuel temperature (90C) and continues operation.
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
D275AX-5E0
Cause

39
SEN01656-00
40 Troubleshooting
Failure code [CA271] PCV1 short error

Action code
Failure code
CALL E03
CA271
Contents of
trouble
Action of
controller
Trouble
PCV1 short error

There is short circuit in PCV1 circuit of supply pump.

None in particular.
Problem that
appears on
machine
Related
information
Cause

Possible causes
and standard
value in normal
state
Defective supply pump

PCV1 (Internal short circuit)

circuit)
PCV1 (male)
Resistance
Between (1) (2)
2.3 5.3 z
Between (1), (2)

chassis ground
Min. 1 Mz
PCV1 (female) (1) and chassis ground
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

3
Hot short (Short circuit with Wiring harness between EGC1 (female) (4)
24V circuit) in wiring harness PCV1 (female) (1) and chassis ground
Voltage
Max. 1 V

Voltage
Max. 1 V
EGC1 (female)
Resistance
Between (4) (5)
2.3 5.3 z
Between (4), (5)

chassis ground
Min. 1 Mz
40
D275AX-5E0
40 Troubleshooting
SEN01656-00
Failure code [CA272] PCV1 open error

Action code
Failure code
CALL E03
CA272
Contents of
trouble
Action of
controller
Trouble
PCV1 open error

There is disconnection in PCV1 circuit of supply pump.

None in particular.
Problem that
appears on
machine
Related
information
Cause


1 PCV1 (Internal disconnection)
PCV1 (male)
Resistance
Between (1) (2)
2.3 5.3 z
Between (1), (2)

chassis ground
Min. 1 Mz
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between EGC1 (female) (4)
2
or defective contact in con- PCV1 (female) (1)
nector)
PCV1 (female) (2)

circuit)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
EGC1 (female)
Resistance
Between (4) (5)
2.3 5.3 z
Between (4), (5)

chassis ground
Min. 1 Mz
D275AX-5E0
41
SEN01656-00
40 Troubleshooting
Failure code [CA273] PCV2 short error

Action code
Failure code
CALL E03
CA273
Contents of
trouble
Action of
controller
Trouble
PCV2 short error

There is short circuit in PCV2 circuit of supply pump.

None in particular.
Problem that
appears on
machine
Related
information
Cause

Possible causes
and standard
value in normal
state

PCV2 (Internal short circuit)

circuit)
PCV2 (male)
Resistance
Between (1) (2)
2.3 5.3 z
Between (1), (2)

chassis ground
Min. 1 Mz
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

3
Hot short (Short circuit with Wiring harness between EGC1 (female) (9)
24V circuit) in wiring harness PCV2 (female) (1) and chassis ground
Voltage
Max. 1 V

Voltage
Max. 1 V
EGC1 (female)
Resistance
Between (9) (10)
2.3 5.3 z
Between (9), (10)

chassis ground
Min. 1 Mz
42
D275AX-5E0
40 Troubleshooting
SEN01656-00
Failure code [CA274] PCV2 open error

Action code
Failure code
CALL E03
CA274
Contents of
trouble
Action of
controller
Trouble
PCV2 open error

There is disconnection in PCV2 circuit of supply pump.

None in particular.
Problem that
appears on
machine
Related
information
Cause


1 PCV2 (Internal disconnection)
PCV2 (male)
Resistance
Between (1) (2)
2.3 5.3 z
Between (1), (2)

chassis ground
Min. 1 Mz
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between EGC1 (female) (9)
2
or defective contact in con- PCV2 (female) (1)
nector)
(10) PCV2 (female) (2)

circuit)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
EGC1 (female)
Resistance
Between (9) (10)
2.3 5.3 z
Between (9), (10)

chassis ground
Min. 1 Mz
D275AX-5E0
43
SEN01656-00
40 Troubleshooting
Failure code [CA322] Inj #1 (L#1) open/short error

Action code
Failure code
CALL E03
CA322
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble

There is disconnection or short circuit in injector #1 circuit.

None in particular.
Output drops.
Rotation is unstable.
Related
information
Cause

Defective injector #1 (Internal trouble)
CN1 (male)
Resistance
Between (1) (2)
0.4 1.1 z
Between (1), (2)

chassis ground
Min. 1 Mz
Possible causes
and standard
value in normal
state
2
or defective contact in con- (45) CN1 (female) (1)
nector)
(53) CN1 (female) (2)

circuit)
Resistance
Max. 1 z
Resistance
Max. 1 z
(45) CN1 (female) (1) and chassis ground
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
EGC1 (female)
Resistance
Between (45) (53)
0.4 1.1 z
Between (45), (53)

chassis ground
Min. 1 Mz
44
D275AX-5E0
40 Troubleshooting
SEN01656-00

Action code
Failure code
CALL E03
CA323
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble


None in particular.
Output drops.
Related
information
Cause

CN5 (male)
Resistance
Between (1) (2)
0.4 1.1 z
Between (1), (2)

chassis ground
Min. 1 Mz
Possible causes
and standard
value in normal
state
2
nector)
(60) CN5 (female) (2)

circuit)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
EGC1 (female)
Resistance
Between (46) (60)
0.4 1.1 z
Between (46), (60)

chassis ground
Min. 1 Mz
D275AX-5E0
45
SEN01656-00
40 Troubleshooting

Action code
Failure code
CALL E03
CA324
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble


None in particular.
Output drops.
Related
information
Cause

CN3 (male)
Resistance
Between (1) (2)
0.4 1.1 z
Between (1), (2)

chassis ground
Min. 1 Mz
Possible causes
and standard
value in normal
state
2
nector)
(52) CN3 (female) (2)

circuit)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
EGC1 (female)
Resistance
Between (55) (52)
0.4 1.1 z
Between (55), (52)

chassis ground
Min. 1 Mz
46
D275AX-5E0
40 Troubleshooting
SEN01656-00

Action code
Failure code
CALL E03
CA325
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble


None in particular.
Output drops.
Related
information
Cause

CN6 (male)
Resistance
Between (1) (2)
0.4 1.1 z
Between (1), (2)

chassis ground
Min. 1 Mz
Possible causes
and standard
value in normal
state
2
nector)
(59) CN6 (female) (2)

circuit)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
EGC1 (female)
Resistance
Between (57) (59)
0.4 1.1 z
Between (57), (59)

chassis ground
Min. 1 Mz
D275AX-5E0
47
SEN01656-00
40 Troubleshooting

Action code
Failure code
CALL E03
CA331
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble


None in particular.
Output drops.
Related
information
Cause

CN2 (male)
Resistance
Between (1) (2)
0.4 1.1 z
Between (1), (2)

chassis ground
Min. 1 Mz
Possible causes
and standard
value in normal
state
2
nector)
(51) CN2 (female) (2)

circuit)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
EGC1 (female)
Resistance
Between (54) (51)
0.4 1.1 z
Between (54), (51)

chassis ground
Min. 1 Mz
48
D275AX-5E0
40 Troubleshooting
SEN01656-00

Action code
Failure code
CALL E03
CA332
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble


None in particular.
Output drops.
Related
information
Cause

CN4 (male)
Resistance
Between (1) (2)
0.4 1.1 z
Between (1), (2)

chassis ground
Min. 1 Mz
Possible causes
and standard
value in normal
state
2
nector)
(58) CN4 (female) (2)

circuit)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
EGC1 (female)
Resistance
Between (56) (58)
0.4 1.1 z
Between (56), (58)

chassis ground
Min. 1 Mz
D275AX-5E0
49
SEN01656-00
40 Troubleshooting
Failure code [CA342] Calibration code incompatibility

Action code
Failure code
CALL E04
CA342
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Calibration code incompatibility

Incompatibility occurred in engine controller data.

None in particular.
Engine continues operation normally, but it may stop during operation or may not be able to start.
Related
information
Possible causes
and standard
value in normal
state
50
Cause

D275AX-5E0
SEN01656-00
40 Troubleshooting
Failure code [CA351] Injectors drive circuit error

Action code
Failure code
CALL E03
CA351
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Injectors drive circuit error

Trouble occurred in injector drive circuit.

Limits engine output and continues operation (Limits common rail pressure).
Cause
2

(CB30 or CB8)

If another failure code (failure code of trouble in injector system) is
indicated, carry out troubleshooting for it.
If circuit breaker is turned OFF, circuit probably has ground fault
(See cause 4).

3
Possible causes
and standard
value in normal
state
Resistance
Max. 1 z
Wiring harness between CB7 (B7S) terminal BRB
Resistance
Max. 1 z

(2) chassis ground (GND11)
Resistance
Max. 1 z
circuit)
52

(4) CB7 (B7L)

(4) CB8 (2) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between CB7 (B7S) terminal BRB and chassis ground
Resistance
Min. 1 Mz

(2) chassis ground (GND11) and chassis
ground
Resistance
Min. 1 Mz

EGC3
Voltage
Between (3), (4) (1), (2)
20 30 V
D275AX-5E0
40 Troubleshooting
SEN01656-00
D275AX-5E0
53
SEN01656-00
40 Troubleshooting
Failure code [CA352] Sens supply 1 volt low error

Action code
Failure code
CALL E03
CA352
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble

Signal voltage in sensor power supply 1 (5 V) circuit of engine controller is abnormally low.
Limits common rail pressure sensor output and continues operation (Limits common rail pressure).
Related
information
Possible causes
and standard
value in normal
state
54
Cause

D275AX-5E0
SEN01656-00
40 Troubleshooting
Failure code [CA386] Sens supply 1 volt high error

Action code
Failure code
CALL E03
CA386
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble

Signal voltage in sensor power supply (5 V) circuit is abnormally high.

Limits common rail pressure sensor output and continues operation (Limits common rail pressure).
Related
information
Cause

Defective sensor (Internal

2
trouble)
Disconnect devices
"E" of failure code
disappears when a
has trouble in it.
Common rail
pressure sensor
PFUEL connector
Possible causes
and standard
value in normal
state
3
or defective contact in con- (33) PFUEL (female) (1)
nector)
(47) PFUEL (female) (3)
Max. 1 z
Resistance
Max. 1 z
circuit)

harness)
56
Resistance

(33) PFUEL (female) (1) and chassis
ground
Resistance
Min. 1 Mz

(47) PFUEL (female) (3) and chassis
ground
Resistance
Min. 1 Mz
(33) PFUEL (female) (1) and between
EGC1 (female) (47) PFUEL (female) (3)
Resistance
Min. 1 Mz

EGC1
Voltage
Between (33) (47)
4.75 5.25 V
D275AX-5E0
40 Troubleshooting
SEN01656-00
D275AX-5E0
57
SEN01656-00
40 Troubleshooting
Failure code [CA441] Battery voltage low error

Action code
Failure code
CALL E04
CA441
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Trouble
Battery voltage low error

Power supply circuit voltage of engine controller is abnormally low.

None in particular.
Cause

Failure code [CA442] Battery voltage high error

Action code
Failure code
CALL E04
CA442
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
58
Trouble
Battery voltage high error

Power supply circuit voltage of engine controller is abnormally low.

None in particular.
Cause

D275AX-5E0
40 Troubleshooting
SEN01656-00
Failure code [CA449] Rail press very high error

Action code
Failure code
CALL E03
CA449
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
D275AX-5E0
Trouble
Rail press very high error

Common rail pressure sensor circuit detected abnormally high pressure (level 2).
Common rail pressure can be checked with real-time monitoring mode.
(Code: 36400 Rail pressure)
Cause

59
SEN01656-00
40 Troubleshooting
Failure code [CA451] Rail press sensor high error

Action code
Failure code
CALL E03
CA451
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Rail press sensor high error

Signal voltage in common rail pressure sensor circuit is abnormally high.

State of common rail pressure sensor signal can be checked with real-time monitoring mode.
(Code: 36401 Rail pressure sens volt)
Cause
1
ply system
for it first.
PFUEL
Defective common rail pres2

sure sensor (Internal trouble)
Voltage
Between (1) (3)
Power supply
4.75 5.25 V
Between (2) (3)
Signal
0.26 4.6 V

3
Possible causes
and standard
value in normal
state

Resistance
Max. 1 z

Resistance
Max. 1 z

Resistance
Max. 1 z
circuit)

PFUEL (female) (1) and chassis ground
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

harness)
60

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
D275AX-5E0
40 Troubleshooting
SEN01656-00
Cause
Possible causes
and standard
value in normal
state

EGC1
Voltage
Between (33) (47)
4.75 5.25 V
Between (25) (47)
0.26 4.6 V
D275AX-5E0
61
SEN01656-00
40 Troubleshooting
Failure code [CA452] Rail press sensor low error

Action code
Failure code
CALL E03
CA452
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Rail press sensor low error

Signal voltage in common rail pressure sensor circuit is abnormally low.

Possible causes
and standard
value in normal
state
Cause

Failure code [CA553] Rail press high error

Action code
Failure code
E02
CA553
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
62
Rail press high error

Common rail pressure sensor circuit detected abnormally high pressure (level 1).
None in particular.
Cause
Possible causes
and standard
value in normal
state
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
common rail pressure sensor troubleshooting for failure code [CA451].
Defective mechanical system

4 of common rail pressure sen- Check mechanical system of common rail pressure sensor directly.
sor
5 Defective overflow valve
Check overflow valve directly for broken spring, worn seat, and
stuck ball.
6 Clogging of overflow piping
Check overflow piping directly for clogging.
7 Defective pressure limiter
Check pressure limiter directly for mechanical defect.
D275AX-5E0
40 Troubleshooting
SEN01656-00
Failure code [CA554] Rail press sensor in range error

Action code
Failure code
CALL E03
CA554
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
D275AX-5E0
Trouble
Rail press sensor in range error

In-range error occurred in common rail pressure sensor circuit.

Cause

Carry out troubleshooting for Failure code [CA451].
63
SEN01656-00
40 Troubleshooting
Failure code [CA559] Rail press low error

Action code
Failure code
E02
CA559
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Rail press low error

Supply pump does not feed fuel (level 1).

Limits common rail pressure.
Cause
2 Use of improper fuel
Check fuel used directly for improper quality.
Defective low-pressure circuit device
4 Clogging of filter/strainer
Possible causes
and standard
value in normal
state
a For contents of troubleshooting, see "Note 1". For check of

pressure in fuel low-pressure circuit, see Testing and adjusting,
"Testing fuel pressure".
Pressure in fuel low-pressure
circuit (high idle)
Min. 0.15 MPa

{Min. 1.5 kg/cm2}
a For contents of troubleshooting, see "Note 2".
Defective electrical system of Supply pump PCV may have electric trouble. Carry out troublesupply pump PCV
shooting for following codes; [CA271], [CA272], [CA273], [CA274].
Defective common rail pres- Common rail pressure sensor may be defective. Check wiring harsure sensor
ness for damage.
a For testing of leakage from pressure limiter, see Testing and
adjusting, "Measuring fuel return rate and fuel leakage".
7 Defective pressure limiter
Leakage from pressure limiter

(Operation equivalent to rated
operation (under stall load))
Max. 10 cc/min
a For measuring of return (spill) limit from injector, see Testing

and adjusting, "Measuring fuel return rate and fuel leakage".
8 Defective injector
9 Defective supply pump
Speed in rated operation

(stall load)
Return (Spill) limit from 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
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
D275AX-5E0
40 Troubleshooting
SEN01656-00
Note 1: Check the low-pressure circuit parts for the following items.
1) Fuel level
2) Clogging of fuel tank breather
3) Sticking and wear of feed pump and clogging of filter
4) Leakage through and clogging of low-pressure fuel piping
5) Defective operation of bypass valve and installation of wrong part (See Fig. 1)
6) Clogging of fuel filter
7) Fuel in oil pan (Fuel leakage inside head cover)
Fig. 1: Locations of overflow valve [1], bypass valve [2], and fuel inlet joint [3]
q
Overflow valve [1]: Spring is seen through both holes.
q
Bypass valve [2]: Spring is seen through hole on nut side.
q
Fuel inlet joint [3]: Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
1) Gauze filter: Disassemble and check. If clogged, clean.
2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too.
3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
D275AX-5E0
65
SEN01656-00
40 Troubleshooting
Check sheet for rail pressure low error

Model
Machine serial No.
Work No.
SAA6D140E-5
Service meter
Date of check
Engine
Engine serial No.
D275AX-5E0
/
h
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

Code
Displayed item
01000 Engine speed
31706
Final accelerator
position
Final fuel injection

18600 rate command
(by weight)
ISO unit
Standard value
(Reference value)
Low idle
r/min
650 750
High idle
r/min
2,100 2,200
r/min
1,570 1,670
Low idle
High idle
100
mg/st
Checking condition
Measured
value
Good NG
36200
Final common rail

pressure command
MPa
36400
Common rail pressure
MPa
Low idle
CA
High idle
CA
CA
kPa
ISO unit
Standard value
(Reference value)
Final injection tim36300

ing command
36500 Boost pressure
04104
Engine coolant temLow idle

perature
14200 Fuel temperature
Low idle
Check of reduced cylinder mode operation (Engine speed)

Setting
66
Reduced cylinder
Checking condition
Measured
value
Good NG
No. 1 cylinder
Low idle
r/min
No. 2 cylinder
Reduce No. 3 cylinder
each
cylinder No. 4 cylinder
No. 5 cylinder
Low idle
r/min
Low idle
r/min
Low idle
r/min
Low idle
r/min
No. 6 cylinder
Low idle
r/min
D275AX-5E0
40 Troubleshooting
C. Check of fuel circuit pressure

6
Fuel low-pressure circuit

pressure
SEN01656-00
Checking condition
High idle
Unit
Standard value
(Reference value)
MPa
{kg/cm2}
0.15 0.3
{1.5 3}
Measured
value
D. Check of strainers and filters
Good NG
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

return rate
11
Leakage through pressure

limiter
12 Return rate from injector
D275AX-5E0
Unit
Standard value
(Reference value)
Torque converter stal
cc/min
Max. 10

1,600 rpm
cc/min
960

1,700 rpm
cc/min
1,020

1,800 rpm
cc/min
1,080

1,900 rpm
cc/min
1,140

2,000 rpm
cc/min
1,200
Checking condition
Measured
value
Good NG
Speed:
Leakage
67
SEN01656-00
40 Troubleshooting
Failure code [CA689] Eng Ne speed sensor error

Action code
Failure code
CALL E03
CA689
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Eng Ne speed sensor error

Trouble occurred in engine Ne speed sensor circuit.

Operates with signals of Bkup speed sensor.
Running engine stops (when Bkup speed sensor is also abnormal).
Stopped engine cannot be started (when Bkup speed sensor is also abnormal).
Related
information
Cause
1
Defective sensor power supIf code [CA238] is indicated, carry out troubleshooting for it first.
ply system

2

Resistance
Max. 1 z

Resistance
Max. 1 z

Resistance
Max. 1 z
circuit)
Possible causes
and standard
value in normal
state

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

harness)

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
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.
Defective engine Ne speed
sensor
If causes 1 5 are not detected, engine Ne speed sensor may be

defective. (Since trouble is in system, troubleshooting cannot be
carried out.)
out.)
68
D275AX-5E0
40 Troubleshooting
SEN01656-00
D275AX-5E0
69
SEN01656-00
40 Troubleshooting
70
D275AX-5E0
SEN01657-00
BULLDOZER
1SHOP MANUAL
D275AX-5E0
Machine model
Serial number
D275AX-5E0
30001 and up
40 Troubleshooting

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 [CA1228] EGR valve servo error 1............................................................................................. 6
Failure code [CA1625] EGR valve servo error 2............................................................................................. 7
Failure code [CA1626] BP valve sol current high error................................................................................... 8
Failure code [CA1627] BP valve sol current low error .................................................................................. 10
Failure code [CA1628] Bypass valve servo error 1........................................................................................11
Failure code [CA1629] Bypass valve servo error 2....................................................................................... 12
Failure code [CA1631] BP valve pos sens high error ................................................................................... 14
Failure code [CA1632] BP valve pos sens low error..................................................................................... 16
Failure code [CA1633] KOMNET datalink timeout error ............................................................................... 18
Failure code [CA1642] EGR inlet press sens low error ................................................................................ 20
Failure code [CA1653] EGR inlet press sens high error ............................................................................... 22
D275AX-5E0
SEN01657-00
40 Troubleshooting
Failure code [CA2185] Throt sens sup volt high error................................................................................... 24

Failure code [CA2186] Throt sens sup volt low error .................................................................................... 26
Failure code [CA2249] Rail press very low error........................................................................................... 26
Failure code [CA2271] EGR valve pos sens high error ................................................................................ 28
Failure code [CA2272] EGR valve pos sens low error.................................................................................. 30
Failure code [CA2351] EGR valve sol current high error .............................................................................. 32
Failure code [CA2352] EGR valve sol current low error ............................................................................... 34
Failure code [CA2555] Grid htr relay volt low error ....................................................................................... 35
Failure code [CA2556] Grid htr relay volt high error...................................................................................... 36
Failure code [D110KA] Battery relay holding disconnection ......................................................................... 38
Failure code [D110KB] Battery relay drive short circuit ................................................................................. 40
Failure code [D130KA] Neutral safety relay disconnection ........................................................................... 42
Failure code [D130KB] Neutral safety relay short circuit............................................................................... 44
Failure code [D161KA] Back-up alarm relay disconnection .......................................................................... 46
Failure code [D161KB] Back-up alarm relay short circuit.............................................................................. 48
Failure code [D190KA] Engine controller ACC signal cut relay .................................................................... 50
Failure code [D190KB] Engine controller ACC signal cut relay short ........................................................... 52
Failure code [D811KR] KOMTRAX controller CAN defective communication .............................................. 54
Failure code [DAFRKR] Machine monitor CAN communication defective communication........................... 56
D275AX-5E0
40 Troubleshooting
SEN01657-00
Failure code [CA731] Eng Bkup speed sens phase error

Action code
Failure code
CALL E03
CA731
Trouble
Eng Bkup speed sens phase error

Contents of
trouble
Engine Bkup sensor circuit detected phase error.
Action of
controller
Controls with signals of engine Ne speed sensor.
Problem that
appears on
machine
Running engine stops (when Ne speed sensor is also abnormal).

Stopped engine cannot be started (when Ne speed sensor is also abnormal).
Related
information
Possible causes
and standard
value in normal
state
Cause
Defective engine Ne speed

sensor system
Engine Ne speed sensor may be defective. Carry out troubleshooting for failure code [CA689].
Defective engine Bkup

speed sensor system
Engine Bkup speed sensor may be defective. Carry out troubleshooting for failure code [CA778].
Failure code [CA757] All continuous data lost error

Action code
Failure code
CALL E04
CA757
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
All continuous data lost error

All data in engine controller are lost.

None in particular.
Related
information
Possible causes
and standard
value in normal
state
D275AX-5E0
Cause

SEN01657-00
40 Troubleshooting
Failure code [CA778] Eng Bkup speed sensor error

Action code
Failure code
CALL E03
CA778
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Eng Bkup speed sensor error

Trouble occurred in engine Bkup speed sensor circuit.

Operates with signals of Ne speed sensor.
Running engine stops (when Ne speed sensor is also abnormal).
Stopped engine cannot be started (when Ne speed sensor is also abnormal).
Related
information
Cause
1
ply system
for it first.

2

(37) G (female) (1)
Resistance
Max. 1 z

(47) G (female) (2)
Resistance
Max. 1 z

(26) G (female) (3)
Resistance
Max. 1 z
circuit)
Possible causes
and standard
value in normal
state

(37) G (female) (1) and chassis ground
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

harness)

(37) G (female) (1) and between EGC1
(female) (47) G (female) (2)
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
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.
6
Defective engine Bkup

speed sensor
If causes 1 5 are not detected, engine Bkup speed sensor may

be defective. (Since trouble is in system, troubleshooting cannot
be carried out.)
out.)
D275AX-5E0
40 Troubleshooting
SEN01657-00
D275AX-5E0
SEN01657-00
40 Troubleshooting
Failure code [CA1228] EGR valve servo error 1

Action code
Failure code
E02
CA1228
Contents of
trouble
Action of
controller
Trouble
EGR valve servo error 1

Trouble (level 1) occurred in EGR valve servo.

Performs open control.
Problem that
appears on
machine
Related
information
Operating condition of EGR valve can be checked with real-time monitoring mode.
(Code: 18100 EGR valve position)
Cause

a For check of engine oil pressure, see Testing and adjusting,
Measuring engine oil pressure.

2
system (main circuit)
Possible causes
and standard
value in normal
state
Engine
Engine oil pressure
Low idle
0.08 MPa {0.8 kg/cm2 }
High idle
0.21 MPa {2.1 kg/cm2 }
If engine oil pressure is abnormal, carry out troubleshooting for "S12 Oil pressure lowers" in S mode.
3
Defective oil pump for EGR

valve
Check oil pump and relief valve for EGR valve circuit directly.
Defective oil feed piping for

EGR valve
Check oil feed piping for EGR valve circuit directly.
Defective oil return piping for

Check oil return piping for EGR valve circuit directly.
EGR valve
6 Defective EGR valve
Check mechanical section of EGR valve directly.
out.)
D275AX-5E0
40 Troubleshooting
SEN01657-00
Failure code [CA1625] EGR valve servo error 2

Action code
Failure code
CALL E03
CA1625
Trouble
EGR valve servo error 2

Contents of
trouble
Trouble (level 2) occurred in EGR valve servo.
Action of
controller
Limits engine output and continues operation.

Closes EGR valve and bypass valve.
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
D275AX-5E0

Operating condition of EGR valve can be checked with real-time monitoring mode.
(Code: 18100 EGR valve position)
Cause

SEN01657-00
40 Troubleshooting
Failure code [CA1626] BP valve sol current high error

Action code
Failure code
CALL E03
CA1626
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
BP valve sol current high error

There is short circuit in drive circuit of bypass valve solenoid.

Related
information
Cause
Defective bypass valve sole1
noid (Internal trouble)

BP (male)
Resistance
Between (1) (2)
10 21 z
Resis2
Max. 1 z
or defective contact in con- (31) BP (female) (1)
tance
nector)
ResisMax. 1 z
(11) BP (female) (2)
tance
Possible causes
and standard
value in normal
state

circuit)
(31) BP (female) (1) and chassis ground
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

4
Hot short (Short circuit with Wiring harness between EGC1 (female)
24V circuit) in wiring harness (31) - BP (female) (1) and chassis ground
Voltage
Max. 1 V

Voltage
Max. 1 V
Prepare with starting switch OFF, then carry out troubleshooting

without turning starting switch ON.
EGC1 (female)
Resistance
Between (31) (11)
10 21 z
D275AX-5E0
40 Troubleshooting
SEN01657-00
D275AX-5E0
SEN01657-00
40 Troubleshooting
Failure code [CA1627] BP valve sol current low error

Action code
Failure code
CALL E03
CA1627
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
BP valve sol current low error

There is disconnection in drive circuit of bypass valve solenoid.

Related
information
Possible causes
and standard
value in normal
state
10
Cause

D275AX-5E0
40 Troubleshooting
SEN01657-00
Failure code [CA1628] Bypass valve servo error 1

Action code
Failure code
E02
CA1628
Contents of
trouble
Action of
controller
Trouble
Bypass valve servo error 1

Trouble (level 1) occurred in bypass valve servo.

Performs open control.
Problem that
appears on
machine
Related
information
Operating condition of bypass valve can be checked with real-time monitoring mode.
(Code: 18200 BPS valve position)
Cause

a For check of engine oil pressure, see Testing and adjusting,
"Measuring engine oil pressure".

2
system (main circuit)
Possible causes
and standard
value in normal
state
D275AX-5E0
Engine
Engine oil pressure
Low idle
0.08 MPa {0.8 kg/cm2 }
High idle
0.21 MPa {2.1 kg/cm2 }
If engine oil pressure is abnormal, carry out troubleshooting for "S

12 Oil pressure lowers" in S mode.
3
Defective oil pump for

bypass valve
Check oil pump and relief valve for bypass valve circuit directly.
Defective oil feed piping for

bypass valve
Check oil feed piping for bypass valve circuit directly.
Defective oil return piping for

Check oil return piping for bypass valve circuit directly.
bypass valve
6 Defective bypass valve
Check mechanical section of bypass valve directly.
out.)
11
SEN01657-00
40 Troubleshooting
Failure code [CA1629] Bypass valve servo error 2

Action code
Failure code
CALL E03
CA1629
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
12
Trouble
Bypass valve servo error 2

Trouble (level 2) occurred in bypass valve servo.

Operating condition of bypass valve can be checked with real-time monitoring mode.
(Code: 18200 BPS valve position)
Cause

D275AX-5E0
SEN01657-00
40 Troubleshooting
Failure code [CA1631] BP valve pos sens high error

Action code
Failure code
CALL E03
CA1631
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
BP valve pos sens high error

Signal voltage in bypass valve lift sensor circuit is abnormally high.

State of bypass valve lift sensor signal can be checked with real-time monitoring mode.
(Code: 18201 BPS valve pos sens volt)
Cause
1
ply system
for it first.
Defective bypass valve lift

SBP
Between (1) (2)
Voltage
Power supply
4.75 5.25 V

3
Possible causes
and standard
value in normal
state

(37) SBP (female) (1)
Resistance
Max. 1 z

(38) SBP (female) (2)
Resistance
Max. 1 z

(29) SBP (female) (3), (4)
Resistance
Max. 1 z
circuit)

(37) SBP (female) (1) and chassis ground
Resistance
Min. 1 Mz

(38) SBP (female) (2) and chassis ground
Resistance
Min. 1 Mz

(29) SBP (female) (3), (4) and chassis
ground
Resistance
Min. 1 Mz

harness)
14

(37) SBP (female) (1) and between EGC1
(female) (38) SBP (female) (2)
Resistance
Min. 1 Mz

(female) (29) SBP (female) (3), (4)
Resistance
Min. 1 Mz

(female) (29) SBP (female) (3), (4)
Resistance
Min. 1 Mz
D275AX-5E0
40 Troubleshooting
SEN01657-00
Cause
Possible causes
and standard
value in normal
state

Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.
EGC1
Voltage
Between (37) (38)
4.75 5.25 V
D275AX-5E0
15
SEN01657-00
40 Troubleshooting
Failure code [CA1632] BP valve pos sens low error

Action code
Failure code
CALL E03
CA1632
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
16
Trouble
BP valve pos sens low error

Signal voltage in bypass valve lift sensor circuit is abnormally low.

State of bypass valve lift sensor signal can be checked with real-time monitoring mode.
(Code: 18201 BPS valve pos sens volt)
Cause

D275AX-5E0
SEN01657-00
40 Troubleshooting
Failure code [CA1633] KOMNET datalink timeout error

Action code
CALL E03
Contents of
trouble
Action of
controller
Failure code
CA1633
Trouble
KOMNET datalink timeout error

Trouble occurred in KOMNET (CAN) communication circuit between engine controller and machine
monitor, transmission controller, and work equipment controller.
Operates in default mode or maintains condition when abnormality occurs.
Problem that
appears on
machine
Related
information
Cause


1
Wiring harness between CM02 (female) (8),

(9) EGC2 (female) (46), STC2 (female)
(32) or WEC2 (female) (32)
Resistance
Max. 1 z
Wiring harness between CM02 (female)

(22) or WEC2 (female) (22)
Resistance
Max. 1 z

circuit)
Possible causes
and standard
value in normal
state
Resistance
Min. 1 Mz

(22), WEC2 (female) (22), ACCN (female)
(18), SRV (male) (10) or CA1 (female) (B)
and chassis ground
Resistance
Min. 1 Mz

Hot short (Contact with

3 ground circuit) in wiring harness
Defective CAN terminal

4 resistance (Internal disconnection or short circuit)
18

(17), SRV (male) (3) or CA1 (female) (A)
and chassis ground

(17), SRV (male) (3) or CA1 (female) (A)
and chassis ground
Voltage
Max. 1 V

(18), SRV (male) (10) or CA1 (female) (B)
and chassis ground
Voltage
Max. 1 V
Prepare with starting switch OFF, then carry out troubleshooting

CA1 (male)
Resistance
Between (A) (B)
Approx. 120 z
out.)
D275AX-5E0
40 Troubleshooting
SEN01657-00
D275AX-5E0
19
SEN01657-00
40 Troubleshooting
Failure code [CA1642] EGR inlet press sens low error

Action code
Failure code
E01
CA1642
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
20
Trouble
EGR inlet press sens low error

Signal voltage in EGR inlet pressure sensor circuit is abnormally low.

Sets EGR inlet pressure to default value (102 kPa {1.04 kg/cm2}) and continues operation.
State of EGR valve inlet pressure sensor signal can be checked with real-time monitoring mode.
(Code: 18001 EGR in press sens volt)
Cause

D275AX-5E0
SEN01657-00
40 Troubleshooting
Failure code [CA1653] EGR inlet press sens high error

Action code
Failure code
E01
CA1653
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
EGR inlet press sens high error

Signal voltage in EGR inlet pressure sensor circuit is abnormally high.

Sets EGR inlet pressure to default value (102 kPa {1.04 kg/cm2}) and continues operation.
State of EGR valve inlet pressure sensor signal can be checked with real-time monitoring mode.
(Code: 18001 EGR in press sens volt)
Cause
1
ply system
for it first.
2
Defective EGR inlet pressure

PEVA
Between (1) (2)
Voltage
Power supply
4.75 5.25 V

3
Possible causes
and standard
value in normal
state

(37) PEVA (female) (1)
Resistance
Max. 1 z

Resistance
Max. 1 z

Resistance
Max. 1 z
circuit)

PEVA (female) (1) and chassis ground
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

harness)

(37) PEVA (female) (1) and between
EGC1 (female) (47) PEVA (female) (2)
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

22
EGC1
Voltage
Between (37) (47)
4.75 5.25 V
D275AX-5E0
40 Troubleshooting
SEN01657-00
D275AX-5E0
23
SEN01657-00
40 Troubleshooting
Failure code [CA2185] Throt sens sup volt high error

Action code
Failure code
CALL E03
CA2185
Contents of
trouble
Action of
controller
Trouble
Throt sens sup volt high error

Signal voltage in throttle sensor power supply (5 V) circuit is abnormally high.

Sets throttle position with signal of fuel control dial and continues operation.
Problem that
appears on
machine
Related
information
Cause


(Internal trouble)
Disconnect devices
"E" of failure code
disappears when a
has trouble in it.
Decelerator pedal
potentiometer
DCL connector
Possible causes
and standard
value in normal
state
2
or defective contact in con- (22) DCL (female) (B)
nector)
(23) DCL (female) (C)

circuit)

harness)
24
Resistance
Max. 1 z
Resistance
Max. 1 z
(22) DCL (female) (B) and chassis ground
Resistance
Min. 1 Mz

(23) DCL (female) (C) and chassis ground
Resistance
Min. 1 Mz
(22) DCL (female) (B) and between EGC2
(female) (23) DCL (female) (C)
Resistance
Min. 1 Mz

EGC2
Voltage
Between (22) (23)
4.75 5.25 V
D275AX-5E0
40 Troubleshooting
SEN01657-00
D275AX-5E0
25
SEN01657-00
40 Troubleshooting
Failure code [CA2186] Throt sens sup volt low error

Action code
Failure code
CALL E03
CA2186
Contents of
trouble
Action of
controller
Trouble
Throt sens sup volt low error

Signal voltage in throttle sensor power supply (5 V) circuit of engine controller is abnormally low.
Sets throttle position with signal of fuel control dial and continues operation.
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Cause

Failure code [CA2249] Rail press very low error

Action code
Failure code
CALL E03
CA2249
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Rail press very low error

Very low pressure error (level 2) occurred in supply pump.

Limits common rail pressure.
Related
information
Possible causes
and standard
value in normal
state
26
Cause

D275AX-5E0
SEN01657-00
40 Troubleshooting
Failure code [CA2271] EGR valve pos sens high error

Action code
Failure code
CALL E03
CA2271
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
EGR valve pos sens high error

Signal voltage in EGR valve lift sensor circuit is abnormally high.

State of EGR valve lift sensor signal can be checked with real-time monitoring mode.
(Code: 18101 EGR valve pos sens volt)
Cause
1
ply
for it first.
2
Defective EGR valve lift sensor (Internal trouble)
SEGR
Between (1) (2)
Voltage
Power supply
4.75 5.25 V

3

(37) SEGR (female) (1)
Resistance
Max. 1 z

(47) SEGR (female) (2)
Resistance
Max. 1 z

(19) SEGR (female) (3), (4)
Resistance
Max. 1 z
Possible causes
and standard
value in normal
state
circuit)

(37) SEGR (female) (1) and chassis
ground
Resistance
Min. 1 Mz

(47) SEGR (female) (2) and chassis
ground
Resistance
Min. 1 Mz

(19) SEGR (female) (3), (4) and chassis
ground
Resistance
Min. 1 Mz

harness)
28

(37) SEGR (female) (1) and between
EGC1 (female) (47) SEGR (female) (2)
Resistance
Min. 1 Mz

EGC1 (female) (19) SEGR (female) (3),
(4)
Resistance
Min. 1 Mz

EGC1 (female) (19) SEGR (female) (3),
(4)
Resistance
Min. 1 Mz
D275AX-5E0
40 Troubleshooting
SEN01657-00
Cause
Possible causes
and standard
value in normal
state

EGC1
Voltage
Between (37) (47)
4.75 5.25 V
D275AX-5E0
29
SEN01657-00
40 Troubleshooting
Failure code [CA2272] EGR valve pos sens low error

Action code
Failure code
CALL E03
CA2272
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
30
Trouble
EGR valve pos sens low error

Signal voltage in EGR valve lift sensor circuit is abnormally low.

State of EGR valve lift sensor signal can be checked with real-time monitoring mode.
(Code: 18101 EGR valve pos sens volt)
Cause

D275AX-5E0
SEN01657-00
40 Troubleshooting
Failure code [CA2351] EGR valve sol current high error

Action code
Failure code
CALL E03
CA2351
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
EGR valve sol current high error

There is short circuit in EGR valve solenoid drive circuit.

Related
information
Cause
Defective EGR valve sole1
noid (Internal trouble)

EGR (male)
Resistance
Between (1) (2)
10 21 z
Resis2
Max. 1 z
or defective contact in con- (22) EGR (female) (1)
tance
nector)
ResisMax. 1 z
(11) EGR (female) (2)
tance
Possible causes
and standard
value in normal
state

circuit)

(22) EGR (female) (1) and chassis
ground
Resistance
Min. 1 Mz

ground
Resistance
Min. 1 Mz

Hot short (Short circuit with (22) EGR (female) (1) and chassis
4
24V circuit) in wiring harness ground
Voltage
Max. 1 V

ground
Voltage
Max. 1 V
32
EGC1 (female)
Resistance
Between (22) (11)
10 21 z
D275AX-5E0
40 Troubleshooting
SEN01657-00
D275AX-5E0
33
SEN01657-00
40 Troubleshooting
Failure code [CA2352] EGR valve sol current low error

Action code
Failure code
CALL E03
CA2352
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
EGR valve sol current low error

There is disconnection in EGR valve solenoid drive circuit.

Related
information
Possible causes
and standard
value in normal
state
34
Cause

Carry out troubleshooting failure code [CA2351].
D275AX-5E0
40 Troubleshooting
SEN01657-00
Failure code [CA2555] Grid htr relay volt low error

Action code
Failure code
E01
CA2555
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
D275AX-5E0
Trouble
Grid htr relay volt low error

There is disconnection in intake air heater relay circuit.

None in particular.
Engine does not start easily at low temperature.
Cause

Carry out troubleshooting failure code [CA2556].
35
SEN01657-00
40 Troubleshooting
Failure code [CA2556] Grid htr relay volt high error

Action code
Failure code
E01
CA2556
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Grid htr relay volt high error

There is short circuit in intake air heater relay.

None in particular.
Engine does not start easily at low temperature.
Engine controller has automatic preheating function, which is turned ON when engine coolant temperature is below -5 C (for up to 30 seconds).
Cause
Defective intake air heater

relay (Internal trouble)

PHR (male)
Resistance
Between (1) (2)
200 400 z
Possible causes
and standard
value in normal
state
2
or defective contact in con- (40) PHR (female) (1)
nector)
Wiring harness between PHR (female) (2)
chassis ground (GND03)
circuit)
Resistance
Max. 1 z
Resistance
Max. 1 z
(40) PHR (female) (1) and chassis ground
Resistance
Min. 1 Mz

36
EGC2
Coolant temperature
Voltage
Between (40)
chassis ground
-5 C or higher
Max. 1 V
Below -5 C
20 30 V
D275AX-5E0
40 Troubleshooting
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D275AX-5E0
37
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40 Troubleshooting
Failure code [D110KA] Battery relay holding disconnection

Action code
Failure code
D110KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Battery relay holding disconnection

Turns signal to battery relay holding circuit, no current flows.

Turns signal to battery relay holding circuit OFF.
Problem may occur in writing data into ROM (non-volatile memory) of each controller.
State of battery relay holding circuit signal can be checked with real-time monitoring mode.
(Code: 60600 BR hold relay)
Method of reproducing failure code: Turn starting switch ON.
Cause
Defective battery relay (Inter1
nal disconnection)
Battery relay
Continuity
Between terminals SW BRE
There is continuity
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between STCN3 (female)
2
or defective contact in con- (4) terminal SW
nector)
Wiring harness between terminal BRE and
chassis ground
circuit)
38
Resistance
Max. 1 z
Resistance
Max. 1 z
Wiring harness between STCN3 (female)
(4) terminal SW, terminal 260 or circuit
branch end and chassis ground
Resistance
Min. 1Mz
STCN3
Continuity
Between (4) chassis ground
Continue
D275AX-5E0
40 Troubleshooting
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39
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40 Troubleshooting
Failure code [D110KB] Battery relay drive short circuit

Action code
Failure code
D110KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Battery relay drive short circuit

When signal was output to battery relay circuit, abnormal current flowed.
Turns signal to battery relay holding circuit OFF.
Problem may occur in writing data into ROM (non-volatile memory) of each controller.
State of battery relay holding circuit signal can be checked with real-time monitoring mode.
(Code: 60600 BR hold relay)
Cause
Defective battery relay (Inter1
nal short circuit)
Battery relay
Continuity/Resistance
Between terminals SW BRE
Possible causes
and standard
value in normal
state
There is continuity

Hot short (Short circuit with

24V circuit) in wiring harness Wiring harness between STCN3 (female)
(4) terminal SW, terminal 260 or circuit
branch end and chassis ground
Voltage
Max. 1 V

40
STCN3
Starting switch
Voltage
Between (4)
chassis ground
ON
10 20 V
D275AX-5E0
40 Troubleshooting
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41
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40 Troubleshooting
Failure code [D130KA] Neutral safety relay disconnection

Action code
Failure code
E02
D130KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Neutral safety relay disconnection

Neutral safety relay circuit voltage does not match controller output state.
Stops ground output to neutral safety relay circuit.
Engine does not start.
Output state (voltage) to neutral safety relay can be checked in real-time monitoring mode.
(Code 50900: Neutral safety relay drive voltage)
Method of reproducing failure code: Turn starting switch ON (+ Operate parking brake lever).
This failure code detects abnormality in primary side (coil side) of neutral safety relay, but not in secondary side (contact side)
Cause
Defective neutral safety relay
1
(Internal disconnection)
NSF (male)
Resistance
200 400 z
Between (1) (2)

Defective disconnection in
wiring harness (Disconnec2
tion in wiring or defective
contact in connector)
Possible causes
and standard
value in normal
state
Wiring harness between TMCN2 (female)
(8) NSF (female) (2)
Resistance
Max. 1 z
Wiring harness between NSF (female) (1)

terminal 270
Resistance
Max. 1 z
Short circuit of wiring harness between
Short circuit with chassis
TMCN2 (female) (8) NSF (female) (2) with
3 ground in wiring harness
chassis ground
(Contact with ground circuit)
Short circuit of wiring harness between NSF
(female) 1 terminal 270 with chassis
ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

4
42
TMCN2
Parking brake lever
Voltage
Between (8)
chassis ground
Lock position
Max. 1 V
Free position
20 30 V
D275AX-5E0
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43
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40 Troubleshooting
Failure code [D130KB] Neutral safety relay short circuit

Action code
Failure code
E02
D130KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Neutral safety relay short circuit

Abnormal current flowed in neutral safety relay circuit at the time of output.
Stops ground output to neutral safety relay circuit.
Engine does not start.
Output state (voltage) to neutral safety relay can be checked in real-time monitoring mode.
(Code 50900: Neutral safety relay drive voltage)
Method of reproducing failure code: Turn starting switch ON and operate parking brake lever (Free
position).
This failure code detects abnormality in primary side (coil side) of neutral safety relay, but not in secondary side (contact side)
Cause
1
(Internal short circuit)
Possible causes
and standard
value in normal
state

NSF (male)
Resistance
Between (1) (2)
200 400 z

Hot short circuit in wiring har2 ness
(Contact with 24V circuit)
TMCN2 (female) (8) NSF (female) (2) with Voltage Max. 1 V
chassis ground
3
44
TMCN2
Parking brake lever
Voltage
Between (8)
chassis ground
Lock position
Max. 1 V
Free position
20 30 V
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40 Troubleshooting
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45
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40 Troubleshooting
Failure code [D161KA] Back-up alarm relay disconnection

Action code
Failure code
E01
D161KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Back-up alarm relay disconnection

Backup alarm relay circuit voltage does not match controller output state.
Turns output of back-up alarm relay circuit OFF.
Back-up alarm does not sound
Output state (voltage) to back-up alarm relay circuit can be checked with real-time monitoring
mode. (Code: 70400 Back alarm relay)
Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (R: Reverse).
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).
Cause
1 Defective fuse (FS22)
Defective back-up alarm
2
relay (Internal disconnection)
Possible causes
and standard
value in normal
state

If fuse is broken, circuit probably has ground fault (See cause 4).
BKAL (male)
Resistance
Between (1) (2)
200 400 z
Disconnection in wiring harness (Disconnection in wiring Wiring harness between TMCN2 (female)
Resis3
Max. 1 z
or defective contact in con- (18) BKAL (female) (2)
tance
nector)
Wiring harness between BKAL (female) (1),
ResisMax. 1 z
(3) FS22 (1)
tance
circuit)

(18) BKAL (female) (2) or circuit branch
end and chassis ground
Resistance
Min. 1 Mz
Wiring harness between BKAL (female) (1),

(3) FS22 (1) and chassis ground
Resistance
Min. 1 Mz

5
TMCN2
Between (18)
chassis ground
46
PCCS lever
(Directional)
Voltage
N (Neutral)
20 30 V
R (Reverse)
Max. 1 V
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40 Troubleshooting
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47
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40 Troubleshooting
Failure code [D161KB] Back-up alarm relay short circuit

Action code
Failure code
E01
D161KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Back-up alarm relay short circuit

When circuit of back-up alarm relay was disconnected, abnormal current flowed.
Turns output of back-up alarm relay circuit OFF.
Back-up alarm does not sound.
Output state (voltage) to back-up alarm relay circuit can be checked with real-time monitoring
mode. (Code: 70400 Back alarm relay)
Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (R: Reverse)
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).
Cause
Possible causes
and standard
value in normal
state

relay (Internal short circuit)

BKAL (male)
Resistance
Between (1) (2)
200 400 z


24V circuit) in wiring harness Wiring harness between TMCN2 (female)
(18) BKAL (female) (2) or circuit branch
Voltage
Max. 1 V

3
TMCN2
Between (18)
chassis ground
48
PCCS lever
(Directional)
Voltage
N (Neutral)
20 30 V
R (Reverse)
Max. 1 V
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40 Troubleshooting
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49
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40 Troubleshooting
Failure code [D190KA] Engine controller ACC signal cut relay

Action code
Failure code
D190KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Engine controller ACC signal cut relay

Engine controller ACC signal cut relay circuit voltage does not match controller output state.
Stops outputting signal to engine controller ACC signal cut relay.
Engine stop function of steering controller does not work.
Signal state of engine controller ACC signal cut relay circuit can be checked in real-time monitoring
mode. (Code: 60500 ENG hold relay)
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).
Cause
1 Defective fuse FS3-1
Defective engine controller
2 ACC signal cut relay (Internal
disconnection)
Possible causes
and standard
value in normal
state

If fuse is broken, circuit probably has ground fault etc.
ACT (male)
Resistance
Between (1) (2)
200 400 z
Resis3
Max. 1 z
or defective contact in con- (8) ACT (female) (2)
tance
nector)
Wiring harness between ACT (female) (1)
ResisMax. 1 z
KEY (female) (1)
tance

circuit)
(8) ACT (female) (2) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between ACT (female) (1)

KEY (female) (1)
Resistance
Min. 1 Mz
5 Defective Steering controller
50
STCN2 (female)
Starting switch
Voltage
Between (8)
chassis ground
ON
Max. 1 V
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40 Troubleshooting
Failure code [D190KB] Engine controller ACC signal cut relay short
Action code
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Failure code
D190KB
Trouble
Engine controller ACC signal cut relay short

When ground circuit of engine controller ACC signal cut relay was disconnected, abnormal current
flowed.
Turns output of engine controller ACC signal cut relay circuit OFF.
Engine stop function of steering controller does not work.
State of engine controller ACC signal cut relay circuit signal can be checked with real-time monitoring mode. (Code: 60500 ENG hold relay)
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).
Cause
1 ACC signal cut relay (Internal
short circuit)
Possible causes
and standard
value in normal
state
Hot short (Contact with 24V

2
circuit) in wiring harness

ACT (male)
Resistance
Between (1) (2)
200 400 z

(8) ACT (female) (2) and chassis ground
Resistance
Max. 1 V

52
STCN2 (female)
Starting switch
Voltage
ON
Max. 1 V
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40 Troubleshooting
Failure code [D811KR] KOMTRAX controller CAN defective

communication
Action code
Failure code
D811KR
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
KOMTRAX controller CAN defective communication

Steering controller cannot recognize KOMTRAX controller in CAN communication circuit.

None in particular
KOMTRAX LED information (Code: 20300) is not displayed in real-time monitoring mode.
Method of reproducing failure code: Turn starting switch ON and select code: 20300 in real-time
monitoring mode.
Cause

Wiring harness between S04 (female) (1),
(2) STCN2 (female) (32), TMCN2
(female) (32), EGC2 (female) (46), CA1
(female) (A), CT1 (female) (A) SRV
(male) (3) KOM1 (female) (8)
Disconnection in wiring harness

1 (Disconnection in wiring or
defective contact in connecWiring harness between S04 (female) (3),
tor)
(female) (22) EGC2 (female) (47) CA1
(female) (B) CT1 (female) (B) SRV
Resistance
Max. 1 z
Resistance
Max. 1 z
Possible causes
and standard
value in normal
state

Short circuit of wiring harness between S04

(female) (1), (2) STCN2 (female) (32),
TMCN2 (female) (32) EGC2 (female) (46),
CA1 (female) (A), CT1 (female) (A)
SRV (male) (3) KOM1 (female) (8) with
chassis ground
Resistance
Min. 1 Mz

TMCN2 (female) (22), EGC2 (female) (47)
CA1 (female) (B), CT1 (female) (B)
chassis ground
Resistance
Min. 1 Mz

54
Hot short in wiring harness

(Contact with 24 V circuit)

TMCN2 (female) (32) EGC2 (female) (46)
chassis ground
Voltage
Max. 1 V

chassis ground
Voltage
Max. 1 V
D275AX-5E0
40 Troubleshooting
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Cause
Possible causes
and standard
value in normal
state

4
resistance
Defective KOMTRAX controller or steering controller

CA1 (male), CT1 (male)
Resistance
Between (A) (B)
100 140 z
If causes 1 4 are not detected, KOMTRAX controller or steering

controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
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55
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40 Troubleshooting
Failure code [DAFRKR] Machine monitor CAN communication defective

communication
1
Action code
Failure code
CALL E03
DAFRKR
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Machine monitor CAN communication defective communication

(Machine monitor system)
Machine monitor cannot recognize steering controller in CAN communication circuit.

Blinks warning lamp and sounds alarm buzzer.
Limits operations of engine and transmission.
System may not operate normally.
Once machine is stopped, gear speed is limited to F1 and R1.
Cause


(2) STCN2 (female) (32) TMCN2
Disconnection in wiring har- (female) (32) EGC2 (female) (46) CA1
ness (Disconnection in wiring (female) (A) CT1 (female) (A) SRV
1
or defective contact in con- (male) (3) KOM1 (female) (8)
nector)
Resistance
Max. 1 z
Resistance
Max. 1 z
Possible causes
and standard
value in normal
state

circuit)

(female) (A) CT1 (female) (A) SRV
(male) (3) KOM1 (female) (8) with chassis
ground
Resistance
Min. 1 Mz

(male) (10) KOM1 (female) (7) with chassis ground
Resistance
Min. 1 Mz

56


(female) (A) CT1 (female) (A) SRV
(male) (3) KOM1 (female) (8) with chassis
ground
Voltage
Max. 1 V

(male) (10) KOM1 (female) (7) with chassis ground
Voltage
Max. 1 V
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40 Troubleshooting
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Cause
Possible causes
and standard
value in normal
state

4
resistor
Defective transmission controller or steering controller

Resistance
Between (A) (B)
100 140 z
If causes 1 4 are not detected, steering controller or transmission

controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
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58
D275AX-5E0
SEN01658-00
BULLDOZER
1SHOP MANUAL
D275AX-5E0
Machine model
Serial number
D275AX-5E0
30001 and up
40 Troubleshooting

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
D275AX-5E0
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40 Troubleshooting
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 component system) .......................................................................................................................................... 34
Failure code [DB3SKR] Steering controller S-NET defective communication (Abnormality in objective component 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
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40 Troubleshooting
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Failure code [DAQ0KT] Transmission controller internal abnormality

Action code
Failure code
E01
DAQ0KT
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
D275AX-5E0
Trouble
Transmission controller internal abnormality

Information of ROM (nonvolatile storage) of transmission controller is not normal.

Sets default internal adjustment value.
Gear shift feeling of transmission may become worse.
Cause
1

Troubleshooting cannot be carried out since it is internal defect.
(It is no problem even if you use controller unless no visible problem appears on machine.)
SEN01658-00
40 Troubleshooting
Failure code [DAQ1KK] Transmission controller main source voltage

reduction
1
Action code
Failure code
CALL E04
DAQ1KK
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Transmission controller main source voltage reduction

Source voltage of transmission controller is below 17 V.

Machine monitor may not display normally.

Relays and solenoids cannot operate, not allowing system operate normally.
Once machine is stopped, it cannot travel any more.
Charge level (voltage) of battery can be checked in real-time monitoring mode.

(Code 03200: Battery voltage)
Cause

(CB30) (30A)
If circuit breaker (30 A) is tripped, circuit probably has short circuit

with chassis ground.
If fuse FS12-2 is tripped, circuit probably has short circuit with

chassis ground.

defective contact in connector)
Possible causes
and standard
value in normal
state

(1), (11) FS12-2
Resistance
Max. 1 z
Wiring harness between FS11 CB105

battery relay terminal BRB
Resistance
Max. 1 z

(21), (31), (32), (33) chassis ground
Resistance
Max. 1 z
TMCN3 (female) (1), (11) FS12-2 with
chassis ground
FS11 CB105 battery relay terminal BRB
with chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

TMCN3
Voltage
Between (1), (11) (21), (31),

(32), (33)
20 30 V
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40 Troubleshooting
Failure code [DAQ2KK] Transmission controller load voltage reduction1

Action code
Failure code
CALL E04
DAQ2KK
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Transmission controller load voltage reduction

Source voltage of transmission controller is below 17 V.



Cause

(CB3) (20 A)


(CB105) (105 A)


defective contact in connector)
Possible causes
and standard
value in normal
state

(2), (12), (22) CB3 (2)
Resistance
Max. 1 z
Wiring harness between CB3 (1) CB105

battery relay terminal BRC
Resistance
Max. 1 z

(21), (31), (32), (33) chassis ground
Resistance
Max. 1 z
TMCN3 (female) (2), (12), (22) CB3 (2)
with chassis ground
Short circuit of wiring harness between CB3
(1) CB105 battery relay terminal BRC
with chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

TMCN3
Voltage
Between (2), (12), (22) (21),

(31), (32), (33)
20 30 V
D275AX-5E0
40 Troubleshooting
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D275AX-5E0
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40 Troubleshooting
Failure code [DAQ5KK] Transmission controller sensor 5 V power

source (1) power supply source voltage reduction
Action code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Failure code
DAQ5KK
Trouble
Transmission controller sensor 5 V power soruce (1) power supply

Voltage of 5V power source (1) circuit of transmission controller sensor is below 4.5V or above 5.5V.
Abnormal current flowed in 5V power source circuit of transmission controller sensor.
Stops output to 5V power source circuit if abnormal voltage flows
Once machine is stopped, travel is limited to F1 an R1.
Cause

Defective forward-reverse
1 potentiometer (Internal short
circuit)
Possible causes
and standard
value in normal
state
TL2 (male)
Sensor
Resistance
Between (4) (1)
3.2 kz 20%
Between (4)
chassis ground
Min. 1 Mz
Resis(Contact with ground circuit) TMCN1 (female) (22) TL2 (female) (4)
Min. 1 Mz
tance
with chassis ground
Hot short circuit in wiring har3 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 con4
troller

TMCN1
Voltage
Between (22) (21)
4.5 5.5 V
D275AX-5E0
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40 Troubleshooting

supply source voltage reduction
Action code
Failure code
E01
DAQ6KK
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Transmission controller sensor 24 V power supply source voltage

reduction (Transmission controller system)
Voltage of 24 V power supply circuit of transmission controller sensor is below 12 V or above 30 V.

Abnormal current flowed in 24 V power supply circuit of transmission controller sensor.
Stops output to 24 V power supply circuit if abnormal voltage flows
None in particular
Method of reproducing failure code: Turn starting switch ON. Since this power supply is not used,
no wiring is made.
Cause
Possible causes
and standard
value in normal
state

TMCN1
Voltage
(16) (21)
20 30 V
10
D275AX-5E0
40 Troubleshooting
SEN01658-00

supply source (2) power source voltage reduction
Action code
Failure code
CALL E03
DAQ7KK
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Transmission controller sensor 5 V power supply source (2) power

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
V.
Abnormal current flowed in 5 V power source circuit of transmission controller sensor.
Stops output of 5 V power source (2) circuit if abnormal voltage has flowed.
Method of reproducing failure code: turn ON the starting switch.
Cause
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
turn the switch ON to diagnose.
a Prepare with starting switch OFF and diagnose with starting
switch still OFF.
2
Possible causes
and standard
value in normal
state
3
Defective harness grounding

(Contact with ground circuit) Between ground and wiring harness
between TMCN3 (female) (34) HHP
(female) (B)
Hot short of wiring harness

Resistance
Min. 1 Mz

switch ON.
Between ground and wiring harness
between TMCN3 (female) (34) HHP
(female) (B)
Voltage
Max. 1 V

switch ON.
TMCN3, TMCN1
Voltage
Between TMCN3 (34)

TMCN1 (21)
4.5 5.5 V
D275AX-5E0
11
SEN01658-00
40 Troubleshooting
Failure code [DAQ9KQ] Transmission controller type collation (Type

select signal inconsistency)
Action code
Failure code
CALL E04
DAQ9KQ
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Transmission controller type collation (Type select signal inconsistency) (Transmission controller system)
Internal spec. setting of transmission controller is inconsistent with spec. set signal.
(Transmission controller may not recognize normally)
Stops all outputs to transmission controller.
Machine does not operate at all.
Cause
1
Possible causes
and standard
value in normal
state
Defective transmission controller adjustment

It is normal if failure code lights on (reset display) after carrying out
adjustment mode.
Adjustment code: 0003: Transmission controller spec.
Disconnection in wiring har- a Prepare with starting switch OFF, carry out troubleshooting
ness
Resisdefective contact in connec- Short circuit of wiring harness between
Max. 1 z
TMCN3
(female)
(10)
with
chassis
ground
tance
tor)

TMCN3
Voltage
Max. 1 V
12
D275AX-5E0
SEN01658-00
40 Troubleshooting
Failure code [DAQRKR] Transmission controller CAN defective

communication (Abnormality in objective component system)
Action code
Failure code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
DAQRKR
Trouble
Transmission controller CAN defective communication (Abnormality in objective component system)

Steering controller cannot recognize transmission controller in CAN communication circuit.

Once machine is stopped, travel is limited to F1 and R1.
Cause


tor)
(female) (B), CT1 (female) (B) SRV
Resistance
Max. 1 z
Resistance
Max. 1 z
Possible causes
and standard
value in normal
state


chassis ground
Resistance
Min. 1 Mz

chassis ground
Resistance
Min. 1 Mz

14


chassis ground
Voltage
Max. 1 V

chassis ground
Voltage
Max. 1 V
D275AX-5E0
40 Troubleshooting
SEN01658-00
Cause
Possible causes
and standard
value in normal
state

4
resistance
Defective transmission con5 troller, defective steering
controller

Resistance
Between (A) (B)
100 140 z
If no problem is found in causes 1 to 4, it is suspected that transmission controller, steering controller is defective. (Troubleshooting
cannot be carried out since it is internal defect.)
D275AX-5E0
15
SEN01658-00
40 Troubleshooting
Failure code [DAQSKR] Transmission controller S-NET defective

Action code
Failure code
E01
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
DAQSKR
Trouble
Transmission controller S-NET defective communication (Abnormality in objective component system)

Transmission controller cannot recognize S-NET.

None in particular
Machine may not acquire switch signal of machine monitor, not allowing normal operation of system.
Cause
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshootness
ing without turning starting switch ON.
Resisdefective contact in connec- Wiring harness between TMCN2 (female)
Max. 1 z
(21)
S01
(female)
(8)
tance
tor)
Possible causes
and standard
value in normal
state
Resis(Contact with ground circuit) TMCN2 (female) (21) S01 (female) (8)
Min. 1 Mz
tance
with chassis ground
16

Defective machine monitor

(Switch module)

TMCN2 (female) (21) S01 (female) (8)
with chassis ground
Voltage
Max. 1 V

S01
Voltage
69V

TMCN2
Voltage
Between (21) (31)
69V
D275AX-5E0
40 Troubleshooting
SEN01658-00
D275AX-5E0
17
SEN01658-00
40 Troubleshooting
Failure code [DB2RKR] Engine controller CAN defective communication1

Action code
Failure code
CALL E03
DB2RKR
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Engine controller CAN defective communication

Steering controller cannot recognize engine controller in CAN communication circuit.

Cause


tor)
Resistance
Max. 1 z
Resistance
Max. 1 z
Possible causes
and standard
value in normal
state


chassis ground
Resistance
Min. 1 Mz

chassis ground
Resistance
Min. 1 Mz

18


chassis ground
Voltage
Max. 1 V

chassis ground
Voltage
Max. 1 V
D275AX-5E0
40 Troubleshooting
SEN01658-00
Cause
Possible causes
and standard
value in normal
state

4
resistance

or steering controller

Resistance
Between (A) (B)
100 140 z
If causes 1 4 are not detected, engine controller or steering controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
D275AX-5E0
19
SEN01658-00
40 Troubleshooting
Failure code [DB30KT] Steering controller abnormality in controller

Action code
Failure code
E01
DB30KT
Contents of
trouble
Trouble
Steering controller abnormality in controller

Information of ROM (nonvolatile storage) of steering controller is not normal.
Action of
controller
Sets default internal adjustment value.
Problem that
appears on
machine
Steering performance may be reduced.

Brake performance may be reduced.
Related
information
Possible causes
and standard
value in normal
state
20
Cause
Troubleshooting cannot be carried out since it is internal defect. (It

1 Defective steering controller is no problem even if you use controller unless no visible problem
appears on machine.)
D275AX-5E0
SEN01658-00
40 Troubleshooting
Failure code [DB31KK] Steering controller main power supply source

voltage reduction
1
Action code
Failure code
CALL E04
DB31KK
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Steering controller main power supply source voltage reduction

Source voltage of steering controller is below 17V.



Cause
1

(CB30)

If circuit breaker is tripped, circuit probably has short circuit with
chassis ground.
If fuse FS12-2 is tripped, circuit probably has short circuit with
chassis ground.

3
Possible causes
and standard
value in normal
state

(1), (11) FS12-2
Resistance
Max. 1 z
Wiring harness between FS11 battery

relay terminal BRB
Resistance
Max. 1 z

(21), (31), (32), (33) chassis ground
Resistance
Max. 1 z
STCN3 (female) (1), (11) FS12-2 with
chassis ground
FS11 battery relay terminal BRB with
chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, turn starting switch ON and

carry out troubleshooting.
22
STCN3
Voltage
Between (1), (11) (21), (31),

(32), (33)
20 30 V
D275AX-5E0
40 Troubleshooting
SEN01658-00
D275AX-5E0
23
SEN01658-00
40 Troubleshooting
Failure code [DB32KK] Load power source of steering controller power

source voltage drop
1
Action code
Failure code
CALL E04
DB32KK
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Load power source of steering controller power source voltage

drop (Steering controller system)
Power source voltage of load (relay, solenoid, etc.) on steering controller is below 17V.
Relay and solenoid may not be driven and therefore system may not operate properly.
Once machine is stopped, it can not travel any more.
Battery charge state (voltage) can be checked in real-time monitoring mode.
Cause
1 Defective circuit breaker CB1
If circuit breaker CB1 is blown, it is highly possible that a defective

grounding, etc. has occurred in the circuit.

CB105
When the circuit breaker is cut off, it is highly possible that a defective harness grounding has occurred in the circuit.
switch still OFF.

3
(Disconnection or defective
contact of connectors)
Possible causes
and standard
value in normal
state

(2), (12), (22) CB1(1)
Resistance
Max. 1 z
Wiring harness between CB1(2) battery

relay BRC terminal
Resistance
Max. 1 z

(21), (31), (32), (33) and ground
Resistance
Max. 1 z

switch still OFF.
Defective harness grounding between STCN3 (female) (2), (12), (22)
4
(Contact with ground circuit) CB1(1)
between CB1(2) battery relay BRC terminal
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

switch ON.
24
STCN3
Voltage
Between (2), (12), (22) (21),

(31), (32), (33)
20 30 V
D275AX-5E0
40 Troubleshooting
SEN01658-00
D275AX-5E0
25
SEN01658-00
40 Troubleshooting
Failure code [DB35KK] Steering controller sensor 5 V power source (1)

1
Action code
Failure code
CALL E03
DB35KK
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Voltage of 5 V power source circuit of steering controller sensor is less than 4.5 V or more than 5.5
V.
Abnormal current flowed in 5 V power source circuit of steering controller sensor.
Stops output of 5 V power source circuit if abnormal voltage has flowed.
Cause
1
Defective brake potentiometer (Internal short circuit)
Defective fuel dial potentiom2

eter (Internal short circuit)
Defective steering potenti3

ometer (Internal short circuit)
Possible causes
and standard
value in normal
state

BRK (male)
Resistance
Between (C) (A)
5 kz 20%
Between (C) and ground
Min. 1 Mz
DIAL (male)
Resistance
Between (1) (3)
5 kz 15%
Between (1) and ground
Min. 1 Mz
TL2 (male)
Resistance
Between (5) (8)
3.2 kz 20 %
Min. 1 Mz

switch still OFF.
Defective harness grounding

(Contact with ground circuit) Between ground and wiring harnesses
between STCN1 (female) (22) DIAL
(female) (1) BRK (female) (C)

26
Steering controller sensor 5 V power source (1) power source voltage drop (Steering controller system)
Resistance
Min. 1 Mz

switch ON.
Between ground and wiring harnesses
between STCN1 (female) (22) DIAL
(female) (1) BRK (female) (C)
Voltage
Max. 1 V

switch ON.
STCN1
Voltage
Between (22) (21)
4.5 5.5 V
D275AX-5E0
40 Troubleshooting
SEN01658-00
D275AX-5E0
27
SEN01658-00
40 Troubleshooting
Failure code [DB36KK] Steering controller sensor 24 V power supply

1
Action code
Failure code
CALL E03
DB36KK
Contents of
trouble
Trouble
Steering controller sensor 24 V power supply source voltage

reduction (Steering controller system)
Voltage of 24V power supply circuit of steering controller sensor is below 12 V or above 30 V.
Abnormal current flowed in 24V power supply circuit of steering controller sensor.
Action of
controller

Stops output of 24V power supply circuit if abnormal voltage flows.
Problem that
appears on
machine

Related
information
Cause
It is internal defect if failure code lights on (reset display) 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 troubleshooting.
Possible causes
and standard
value in normal
state
Resis(Contact with ground circuit) STCN1 (female) (16) PT1 (female) (C)
Min. 1 Mz
tance
with chassis ground

STCN1
Voltage
Between (16) (21)
20 30 V
28
D275AX-5E0
SEN01658-00
40 Troubleshooting
Failure code [DB37KK] Steering controller sensor 5 V power source (2)

1
Action code
Failure code
CALL E03
DB37KK
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Steering controller sensor 5 V power source (2) power source voltage 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
5.5 V.
Abnormal current flowed in 5 V power source circuit of steering controller sensor.
Stops output of 5 V power source (2) circuit if abnormal voltage has flowed.
Cause
Defective acceleration sen1

sor (Internal short circuit)

right connector is disconnected, the defect is internal.
SSA
Defective HSS pump oil

2 pressure sensor (Internal
short circuit)

right connector is disconnected, the defect is internal. ST1, ST2
switch still OFF.
Possible causes
and standard
value in normal
state
Defective harness grounding Between ground and wiring harness

(Contact with ground circuit) between STCN3 (female) (34) SSA
(female) (1) ST1 (female) (B) ST2
(female) (B)
Resistance
Min. 1 Mz

switch ON.
4


between STCN3 (female) (34) SSA
(female) (1) ST1 (female) (B) ST2
(female) (B)
Resistance
Min. 1 Mz

switch ON.
30
STCN3, STCN1
Voltage
Between STCN3 (34)

STCN1 (21)
4.5 5.5 V
D275AX-5E0
40 Troubleshooting
SEN01658-00
D275AX-5E0
31
SEN01658-00
40 Troubleshooting
Failure code [DB39KQ] Steering controller type collation (Type select

signal inconsistency)
1
Action code
Failure code
CALL E04
DB39KQ
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Internal spec. setting of steering controller is inconsistent with spec. set signal.
(Steering controller may not recognizes normally)
Stops all outputs of steering controller.
Machine does not operate at all.
Cause
1
Possible causes
and standard
value in normal
state
Steering controller type collation (Type select signal inconsistency)

It is normal if failure code lights on (reset display) after carrying out

Defective steering controller
adjustment mode.
adjustment
Adjustment code: 0002 (Steering controller spec. set)
2
ResisMax. 1 z
nector)
(20) chassis ground
tance
Prepare with starting switch OFF, turn starting switch ON and carry
STCN3
Voltage
Max. 1V
32
D275AX-5E0
SEN01658-00
40 Troubleshooting
Failure code [DB3RKR] Steering controller CAN defective

Action code
Failure code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
DB3RKR
Trouble
Steering controller CAN defective communication (Abnormality in

objective component system)
Transmission controller cannot recognize steering controller with CAN communication circuit.
Cause


tor)
Resistance
Max. 1 z
Resistance
Max. 1 z
Possible causes
and standard
value in normal
state


chassis ground
Resistance
Min. 1 Mz

chassis ground
Resistance
Min. 1 Mz

34


chassis ground
Voltage
Max. 1 V

chassis ground
Voltage
Max. 1 V
D275AX-5E0
40 Troubleshooting
SEN01658-00
Cause
Possible causes
and standard
value in normal
state

4
resistance
Defective transmission con5 troller or defective steering
controller

Resistance
Between (A) (B)
100 140 z
If no problem is found in causes 1 to 4, it is suspected that transmission controller, or steering controller either is defective. (Troubleshooting cannot be carried out since it is internal defect.)
D275AX-5E0
35
SEN01658-00
40 Troubleshooting
Failure code [DB3SKR] Steering controller S-NET defective

Action code
Failure code
E01
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
DB3SKR
Trouble
Steering controller S-NET defective communication (Abnormality in

objective component system)
Transmission controller cannot recognize S-NET.

None in particular
Machine may not acquire switch signal of machine monitor, not allowing normal operation of system.
Cause
1
ResisMax. 1 z
nector)
(21) S01 (female) (8)
tance
Resis(Contact with ground circuit) STCN2 (female) (21) S01 (female) (8) with
Min. 1 Mz
tance
chassis ground
Possible causes
and standard
value in normal
state

Hot short circuit in wiring har3 ness (Contact with 24V cir- Short circuit of wiring harness between
cuit)
STCN2 (female) (21) S01 (female) (8) with Voltage Max. 1 V
chassis ground

(Switch module)
36

S01
Voltage
69V

STCN2
Voltage
Between (21) (31)
69V
D275AX-5E0
40 Troubleshooting
SEN01658-00
D275AX-5E0
37
SEN01658-00
40 Troubleshooting
Failure code [DD12KA] Shift up switch disconnection

Action code
Failure code
E02
DD12KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Shift up switch disconnection

Signals of two systems of shift up switch circuit were turned OFF (OPEN) at the same time.
Recognizes that switch is not pressed.
Shift up is not possible.
Auto shift down does not function.
Of signals of two systems of switch, NO is for operation detection and NC is for error detection.
Input state (ON/OFF) from shift up switch can be checked in real-time monitoring mode.
(Code 40905: Transmission controller input signal 1)
Method of reproducing failure code: Turn starting switch ON (+ Operate shift up switch).
Cause

Defective shift up switch

1
SFTU (male)
Shift up switch
OFF (Release)
ON (Press)
Resistance between
(2) (3)
Max. 1 z
Min. 1 Mz
Resistance between
(1) (2)
Min. 1 Mz
Max. 1 z
2
Possible causes
and standard
value in normal
state

(6) SFTU (female) (3)
Resistance
Max. 1 z

(37) SFTU (female) (1)
Resistance
Max. 1 z

(4), SFTU (female) (2)
Resistance
Max. 1 z

Hot short circuit in wiring harTMCN1 (female) (6) SFTU (female) (3)
3 ness (Contact with 24V cirwith chassis ground
cuit)
TMCN2 (female) (37) SFTU (female) (1)
with chassis ground
Voltage
Max. 1 V
Voltage
Max. 1 V

TMCN1, TMCN2
troller
38
Shift up switch
OFF (Release)
ON (Press)
Voltage between
TMCN1 (6)
TMCN1 (4)
Max. 1V
5 11V
Voltage between
TMCN2 (37)
TMCN1 (4)
5 11V
Max. 1V
D275AX-5E0
40 Troubleshooting
SEN01658-00
D275AX-5E0
39
SEN01658-00
40 Troubleshooting
Failure code [DD12KB] Shift up switch short circuit

Action code
Failure code
E02
DD12KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Shift up switch short circuit

Signals of two systems of shift up switch circuit were turned ON (CLOSE) at the same time.
Shift up is not possible.
Input state (ON/OFF) from shift up switch can be checked in real-time monitoring mode.
Cause

Defective shift up switch

1
SFTU (male)
Shift up switch
OFF (Release)
ON (Press)
Resistance between
(2) (3)
Max. 1 z
Min. 1 Mz
Resistance between
(1) (2)
Min. 1 Mz
Max. 1 z
Possible causes
and standard
value in normal
state

with chassis ground
with chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

TMCN1, TMCN2
troller
40
Shift up switch
OFF (Release)
ON (Press)
Voltage between
TMCN1 (6)
TMCN1 (4)
Max. 1V
5 11V
Voltage between
TMCN2 (37)
TMCN1 (4)
5 11V
Max. 1V
D275AX-5E0
40 Troubleshooting
SEN01658-00
D275AX-5E0
41
SEN01658-00
40 Troubleshooting
Failure code [DD13KA] Shift down switch disconnection

Action code
Failure code
E02
DD13KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Shift down switch disconnection

Signals of two systems of shift down switch circuit were turned OFF (OPEN) at the same time.
Shift down is not possible.
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).
Cause

Defective shift down switch

1
SFTD (female)
Shift down switch

OFF (Release)
ON (Press)
Resistance between
(2) (3)
Max. 1 z
Min. 1 Mz
Resistance between
(1) (2)
Min. 1 Mz
Max. 1 z
2
Possible causes
and standard
value in normal
state

(19) SFTD (male) (3)
Resistance
Max. 1 z

(29) SFTD (male) (1)
Resistance
Max. 1 z

(4) SFTD (male) (2)
Resistance
Max. 1 z

Hot short circuit in wiring harTMCN3 (female) (19) SFTD (male) (3)
cuit)
TMCN3 (female) (29) SFTD (male) (1)
with chassis ground
Voltage
Max. 1 V
Voltage
Max. 1 V

TMCN1, TMCN3
troller
42
Shift down switch

OFF (Release)
ON (Press)
Voltage between
TMCN3 (19)
TMCN1 (4)
Max. 1V
5 11V
Voltage between
TMCN3 (29)
TMCN1 (4)
5 11V
Max. 1V
D275AX-5E0
40 Troubleshooting
SEN01658-00
D275AX-5E0
43
SEN01658-00
40 Troubleshooting
Failure code [DD13KB] Shift down switch short circuit

Action code
Failure code
E02
DD13KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Shift down switch short circuit

Signals of two systems of shift down switch circuit were turned ON (CLOSE) at the same time.
Shift down is not possible.
Input state (ON/OFF) from shift down switch can be checked in real-time monitoring mode.
Cause

Defective shift down switch

1
SFTD (female)
Shift down switch

OFF (Release)
ON (Press)
Resistance between
(2) (3)
Max. 1 z
Min. 1 Mz
Resistance between
(1) (2)
Min. 1 Mz
Max. 1 z
Possible causes
and standard
value in normal
state

with chassis ground
with chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

TMCN1, TMCN3
troller
44
Shift down switch

OFF (Release)
ON (Press)
Voltage between
TMCN3 (19)
TMCN1 (4)
Max. 1V
5 11V
Voltage between
TMCN3 (29)
TMCN1 (4)
5 11V
Max. 1V
D275AX-5E0
40 Troubleshooting
SEN01658-00
D275AX-5E0
45
SEN01658-00
40 Troubleshooting
Failure code [DD14KA] Parking brake lever switch disconnection

Action code
Failure code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
DD14KA
Parking brake lever switch disconnection

Signals of two systems of parking brake lever switch circuit were turned OFF (OPEN) at the same
time.
Recognizes parking brake lever is in Free position.
a Signals of parking brake switch are commonly used by transmission controller and steering controller. Depending on where problem occurs, related codes may be displayed at the same time.
(Related code: DDQ2KA, DDQ2L4).
NC of 2 system signals of switch is for detection of operation and NO is for detection or error.
Input state (ON/OFF) from parking brake switch can be checked in real-time monitoring mode.
When failure code [DD14KA] occurred alone
Cause

Possible causes
and standard
value in normal
state
1
or defective contact in con- (18) branched point of circuit
nector)
(12) branched point of circuit
Resistance
Max. 1 z
Resistance
Max. 1 z

TMCN1
Parking brake lever

Free position
Lock position
Between (18)
chassis ground
Max. 1V
5 11V
Between (12)
chassis ground
5 11V
Max. 1V
When failure codes [DD14KA] and [DDQ2KA] occurred at the same time
Cause

Parking brake lever switch

Possible causes
and standard
value in normal
state
Parking brake lever

Free position
Lock position
Between (A) (B)
Max. 1 z
Min. 1 Mz
Between (A) (C)
Min. 1 Mz
Max. 1 z
2
46
NSW (male)
Wiring harness between NSW (female) (B)

branched point of circuit
Resistance
Max. 1 z
Wiring harness between NSW (female) (C)

branched point of circuit
Resistance
Max. 1 z
Wiring harness between NSW (female) (A)

chassis ground
Resistance
Max. 1 z
D275AX-5E0
40 Troubleshooting
SEN01658-00
When failure codes [DD14KA] and [DDQ2KA] occurred at the same time
Cause
Possible causes
and standard
value in normal
state


Hot short circuit in wiring harNSW (female) (B) TMCN1 (female) (18)
3 ness (Contact with 24V cirSTCN2 (female) (5) with chassis ground
cuit)
NSW (female) (C) TMCN1 (female) (12)
STCN2 (female) (15) with chassis ground
Voltage
Max. 1V
Voltage
Max. 1V
D275AX-5E0
47
SEN01658-00
40 Troubleshooting
Failure code [DD14KB] Parking brake lever switch short circuit

Action code
Failure code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
DD14KB
Trouble
Parking brake lever switch short circuit

Signals of two systems of parking brake lever switch circuit were turned ON (CLOSE) at the same
time.
(Related code: DDQ2KB, DDQ2L4).
NC of 2 system signals of switch is for detection of operation and NO is for detection or error.
Cause


NSW (male)
Parking brake lever

Free position
Lock position
Between (A) (B)
Max. 1 z
Min. 1 Mz
Between (A) (C)
Min. 1 Mz
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch OFF.
Possible causes
and standard
value in normal
state

TMCN1 (female) (18) STCN2 (female)
(5) with chassis ground
TMCN1 (female) (12) STCN2 (female)
(15) with chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

48
TMCN1
Parking brake lever

Free position
Lock position
Between (18)
chassis ground
Max. 1V
5 11V
Between (12)
chassis ground
5 11V
Max. 1V
D275AX-5E0
40 Troubleshooting
SEN01658-00
D275AX-5E0
49
SEN01658-00
40 Troubleshooting
Failure code [DDB9L4] Reverse switch disagreement

Action code
Failure code
CALL E03
DDB9L4
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Reverse switch disagreement

Signals of 2 reverse switch circuit systems of optional type travel lever disagree with each other.
Assumes that switch is not pressed.
Limits operations of engine, transmission and brake.
Once machine is stopped, gear speed is limited to F1.
Input state (ON/OFF) from reverse switch can be checked in real-time monitoring mode.
Method of reproducing failure code: Turn starting switch ON (+ Operate reverse switch).
Cause
Possible causes
and standard Wrong selection of travel lever
Check travel lever type in adjust- Select PCCS standard type
value in normal type
(Failure code DDT5KQ is display ment mode ID: 0004.
lever.
state
simultaneously)
50
D275AX-5E0
40 Troubleshooting
SEN01658-00
Failure code [DDK3L4] Forward switch disagreement

Action code
Failure code
CALL E03
DDK3L4
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Forward switch disagreement

Signals of 2 forward switch circuit systems of optional type travel lever disagree with each other.
Once machine is stopped, gear speed is limited to F1.
Input state (ON/OFF) from forward switch can be checked in real-time monitoring mode.
Method of reproducing failure code: Turn starting switch ON (+ Operate forward switch).
Cause
Possible causes
(Failure code DDT5KQ is display ment mode ID: 0004.
lever.
state
simultaneously)
D275AX-5E0
51
SEN01658-00
40 Troubleshooting
Failure code [DDK5KA] Gearshift switch disconnection

Action code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Failure code
DDK5KA
Trouble
Gearshift switch disconnection

Signals of 2 gearshift switch circuit systems of optional type travel lever are turned OFF (OPEN)
simultaneously.
Gear cannot be shifted up or down (1st i
o 2nd).
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.
Method of reproducing failure code: Turn starting switch ON (+ Operate gearshift switch).
Cause
Possible causes
Wrong
selection
of
travel
lever
and standard
(Failure
code
DDT5KQ
is
display
ment mode ID: 0004.
lever.
state
simultaneously)
52
D275AX-5E0
40 Troubleshooting
SEN01658-00
Failure code [DDK5KB] Gearshift switch short circuit

Action code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Failure code
DDK5KB
Trouble
Gearshift switch short circuit

Signals of 2 gearshift switch circuit systems of optional type travel lever are turned ON (CLOSE)
simultaneously.
Gear cannot be shifted up or down (1st i
o 2nd).
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.
Method of reproducing failure code: Turn starting switch ON (+ Operate gearshift switch).
Cause
Possible causes
Wrong
selection
of
travel
lever
and standard
(Failure
code
DDT5KQ
is
display
ment mode ID: 0004.
lever.
state
simultaneously)
D275AX-5E0
53
SEN01658-00
40 Troubleshooting
Failure code [DDN7KA] Blade pitch switch disconnection

Action code
Failure code
E02
DDN7KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Blade pitch switch disconnection

Signals of two systems of blade pitch switch circuit were turned OFF (OPEN) at the same time.
Blade pitch does not function. (Operating blade pitch causes tilt operation.)
Input state (ON/OFF) from blade pitch switch can be checked in real-time monitoring mode.
(Code 70300: Blade lever knob switch input signal 1)
Method of reproducing failure code: Turn starting switch ON (and operate blade pitch switch).
Cause

Defective blade pitch switch

1
WNBL (female)
Blade pitch switch

OFF (Release)
ON (Press)
Resistance between
(2) (3)
Max. 1 z
Min. 1 Mz
Resistance between
(1) (2)
Min. 1 Mz
Max. 1 z
2
Possible causes
and standard
value in normal
state

(15) WNBL (male) (3)
Resistance
Max. 1 z

(5) WNBL (male) (1)
Resistance
Max. 1 z

(10) WNBL (male) (2)
Resistance
Max. 1 z

Hot short circuit in wiring harTMCN2 (female) (15) WNBL (male) (3)
cuit)
TMCN2 (female) (5) WNBL (male) (1) with
chassis ground
Voltage
Max. 1 V
Voltage
Max. 1 V

TMCN1, TMCN2
troller
54
Blade pitch switch

OFF (Release)
ON (Press)
Voltage between
TMCN2 (15)
TMCN1 (10)
Max. 1V
5 11V
Voltage between
TMCN2 (5)
TMCN1 (10)
5 11V
Max. 1V
D275AX-5E0
40 Troubleshooting
SEN01658-00
D275AX-5E0
55
SEN01658-00
40 Troubleshooting
Failure code [DDN7KB] Blade pitch switch short circuit

Action code
Failure code
E02
DDN7KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Blade pitch switch short circuit

Signals of two systems of blade pitch switch circuit were turned ON (CLOSE) at the same time.
Blade pitch does not function (Operating blade pitch causes tilt operation.)
Input state (ON/OFF) from blade pitch switch can be checked in real-time monitoring mode.
(Code 70300: Blade lever knob switch input)
Method of reproducing failure code: Turn starting switch ON and operate blade pitch switch.
Cause

Defective blade pitch switch

1
WNBL (female)
Blade pitch switch

OFF (Release)
ON (Press)
Resistance between
(2) (3)
Max. 1 z
Min. 1 Mz
Resistance between
(1) (2)
Min. 1 Mz
Max. 1 z
Possible causes
and standard
value in normal
state

TMCN2 (female) (15) WNBL (male) (3)
with chassis ground
TMCN2 (female) (5) WNBL (male) (1) with
chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

TMCN1, TMCN2
troller
56
Blade pitch switch

OFF (Release)
ON (Press)
Voltage between
TMCN2 (15)
TMCN1 (10)
Max. 1V
5 11V
Voltage between
TMCN2 (5)
TMCN1 (10)
5 11V
Max. 1V
D275AX-5E0
40 Troubleshooting
SEN01658-00
D275AX-5E0
57
SEN01658-00
40 Troubleshooting
Failure code [DDN9KA] Blade tilt switch disconnection

Action code
Failure code
E01
DDN9KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Blade tilt switch disconnection

Signals of two systems of blade tilt switch circuit were turned OFF (OPEN) at the same time.
Recognizes switch is set at SINGLE side.
Blade dual tilt does not function. (Operating dual tilt causes single tilt operation.)
Input state (ON/OFF) from blade tilt switch can be checked in real-time monitoring mode.
(Code 70300: Blade lever knob switch input signal)
Method of reproducing failure code: Turn starting switch ON (and operate blade tilt switch).
Cause

Defective blade tilt switch

1
WNBU (male)
Blade tilt switch

SINGLE
DUAL
Resistance between
(2) (3)
Max. 1 z
Min. 1 Mz
Resistance between
(1) (2)
Min. 1 Mz
Max. 1 z
2
Possible causes
and standard
value in normal
state

(35) WNBU (female) (3)
Resistance
Max. 1 z

Resistance
Max. 1 z

Resistance
Max. 1 z

Hot short circuit in wiring harTMCN2 (female) (35) WNBU (female) (3)
cuit)
TMCN2 (female) (25) WNBU (female) (1)
with chassis ground
Voltage
Max. 1 V
Voltage
Max. 1 V

TMCN1, TMCN2
troller
58
Blade tilt switch

SINGLE
DUAL
Voltage between
TMCN2 (35)
TMCN1 (10)
Max. 1V
5 11V
Voltage between
TMCN2 (25)
TMCN1 (10)
5 11V
Max. 1V
D275AX-5E0
40 Troubleshooting
SEN01658-00
D275AX-5E0
59
SEN01658-00
40 Troubleshooting
Failure code [DDN9KB] Blade tilt switch short circuit

Action code
Failure code
E01
DDN9KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Blade tilt switch short circuit

Signals of two systems of blade tilt switch circuit were turned ON (CLOSE) at the same time.
Recognizes switch is set at SINGLE side.
Blade dual tilt does not function. (Operating dual tilt causes single tilt operation.)
Input state (ON/OFF) from blade tilt switch can be checked in real-time monitoring mode.
(Code 70300: Blade lever knob switch input state)
Method of reproducing failure code: Turn starting switch ON (and operate blade tilt switch).
Cause

Defective blade tilt switch

1
WNBU (male)
Blade tilt switch

SINGLE
DUAL
Resistance between
(2) (3)
Max. 1 z
Min. 1 Mz
Resistance between
(1) (2)
Min. 1 Mz
Max. 1 z
Possible causes
and standard
value in normal
state

with chassis ground
with chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

TMCN1, TMCN2
troller
60
Blade tilt switch

SINGLE
DUAL
Voltage between
TMCN2 (35)
TMCN1 (10)
Max. 1V
5 11V
Voltage between
TMCN2 (25)
TMCN1 (10)
5 11V
Max. 1V
D275AX-5E0
40 Troubleshooting
SEN01658-00
D275AX-5E0
61
SEN01658-00
40 Troubleshooting
Failure code [DDNBLD] Ripper lift raise oil pressure switch is kept ON
for long time
1
Action code
Failure code
DDNBLD
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
The signal of the ripper lift raise oil pressure switch circuit is kept turned ON for 60 seconds.
Recognizes that the oil pressure switch is turned OFF.
The shoe slip control (SSC) function does not operate normally.
Ripper raise operation speed decreases.
The input state (ON/OFF) from the ripper lift raise oil pressure switch can be checked in the realtime monitoring mode. (Code 70305: Steering controller input signal 3)
Method of reproducing failure code: Turn the starting switch ON (Error is reproduced after 60 seconds).
Cause
Wrong operation of lever
1 (When electrical system is
normal)
Defective ripper lift raise oil
2 pressure switch
Possible causes
and standard
value in normal
state
Ripper lift raise oil pressure switch is kept ON for long time

If the failure code lamp still lights up (resetting is still urged) after
the resetting operation is performed, it is suspected that the lever
was operated to cause an error.
RPU (male)
Between (1) and (2)
Ripper lever
Resistance
Neutral
Min. 1 Mz
Raise
Max. 1 z
Between wiring harness between TMCN2
Resis(Contact with ground circuit) (female) (13) and RPU (female) (1) and
Min. 1 Mz
tance
chassis ground
4
TMCN2, TMCN1
Ripper lever
Voltage
Between TMCN2
(13) and TMCN1 (10)
Neutral
5 11 V
Raise
Max. 1 V
62
D275AX-5E0
40 Troubleshooting
SEN01658-00
Failure code [DDNCLD] Ripper lift lower oil pressure switch is kept ON
for long time
1
Action code
Failure code
DDNCLD
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
The signal of the ripper lift lower oil pressure switch circuit is kept turned ON for 60 seconds.
Ripper raise operation speed decreases.
The input state (ON/OFF) from the ripper lift lower oil pressure switch can be checked in the realtime monitoring mode. (Code 70305: Steering controller input signal 3)
Cause
normal)
Defective ripper lift lower oil
2 pressure switch
Possible causes
and standard
value in normal
state
Ripper lift lower oil pressure switch is kept ON for long time

If the service code lamp still lights up (resetting is still urged) after
RPD (male)
Between (1) and (2)
Ripper lever
Resistance
Neutral
Min. 1 Mz
Lower
Max. 1 z
(Contact with ground circuit) (female) (3) and RPD (female) (1) and chas- Resis- Min. 1 Mz
tance
sis ground
4
TMCN1, TMCN2
Ripper lever
Voltage
Between TMCN2 (3)

and TMCN1 (10)
Neutral
5 11 V
Lower
Max. 1 V
D275AX-5E0
63
SEN01658-00
40 Troubleshooting
Failure code [DDNDLD] Ripper lift tilt-in oil pressure switch is kept ON
for long time
1
Action code
Failure code
DDNDLD
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
The signal of the ripper tilt in oil pressure switch circuit is kept turned ON for 60 seconds.
The input state (ON/OFF) from the ripper tilt in oil pressure switch can be checked in the real-time
monitoring mode. (Code 70305: Ripper lever oil pressure switch input signal)
Cause
normal)
Defective ripper tilt in oil
2 pressure switch (Internal
short circuit)
Possible causes
and standard
value in normal
state
Ripper lift tilt-in oil pressure switch is kept ON for long time

If the service code lamp still lights up (resetting is still urged) after
RT1 (male)
Between (1) and (2)
Ripper lever
Resistance
Neutral
Min. 1 Mz
Tilt in
Max. 1 z
(Contact with ground circuit) (female) (2) and RT1 (female) (1) and chas- Resis- Min. 1 Mz
tance
sis ground
4
Defective transmission
controller
TMCN1, TMCN2
Ripper lever
Voltage
Between TMCN2 (2)

and TMCN1 (10)
Neutral
5 11 V
Tilt in
Max. 1 V
64
D275AX-5E0
SEN01658-00
40 Troubleshooting
Failure code [DDQ2KA] Parking brake lever switch disconnection

Action code
Failure code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
DDQ2KA
Parking brake lever switch disconnection

Signals of two systems of parking brake lever switch circuit were turned OFF (OPEN) at the same
time.
(Related code: DD14KA, DDQ2L4).
Method of reproducing failure code: Turn starting switch ON and operate parking brake lever.
When failurecode [DDQ2KA] occurred alone
Cause

Possible causes
and standard
value in normal
state
1
or defective contact in con- (5) branched point of circuit M
nector)
(15) branched point of circuit N
Resistance
Max. 1 z
Resistance
Max. 1 z

STCN2
Parking brake lever

Free position
Lock position
Between (5)
chassis ground
Max. 1V
5 11V
Between (15)
chassis ground
5 11V
Max. 1V
When failure codes [DDQ2KA] and [DD14KA] occurred at the same time
Cause


Possible causes
and standard
value in normal
state
Parking brake lever

Free position
Lock position
Between (A) (B)
Max. 1 z
Min. 1 Mz
Between (A) (C)
Min. 1 Mz
Max. 1 z
2
66
NSW

branched point of circuit M
Resistance
Max. 1 z

branched point of circuit N
Resistance
Max. 1 z
Wiring harness between NSW (female) (A)

chassis ground
Resistance
Max. 1 z
D275AX-5E0
40 Troubleshooting
SEN01658-00
When failure codes [DDQ2KA] and [DD14KA] occurred at the same time
Cause

Possible causes
and standard
value in normal
state

NSW (female) (B) TMCN1 (female) (18)
Hot short circuit in wiring har- STCN2 (female) (5) with chassis ground
3 ness (Contact with 24V cirShort circuit of wiring harness between
cuit)
NSW (female) (4) with chassis ground
Voltage
Max. 1V
Voltage
Max. 1V
Voltage
Max. 1V
D275AX-5E0
67
SEN01658-00
40 Troubleshooting
Failure code [DDQ2KB] Parking brake lever switch short circuit

Action code
Failure code
CALL E03
DDQ2KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Parking brake lever switch short circuit

Signals of both parking brake lever switch circuit systems are turned ON (closed) simultaneously.
Recognizes that parking brake lever is at FREE position.
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)
(Code 40907: Blade control lever knob switch input signal)
Cause

Defective parking brake lever

switch (Internal short circuit)
NSW
Parking brake lever

At FREE
At LOCK
Between (A) (B)
Max. 1 z
Min. 1 Mz
Between (A) (C)
Min. 1 Mz
Max. 1 z
Possible causes
and standard
value in normal
state

NSW (female) (B) TMCN1 (female) (18)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

STCN2
68
Parking brake lever

At FREE
At LOCK
Between (5)
chassis ground
Max. 1 V
5 11 V
Between (15)
chassis ground
5 11 V
Max. 1 V
D275AX-5E0
40 Troubleshooting
SEN01658-00
D275AX-5E0
69
SEN01658-00
40 Troubleshooting
Failure code [DDQ2L4] Parking brake lever switch disagreement

Action code
Failure code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
DDQ2L4
Trouble
Parking brake lever switch: Disagreement

Switch input signal of steering controller disagrees with communication signal from transmission
controller.
a Since parking brake switch signal is used by both transmission controller and steering controller
and information is exchanged by CAN communication, related codes may be displayed simultaneously, depending on troubled part. (Related codes: DAFRKR, DB2RKR, DB3RKR, DAQRKR,
DD14KA, DD14KB, DDQ2KA, DDN4LD, DDN5LD)
Cause
Possible causes
and standard
value in normal
state

See if failure codes [DAFRKR], [DB2RKR], [DB3RKR], and
[DAQRKR] are displayed. If they are displayed, carry out troubleshooting for them first.
Defective CAN communication signal system
See if failure codes [DD14KA], [DD14KB], [DDQ2KA], and

[DDQ2KB] are displayed. If they are displayed, carry out troubleswitch signal system
shooting for them first.
3 Defective steering controller Since trouble is in system, troubleshooting cannot be carried out.
70
D275AX-5E0
40 Troubleshooting
SEN01658-00
Failure code [DDT5KA] Neutral switch disconnection

Action code
CALL E04
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Failure code
DDT5KA
Trouble
Neutral switch disconnection

Signals of 2 neutral switch circuit systems of optional type travel lever are turned OFF (OPEN)
simultaneously.
Once machine is stopped, it cannot travel at all.
Input state (ON/OFF) from neutral switch can be checked in real-time monitoring mode.
Method of reproducing failure code: Turn starting switch ON (+ operate neutral switch).
Cause
Possible causes
Wrong
selection
of
travel
lever
and standard
(Failure
code
DDT5KQ
is
display
ment mode ID: 0004.
lever.
state
simultaneously)
D275AX-5E0
71
SEN01658-00
40 Troubleshooting
Failure code [DDT5KB] Neutral switch short circuit

Action code
CALL E04
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Failure code
DDT5KB
Trouble
Neutral switch short circuit

Signals of 2 neutral switch circuit systems of optional type travel lever are turned ON (CLOSE)
simultaneously.
Method of reproducing failure code: Turn starting switch ON (+ operate neutral switch).
Cause
Possible causes
(Failure
code
DDT5KQ
is
display
ment mode ID: 0004.
lever.
state
simultaneously)
72
D275AX-5E0
40 Troubleshooting
SEN01658-00
Failure code [DDT5KQ] Lever specification selection (Model selection

signal disagreement)
1
Action code
Failure code
CALL E04
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
DDT5KQ
Trouble
Specification of standard PCCS lever is not selected.

Cause
Possible causes
and standard
value in normal
state
D275AX-5E0
Lever specification selection (Model selection signal disagreement)

Wrong selection of travel

lever type

ment mode ID: 0004.
lever.
If cause 1 is not detected, transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried
out.)
73
SEN01658-00
40 Troubleshooting
Failure code [DGS1KX] Hydraulic oil temperature sensor input signal is

out of normal range
1
Action code
Failure code
DGS1KX
Trouble
Hydraulic oil temperature sensor input signal is out of normal range

Contents of
trouble
Hydraulic oil temperature sensor signal is out of normal range.
Action of
controller
Hydraulic oil temperature sensor signal is out of normal range.
Problem that
appears on
machine
Related
information
Hydraulic oil temperature gauge of machine monitor may not display normally.
Hydraulic oil temperature (temperature) can be checked in real-time monitoring mode.
(Code 04401: Hydraulic oil temperature)
Method of reproducing failure code: Turn starting switch ON or start engine.
Cause
Defective hydraulic oil tem1 perature sensor (Internal disconnection or short circuit)
Possible causes
and standard
value in normal
state
452 (male)
Resistance
Between (1) (2)
3.5 90 kz
Min. 1 Mz
Resis2
Max. 1 z
or defective contact in con- (14) 452 (female) (1)
tance
nector)
ResisMax. 1 z
(21) 452 (female) (2)
tance
Resis(Contact with ground circuit) TMCN1 (female) (14) 452 (female) (1)
Min. 1 Mz
tance
with chassis ground
Short circuit with power
4 source in wiring harness
74

TMCN1 (female) (14) 452 (female) (1)
with chassis ground
Voltage
Max. 1 V
If causes 1 4 are not detected, tranmission controller may be

carried out.)
D275AX-5E0
40 Troubleshooting
SEN01658-00
D275AX-5E0
75
SEN01658-00
40 Troubleshooting
76
D275AX-5E0
SEN01659-00
BULLDOZER
1SHOP MANUAL
D275AX-5E0
Machine model
Serial number
D275AX-5E0
30001 and up
40 Troubleshooting

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 [DHH3KA] HSS pump oil pressure sensor A disconnection .................................................... 14
Failure code [DHH3KB] HSS pump oil pressure sensor A short circuit ........................................................ 16
Failure code [DHH4KA] HSS pump oil pressure sensor B disconnection .................................................... 18
Failure code [DHH4KB] HSS pump oil pressure sensor B short circuit ........................................................ 20
Failure code [DK10KA] Fuel control dial disconnection ................................................................................ 22
Failure code [DK10KB] Fuel control dial short circuit.................................................................................... 24
Failure code [DK30KA] Steering potentiometer (1) disconnection................................................................ 26
Failure code [DK30KB] Steering potentiometer (1) short circuit ................................................................... 28
Failure code [DK30KX] Steering potentiometer (1) out of input signal range ............................................... 30
D275AX-5E0
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40 Troubleshooting
Failure code [DK30KZ] Steering potentiometer (1) disconnection or short circuit......................................... 31

Failure code [DK30L8] Steering potentiometer (1) analog signals do not agree........................................... 32
Failure code [DK31KA] Steering potentiometer (2) disconnection ................................................................ 34
Failure code [DK31KB] Steering potentiometer (2) short circuit.................................................................... 36
Failure code [DK40KA] Brake potentiometer disconnection ......................................................................... 38
Failure code [DK40KB] Brake potentiometer short circuit............................................................................. 40
Failure code [DK55KX] Directional potentiometer out of input signal range ................................................. 42
Failure code [DK55KZ] Directional potentiometer disconnection or short circuit .......................................... 43
Failure code [DK55L8] Directional potentiometer analog signals do not agree ............................................ 44
Failure code [DK56KA] F-R potentiometer (1) disconnection ....................................................................... 46
Failure code [DK56KB] F-R potentiometer (1) short circuit........................................................................... 48
Failure code [DK57KA] F-R potentiometer (2) disconnection ....................................................................... 50
Failure code [DK57KB] F-R potentiometer (2) short circuit........................................................................... 52
Failure code [DK60KA] Acceleration sensor disconnection .......................................................................... 54
Failure code [DK60KB] Acceleration sensor short circuit.............................................................................. 56
Failure code [DKH1KA] Pitch angle sensor disconnection ........................................................................... 58
Failure code [DKH1KB] Pitch angle sensor short circuit ............................................................................... 60
Failure code [DKH1KX] Pitch angle sensor out of input signal range ........................................................... 62
Failure code [DLT3KA] Transmission out-speed sensor disconnection ........................................................ 64
Failure code [DLT3KB] Transmission out-speed sensor abnormal ............................................................... 66
Failure code [DV00KB] Caution buzzer short circuit ..................................................................................... 67
Failure code [DW59KA] Blade dual selector solenoid disconnection............................................................ 68
Failure code [DW59KB] Blade dual selector solenoid short circuit ............................................................... 70
Failure code [DW59KY] Blade dual selector solenoid hot short.................................................................... 72
Failure code [DW5AKA] Blade pitch selector solenoid disconnection .......................................................... 73
Failure code [DW5AKB] Blade pitch selector solenoid short circuit .............................................................. 74
Failure code [DW5AKY] Blade pitch selection solenoid hot short circuit ...................................................... 76
D275AX-5E0
SEN01659-00
40 Troubleshooting
Failure code [DGT1KA] Power train oil temp sensor disconnection

Action code
Failure code
E01
DGT1KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Power train oil temp sensor disconnection

(Transmission system)
Signal of torque converter oil temperature sensor is below specified value.

Limits operations of fan.
Power train oil temperature gauge of machine monitor does not indicate normally.
Fan speed is limited to medium (half).
Transmission gear shift shock is large.
Power train oil temperature can be checked with real-time monitoring mode.
(Code: 30100 Power train oil temperature)
Cause
Defective power train oil temperature sensor (Internal
453 (male)
Resistance
1
short circuit or disconnecBetween (1) (2)
3.5 90 kz (10C 100C)
tion)
Min. 1 Mz
Possible causes
and standard
value in normal
state
2
or defective contact in con- 453 (female) (1)
nector)
(4) 453 (female) (2)
circuit)
Resistance
Max. 1 z
Resistance
Max. 1 z
Wiring harness between S04 (female) (12)
453 (female) (1) and chassis ground
Resistance
Min. 1 Mz

4
24V circuit) in wiring harness Wiring harness between S04 (female) (12)
Voltage Max. 1 V
If causes 1 4 are not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried
out.)
D275AX-5E0
40 Troubleshooting
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D275AX-5E0
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40 Troubleshooting
Failure code [DGT1KX] Power train oil temp sensor out of input signal
range
1
Action code
Failure code
E01
DGT1KX
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Power train oil temp sensor out of input signal range

Power train oil temperature sensor signal is out of normal range.

Limits operations of fan.
Power train oil temperature gauge of machine monitor does not indicate normally.
Fan speed is limited to medium (half).
Transmission gear shift shock is large.
Power train oil temperature can be checked with real-time monitoring mode.
(Code: 30100 Power train oil temperature)
Cause
Defective Power train oil
temperature sensor (Internal
1
short circuit or disconnection)

453 (male)
Resistance
(Oil temperature: At 10 100C)
Between (1) (2)
35 90 kz
Min. 1 Mz
Possible causes
and standard
value in normal
state
2
or defective contact in con- 453 (female) (1)
nector)
(4) 453 (female) (2)
circuit)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Min. 1 Mz

4
24V circuit) in wiring harness Wiring harness between S04 (female) (12)
Voltage Max. 1 V
If causes 1 4 are not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried
out.)
D275AX-5E0
40 Troubleshooting
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D275AX-5E0
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40 Troubleshooting
Failure code [DH21KB] Work equipment pump oil pressure sensor short
circuit
1
Action code
Failure code
E01
DH21KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Work equipment pump oil pressure sensor short circuit

Work equipment pump oil pressure sensor signal voltage is out of specified range.
None in particular
Reference: Detection information in transmission controller is sent through CAN to steering controller
and detected.
Work equipment oil pressure cannot be monitored.
Power may become insufficient during steering operation.
Input (Voltage) from work equipment pump oil pressure sensor can be checked in real-time monitoring mode. (Code 70701: Voltage of work equipment pump oil pressure sensor)
DH22KA, DH22KB and DAQRKR are displayed this code at the same time.
Possible causes
Cause
and standard
value in normal If DH22KA, DH22KB and/or DAQRKR are displayed, carry out troubleshooting for them.
state
D275AX-5E0
SEN01659-00
40 Troubleshooting
Failure code [DH22KA] Work equipment pump oil pressure sensor

disconnection
Action code
Failure code
DH22KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Work equipment pump oil pressure sensor disconnection

(Transmision controller system)
Signal voltage of work equipment pump oil pressure sensor circuit is below specified value.
None in particular
Work equipment pump oil pressure cannot be monitored.
Input (Voltage) from work equipment pump oil pressure sensor can be checked in real-time monitoring mode. (Code 70701: Voltage of work equipment pump oil sensor)
DH21KB is displayed as well as this code.
Cause
1
Defective 5 V power source

system
Defective work equipment

2 pump oil pressure sensor
(Internal trouble)

See if failure code [DAQ7KK] is displayed. If it is displayed, carry
out troubleshooting for it first.
HHP
Voltage
Between (C) (A)
0.5 6.0 V
Possible causes
and standard
value in normal
state

3

(34) HHP (female) (B)
Resistance
Max. 1 z

(9) HHP (female) (C)
Resistance
Max. 1 z

(21) HHP (female) (A)
Resistance
Max. 1 z
TMCN1 (female) (9) HHP (female) (C)
with chassis ground
TMCN3 (female) (34) HHP (female) (B)
with chassis ground
5
10
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
If causes 1 4 are not detected, transmission controller may be

carried out.)
D275AX-5E0
40 Troubleshooting
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11
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40 Troubleshooting
Failure code [DH22KB] Work equipment pump oil pressure sensor short
circuit
1
Action code
Failure code
E01
DH22KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Signal voltage of work equipment pump oil pressure sensor circuit is above specified value.
None in particular
Work equipment pump oil pressure cannot be monitored.
Input (Voltage) from work equipment pump oil pressure sensor can be checked in real-time monitoring mode. (Code 70701: Voltage of work equipment pump oil pressure sensor)
DH21KB is displayed as well as this code.
Cause
1

system

2 pump oil pressure sensor
(Internal trouble)
Possible causes
and standard
value in normal
state

See if failure code [DAQ7KK] is displayed. If it is displayed, carry
HHP
Voltage
Between (C) (A)
0.5 6.0 V


12
Work equipment pump oil pressure sensor short circuit

(Transmision controller system)

TMCN1 (female) (9) HHP (female) (C)
with chassis ground
Voltage
Max. 1 V

TMCN3 (female) (34) HHP (female) (B)
with chassis ground
Voltage
Max. 1 V

TMCN1 (female) (21) HHP (female) (A)
with chassis ground
Voltage
Max. 1 V

carried out.)
D275AX-5E0
40 Troubleshooting
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D275AX-5E0
13
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40 Troubleshooting
Failure code [DHH3KA] HSS pump oil pressure sensor A

disconnection
Action code
Failure code
CALL E03
DHH3KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
HSS pump oil pressure sensor A disconnection

Signal voltage of HSS pump oil pressure sensor A circuit is below specified value.
HSS pump oil pressure (A side) cannot be monitored.
Input (Voltage) from HSS pump oil pressure sensor A can be checked in real-time monitoring mode.
(Code 50503: Voltage of HSS pump oil pressure sensor A)
Cause
1

system

2 pressure sensor A (Internal
trouble)

See if failure code [DB37KK] is displayed. If it is displayed, carry
ST1
Voltage
Between (C) (A)
0.5 6.0 V
Possible causes
and standard
value in normal
state

3

(34) ST1 (female) (B)
Resistance
Max. 1 z

(20) ST1 (female) (C)
Resistance
Max. 1 z

(21) ST1 (female) (A)
Resistance
Max. 1 z
STCN1 (female) (20) ST1 (female) (C)
with chassis ground
STCN3 (female) (34) ST1 (female) (B)
with chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
If causes 1 4 are not detected, steering controller may be defec5 Defective steering controller tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
14
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40 Troubleshooting
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15
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40 Troubleshooting
Failure code [DHH3KB] HSS pump oil pressure sensor A short circuit 1
Action code
Failure code
CALL E03
DHH3KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Signal voltage of HSS pump oil pressure sensor A circuit is above specified value.
HSS pump oil pressure (A side) cannot be monitored.
Input (Voltage) from HSS pump oil pressure sensor A can be checked in real-time monitoring mode.
(Code 50503: Voltage of HSS pump oil pressure sensor A)
Cause
Defective 5V power source
1
system
2 pressure sensor A (Internal
trouble)
Possible causes
and standard
value in normal
state
HSS pump oil pressure sensor A short circuit


ST1
Voltage
Between (C) (A)
0.5 6.0 V



with chassis ground
Voltage
Max. 1 V

with chassis ground
Voltage
Max. 1 V

STCN1 (female) (21) ST1 (female) (A)
with chassis ground
Voltage
Max. 1 V
out.)
16
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40 Troubleshooting
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17
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40 Troubleshooting
Failure code [DHH4KA] HSS pump oil pressure sensor B disconnection1

Action code
Failure code
CALL E03
DHH4KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
HSS pump oil pressure sensor B disconnection

Signal voltage of HSS pump oil pressure sensor B circuit is below specified value.
HSS pump oil pressure (B side) cannot be monitored.
Input (Voltage) from HSS pump oil pressure sensor B can be checked in real-time monitoring mode.
(Code 50504: Voltage of HSS pump oil pressure sensor B)
Cause
1
system
2 pressure sensor B (Internal
trouble)

ST2
Voltage
Between (C) (A)
0.5 6.0 V
Possible causes
and standard
value in normal
state

3

(34) ST2 (female) (B)
Resistance
Max. 1 z

(14) ST2 (female) (C)
Resistance
Max. 1 z

(21) ST2 (female) (4)
Resistance
Max. 1 z
with chassis ground
with chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
out.)
18
D275AX-5E0
40 Troubleshooting
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19
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40 Troubleshooting
Failure code [DHH4KB] HSS pump oil pressure sensor B short circuit 1
Action code
Failure code
CALL E03
DHH4KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Signal voltage of HSS pump oil pressure sensor B circuit is above specified value.
HSS pump oil pressure (B side) cannot be monitored.
Input (Voltage) from HSS pump oil pressure sensor B can be checked in real-time monitoring mode.
(Code 50504: Voltage of HSS pump oil pressure sensor B)
Cause
1
system
2 pressure sensor B (Internal
trouble)
Possible causes
and standard
value in normal
state
HSS pump oil pressure sensor B short circuit


ST2
Voltage
Between (C) (A)
0.5 6.0 V



with chassis ground
Voltage
Max. 1 V

with chassis ground
Voltage
Max. 1 V

STCN1 (female) (21) ST2 (female) (A)
with chassis ground
Voltage
Max. 1 V
out.)
20
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40 Troubleshooting
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21
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40 Troubleshooting
Failure code [DK10KA] Fuel control dial disconnection

Action code
Failure code
CALL E03
DK10KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Fuel control dial disconnection

Input voltage from fuel control dial is below specified value

Continues control with signal of decelerator pedal potentiometer.
Input voltage of fuel control dial can be checked in real-time monitoring mode.
(Code: 03000: Fuel control dial input voltage)
Cause

1
system
If failure code [DB35KK] is displayed, carry out troubleshooting for

it first.

2 (Internal disconnection or
short circuit)
DIAL (male)
Resistance
(1) (3)
4.0 6.0 kz
(1) (2)
0.5 4.5 kz
(3) (2)
0.5 4.5 kz
Possible causes
and standard
value in normal
state

3

circuit)

(22) AL DIAL (female) (1)
Resistance
Max. 1 z

(21) CH DIAL (female) (3)
Resistance
Max. 1 z

(8) DIAL (female) (2)
Resistance
Max. 1 z
(22) AL DIAL (female) (1)
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

22
STCN1
Voltage
Between STCN1 (22) (21)
4.6 5.4 V
0.5 4.5 V
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40 Troubleshooting
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23
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40 Troubleshooting
Failure code [DK10KB] Fuel control dial short circuit

Action code
Failure code
CALL E03
DK10KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Fuel control dial short circuit

Input voltage from fuel control dial is above specified value.

Continues control with signal of decelerator pedal potentiometer.
Input voltage of fuel control dial can be checked in real-time monitoring mode.
(Code: 03000: Fuel control dial input voltage)
Cause

1
system
If failure code [DB35KK] is displayed, carry out troubleshooting for

it first.

short circuit)
Possible causes
and standard
value in normal
state
DIAL (male)
Resistance
(1) (3)
4.0 6.0 kz
(1) (2)
0.5 4.5 kz
(3) (2)
0.5 4.5 kz
3
ResisMax. 1 z
nector)
tance
Hot short (Short circuit with (22) DIAL (female) (1) with chassis ground
4
(8) DIAL (female) (2) with chassis ground
(21) DIAL (female) (3) with chassis ground
Voltage
Min. 1 V
Voltage
Min. 1 V
Voltage
Min. 1 V

24
STCN1
Voltage
4.6 5.4 V
0.5 4.5 V
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40 Troubleshooting
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25
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40 Troubleshooting
Failure code [DK30KA] Steering potentiometer (1) disconnection

Action code
Failure code
CALL E03
DK30KA
Contents of
trouble
Trouble
Steering potentiometer (1) disconnection

Signal voltage of steering potentiometer 1 system (L) is below specified value.
Action of
controller
Continues control with signal of steering potentiometer 2 system (R).

Problem that
appears on
machine

Related
information
State of steering potentiometer 1 (L) signal can be checked with real-time monitoring mode. (Code:
50300 Steering lever potentio 1 voltage)
Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (in steering
direction).
Cause
1
Defective sensor 5V power

supply system

If failure code [DB35KK] is also displayed, carry out troubleshooting for it first.
Defective steering potenti2 ometer 1 (Internal disconnection)
Possible causes
and standard
value in normal
state
Resistance
Between (5) (8)
3.2 kz 20%
Between (5) (7)
61z
(Right Left steering)
Between (7) (8)
16z
3
or defective contact in con- (22) TL2 (female) (5)
nector)
(2) TL2 (female) (7)

circuit)
26
TL2 (male)
Resistance
Max. 1 z
Resistance
Max. 1 z
(2) TL2 (female) (7) with chassis ground
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

STCN1
Voltage
Between (2) (21)
0.5 4.5 V
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40 Troubleshooting
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27
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40 Troubleshooting
Failure code [DK30KB] Steering potentiometer (1) short circuit

Action code
Failure code
CALL E03
DK30KB
Trouble
Steering potentiometer 1 short circuit

Contents of
trouble
Signal voltage of steering potentiometer 1 system (L) is above 4.5 V.
Action of
controller
Continues control with signal of steering potentiometer 2 system (R).

Problem that
appears on
machine

Related
information
State of steering potentiometer 1 (L) signal can be checked with real-time monitoring mode. (Code:
direction).
Cause
1

supply system

Defective steering potenti2 ometer 1 (Internal short circuit)

Possible causes
and standard
value in normal
state
TL2 (male)
Resistance
Between (5) (8)
3.2 kz 20%
Between (5) (7)
1 6 kz
Between (7) (8)
6 1 kz

3
Hot short (Short circuit with Wiring harness between STCN1 (female)
24V circuit) in wiring harness (2) TL2 (female) (7) with chassis ground
28
Voltage
Max. 1 V
Voltage
Max. 1 V

STCN1
Voltage
Between (2) (21)
0.5 4.5 V
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29
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40 Troubleshooting
Failure code [DK30KX] Steering potentiometer (1) out of input signal

range
Action code
Failure code
CALL E04
DK30KX
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
30
Trouble
Steering potentiometer (1) out of input signal range

In steering potentiometer 1 and 2 systems, either of failure codes [DK30KA] and [DK30KB] and
either of failure codes [DK31KA] and [DK31KB] occurred simultaneously.
State of steering potentiometer signal can be checked with real-time monitoring mode.
(Code: 50300 Steering lever potentio 1 voltage)
direction).
Cause
Carry out troubleshooting for failure codes [DK30KA], [DK30KB], [DK31KA], and [DK31KB].
D275AX-5E0
40 Troubleshooting
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Failure code [DK30KZ] Steering potentiometer (1) disconnection or

short circuit
Action code
Failure code
CALL E04
DK30KZ
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
D275AX-5E0
Trouble
Steering potentiometer (1) disconnection or short circuit

In steering potentiometer 1 and 2 systems, when starting switch is turned ON, only either side is
abnormal and then either of failure codes [DK30KA] and [DK30KB] and either of failure codes
[DK31KA] and [DK31KB] occurred simultaneously.
direction).
Cause
31
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40 Troubleshooting
Failure code [DK30L8] Steering potentiometer (1) analog signals do not

agree
1
Action code
Failure code
CALL E03
DK30L8
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
32
Trouble
Steering potentiometer (1) analog signals do not agree

Total of signal voltages of steering potentiometer 1 and 2 systems is above specified range.
Continues control with signal of normal one of PCCS lever steering potentiometer 1 and 2 systems.
direction).
Cause
D275AX-5E0
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40 Troubleshooting
Failure code [DK31KA] Steering potentiometer (2) disconnection

Action code
Failure code
CALL E03
DK31KA
Contents of
trouble
Trouble
Steering potentiometer (2) disconnection

Signal voltage of steering potentiometer 2 system (R) is below specified value.
Action of
controller
Continues control with signal of steering potentiometer 1 system (L).

Problem that
appears on
machine

Related
information
State of steering potentiometer 2 (R) signal can be checked with real-time monitoring mode.
direction).
Cause
1

supply system

Defective steering potenti2 ometer 2 (Internal disconnection)
Possible causes
and standard
value in normal
state
Resistance
Between (5) (8)
3.2 kz 20%
Between (5) (6)
61z
Between (6) (8)
16z
3
nector)
(19) TL2 (female) (6)

circuit)
34
TL2 (male)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

STCN1
Voltage
Between (19) (21)
0.5 4.5 V
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40 Troubleshooting
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35
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40 Troubleshooting
Failure code [DK31KB] Steering potentiometer (2) short circuit

Action code
Failure code
CALL E03
DK31KB
Contents of
trouble
Trouble
Steering potentiometer (2) short circuit

Signal voltage of steering potentiometer 2 system (R) is above specified value.
Action of
controller
Continues control with signal of steering potentiometer 1 system (L).

Problem that
appears on
machine

Related
information
State of steering potentiometer 2 (R) signal can be checked with real-time monitoring mode. (Code:
direction).
Cause
1

supply system

Defective steering potenti2 ometer 2 (Internal short circuit)

Possible causes
and standard
value in normal
state
Resistance
Between (5) (8)
3.2 kz 20%
Between (5) (6)
61z
Between (6) (8)
16z

3
24V circuit) in wiring harness (19) TL2 (female) (6) with chassis ground
Voltage
Max. 1 V

Voltage
Max. 1 V
36
TL2 (male)

STCN1
Voltage
Between (19) (21)
0.5 4.5 V
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37
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Failure code [DK40KA] Brake potentiometer disconnection

Action code
Failure code
CALL E03
DK40KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Brake potentiometer disconnection

Signal voltage of brake pedal potentiometer is below specified value

Does not control brake with brake potentiometer signal (Pedal can be operated).
Brake control performance of brake pedal lowers.
State of brake pedal potentiometer signal can be checked with real-time monitoring mode.
(Code: 50400 Brake pedal potentio voltage)
Method of reproducing failure code: Turn starting switch ON + Operate brake pedal.
Cause
1

supply system

Defective brake pedal poten2 tiometer (Internal disconnection)
BRK (male)
Resistance
Between (A) (C)
4.0 6.0 kz
Between (A) (B)
1.5 4.5 kz (Free fullstroke)
Between (B) (C)
Possible causes
and standard
value in normal
state

3

(21) BRK (female) (A)
Resistance
Max. 1 z

(3) BRK (female) (B)
Resistance
Max. 1 z

(22) BRK (female) (C)
Resistance
Max. 1 z
circuit)
38

(3) BRK (female) (B) and chassis ground
Resistance
Min. 1 Mz

(22) BRK (female) (C) or circuit branch
Resistance
Min. 1 Mz

STCN1
Voltage
Between (3) (21)
1.5 4.5 V
D275AX-5E0
40 Troubleshooting
SEN01659-00
D275AX-5E0
39
SEN01659-00
40 Troubleshooting
Failure code [DK40KB] Brake potentiometer short circuit

Action code
Failure code
CALL E03
DK40KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Brake potentiometer short circuit

Signal voltage of brake pedal potentiometer is above specified value.

Does not control brake with brake potentiometer signal (Pedal can be operated).
Brake control performance of brake pedal lowers.
State of brake pedal potentiometer signal can be checked with real-time monitoring mode.
(Code: 50400 Brake pedal potentio voltage)
Method of reproducing failure code: Turn starting switch ON + Operate brake pedal.
Cause
1

supply system

Defective brake pedal poten2 tiometer (Internal short circuit)
Possible causes
and standard
value in normal
state
BRK (male)
Resistance
Between (A) (C)
4.0 6.0 kz
Between (A) (B)
Between (B) (C)

3

(3) BRK (female) (B) and chassis ground
24V circuit) in wiring harness
(22) BRK (female) (C) or circuit branch
Voltage
Max. 1 V
Voltage
Max. 1 V
4
ResisMax. 1 z
nector)
(21) BRK (female) (A)
tance
40

STCN1
Voltage
Between (3) (21)
1.5 4.5 V
D275AX-5E0
40 Troubleshooting
SEN01659-00
D275AX-5E0
41
SEN01659-00
40 Troubleshooting
Failure code [DK55KX] Directional potentiometer out of input signal

range
Action code
Failure code
CALL E04
DK55KX
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
42
Trouble
Directional potentiometer out of input signal range

In F-R potentiometer 1 and 2 systems, either of failure codes [DK56KA] and [DK56KB] and either
of failure codes [DK57KA] and [DK57KB] occurred simultaneously.
State of F-R potentiometer signal can be checked with real-time monitoring mode.
(Code: 50200 F-R lever potentio 1 voltage)
Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (in F-R direction).
Cause
D275AX-5E0
40 Troubleshooting
SEN01659-00
Failure code [DK55KZ] Directional potentiometer disconnection or short

circuit
1
Action code
Failure code
CALL E04
DK55KZ
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
D275AX-5E0
Trouble
Directional potentiometer disconnection or short circuit

In F-R potentiometer 1 and 2 systems, when starting switch is turned ON, only either side is abnormal and then either of failure codes [DK56KA] and [DK56KB] and either of failure codes [DK57KA]
and [DK57KB] occurred simultaneously.
Cause
43
SEN01659-00
40 Troubleshooting
Failure code [DK55L8] Directional potentiometer analog signals do not

agree
1
Action code
Failure code
CALL E03
DK55L8
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
44
Trouble
Directional potentiometer analog signals do not agree

Total of signal voltages of directional potentiometer 1 and 2 systems is above specified range.
Continues control with signal of normal one of F-R potentiometer 1 and 2 systems.
Cause
D275AX-5E0
SEN01659-00
40 Troubleshooting
Failure code [DK56KA] F-R potentiometer (1) disconnection

Action code
Failure code
CALL E03
DK56KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
F-R potentiometer (1) disconnection

Signal voltage of F-R potentiometer 1 system (R) is below specified value.

Continues control with signal of F-R potentiometer 2 system (F).
State of F-R potentiometer 1 (R) signal can be checked with real-time monitoring mode.
Cause
1

supply system

If failure code [DAQ5KK] is also displayed, carry out troubleshooting for it first.
Possible causes
and standard
value in normal
state
Defective F-R potentiometer

1 (Internal disconnection)
Resistance
Between (4) (1)
3.2 kz 20%
Between (4) (3)
6 1 kz (F-R)
Between (3) (1)
1 6 kz (F-R)
3
nector)
(2) TL2 (female) (3)

circuit)
46
TL2 (male)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

TMCN1
Voltage
Between (2) (21)
0.5 4.5 V
D275AX-5E0
40 Troubleshooting
SEN01659-00
D275AX-5E0
47
SEN01659-00
40 Troubleshooting
Failure code [DK56KB] F-R potentiometer (1) short circuit

Action code
Failure code
CALL E03
DK56KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
F-R potentiometer (1) short circuit

Signal voltage of directional potentiometer 1 system (R) is above specified value.

Continues control with signal of F-R potentiometer 2 system.
Cause
1

supply system

Possible causes
and standard
value in normal
state

1 (Internal short circuit)
TL2 (male)
Resistance
Between (4) (1)
3.2 kz 20%
Between (4) (3)
6 1 kz (F-R)
Between (3) (1)
1 6 kz (F-R)



Voltage
Max. 1 V
Voltage
Max. 1 V
Voltage
Max. 1 V
4
ResisMax. 1 z
nector)
(21) TL2 (female) (1)
tance
48

TMCN1
Voltage
Between (2) (21)
0.5 4.5 V
D275AX-5E0
40 Troubleshooting
SEN01659-00
D275AX-5E0
49
SEN01659-00
40 Troubleshooting
Failure code [DK57KA] F-R potentiometer (2) disconnection

Action code
Failure code
CALL E03
DK57KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
F-R potentiometer (2) disconnection

Signal voltage of F-R potentiometer 2 system (F) is below specified value.

Continues control with signal of F-R potentiometer 1 system (R).
Cause
1

supply system

Possible causes
and standard
value in normal
state

2 (Internal disconnection)
Resistance
Between (4) (1)
3.2 kz 20%
Between (4) (2)
1 6 kz (F-R)
Between (2) (1)
6 1 kz (F-R)
3
nector)
(19) TL2 (female) (2)

circuit)
50
TL2 (male)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

TMCN1
Voltage
Between (19) (21)
0.5 4.5 V
D275AX-5E0
40 Troubleshooting
SEN01659-00
D275AX-5E0
51
SEN01659-00
40 Troubleshooting
Failure code [DK57KB] F-R potentiometer (2) short circuit

Action code
Failure code
CALL E03
DK57KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
F-R potentiometer (2) short circuit

Signal voltage of F-R potentiometer 2 system (F) is above specified value.

Continues control with signal of F-R potentiometer 1 system (R).
State of F-R potentiometer 2 (F) signal can be checked with real-time monitoring mode.
Cause
1

supply system

Possible causes
and standard
value in normal
state

2 (Internal short circuit)
TL2 (male)
Resistance
Between (4) (1)
3.2 kz 20%
Between (4) (2)
1 6 kz (F-R)
Between (2) (1)
6 1 kz (F-R)



Voltage
Max. 1 V
Voltage
Max. 1 V
Voltage
Max. 1 V
4
ResisMax. 1 z
nector)
(21) TL2 (female) (1)
tance
52

TMCN1
Voltage
Between (19) (21)
0.5 4.5 V
D275AX-5E0
40 Troubleshooting
SEN01659-00
D275AX-5E0
53
SEN01659-00
40 Troubleshooting
Failure code [DK60KA] Acceleration sensor disconnection

Action code
Failure code
E01
DK60KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Acceleration sensor disconnection

Signal voltage of acceleration sensor is below specified value.

Turns shoe slip control (SSC) function OFF.
Even if shoe slips, engine speed does not change.
Input (Voltage) from acceleration sensor can be checked in real-time monitoring mode.
(Code 60200: Voltage of acceleration sensor)
Cause
1
system
Defective acceleration sensor (Internal trouble)

SSA
Voltage
Between (2) (3)
0.75 4.25 V
Possible causes
and standard
value in normal
state
3
or defective contact in con- (34) SSA (female) (1)
nector)
(1) SSA (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
STCN1 (female) (1) SSA (female) (2) with
chassis ground
STCN3 (female) (34) SSA (female) (1)
with chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
out.)
54
D275AX-5E0
40 Troubleshooting
SEN01659-00
D275AX-5E0
55
SEN01659-00
40 Troubleshooting
Failure code [DK60KB] Acceleration sensor short circuit

Action code
Failure code
E01
DK60KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Acceleration sensor short circuit

Signal voltage of acceleration sensor is below specified value

Turns shoe slip control (SSC) function OFF.
Even if shoe slips, engine speed does not change.
Input (Voltage) from acceleration sensor can be checked in real-time monitoring mode.
(Code 60200: Voltage of acceleration sensor)
Cause
1
system
Defective acceleration sensor (Internal trouble)

SSA
Voltage
Between (2) (3)
0.75 4.25 V

Possible causes
and standard
value in normal
state


STCN1 (female) (1) SSA (female) (2) with
chassis ground
Voltage
Max. 1 V

with chassis ground
Voltage
Max. 1 V

with chassis ground
Voltage
Max. 1 V
4
ResisMax. 1 z
nector)
(21) SSA (female) (3)
tance
out.)
56
D275AX-5E0
40 Troubleshooting
SEN01659-00
D275AX-5E0
57
SEN01659-00
40 Troubleshooting
Failure code [DKH1KA] Pitch angle sensor disconnection

Action code
Failure code
CALL E03
DKH1KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Pitch angle sensor disconnection

Signal voltage of pitch angle sensor is below specified value.

Cannot sense pitch angle of machine.
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.
(Code: 60100 voltage of pitch angle sensor)
Cause
1
Defective sensor 24V power If failure code [DB36KK] is also displayed, carry out troubleshootsupply system
ing for it first.
PT1
Defective pitch angle sensor

(Internal trouble)
Voltage
Between (C) (A)
Power supply
20 30 V
Between (B) (A)
Signal
0.15 4.85 V

Possible causes
and standard
value in normal
state
Resis3
Max. 1 z
or defective contact in con- (13) PT1 (female) (B)
tance
nector)
ResisMax. 1 z
(16) PT1 (female) (C)
tance

circuit)
(13) PT1 (female) (B) with chassis ground
Resistance
Min. 1 Mz

(16) PT1 (female) (C) with chassis ground
Resistance
Min. 1 Mz
out.)
58
D275AX-5E0
40 Troubleshooting
SEN01659-00
D275AX-5E0
59
SEN01659-00
40 Troubleshooting
Failure code [DKH1KB] Pitch angle sensor short circuit

Action code
Failure code
CALL E03
DKH1KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Pitch angle sensor short circuit

Signal voltage of pitch angle sensor is above specified value

Cannot sense pitch angle of machine.
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.
(Code: 60100 Pitch angle sensor voltage)
Cause
1
Defective sensor 24V power If failure code [DB36KK] is also displayed, carry out troubleshootsupply system
ing for it first.
PT1
Defective pitch angle sensor

(Internal trouble)
Voltage
Between (C) (A)
Power supply
20 30 V
Between (B) (A)
Signal
0.15 4.85 V

Possible causes
and standard
value in normal
state

3
24V circuit) in wiring harness (13) PT1 (female) (B) with chassis ground
Voltage
Max. 1 V

(21) PT1 (female) (A) with chassis ground
Voltage
Max. 1 V
4
ResisMax. 1 z
nector)
(21) PT1 (female) (A)
tance
out.)
60
D275AX-5E0
40 Troubleshooting
SEN01659-00
D275AX-5E0
61
SEN01659-00
40 Troubleshooting
Failure code [DKH1KX] Pitch angle sensor out of input signal range
Action code
E01
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Failure code
DKH1KX
Trouble
Pitch angle sensor out of input signal range

Either of pitch angle sensor errors [DKH1KA] and [DKH1KB] occurred or steering controller CAN
communication failure code [DB3RKR] occurred.
Cannot recognize pitch angle.
Gear speed is not changed automatically.
Input voltage from pitch angle sensor can be checked in real-time monitoring mode.
(Code: 60100: Pitch angle sensor voltage)
Possible causes
Cause
and standard
value in normal Carry out troubleshooting for disconnection in pitch angle sensor [DKH1KA] and short circuit
[DKH1KB] and steering controller CAN communication error [DB3RKR].
state
62
D275AX-5E0
SEN01659-00
40 Troubleshooting
Failure code [DLT3KA] Transmission out-speed sensor disconnection 1

Action code
Failure code
E01
DLT3KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
No signal is input from transmission bevel speed sensor.

Recognizes that transmission bevel speed is 0 rpm.
Transmission bevel speed cannot be monitored.

Traction force cannot be calculated.
Auto shift down function does not work normally.
Gear shift shock is large.
Transmission bevel speed can be checked with real-time monitoring mode.

(Code: 31400 Transmission output speed)
Method of reproducing failure code: Turn starting switch ON + Drive machine (actually or with no
load).
Cause
Defective transmission bevel
1 speed sensor (Internal disconnection or short circuit)
Possible causes
and standard
value in normal
state
Transmission out-speed sensor disconnection


TM1 (male)
Resistance
Between (1) (2)
500 1,000 z
Min. 1 Mz
Resis2
Max. 1 z
or defective contact in con- (30) TM1 (female) (1)
tance
nector)
ResisMax. 1 z
(39) TM1 (female) (2)
tance

circuit)
(30) TM1 (female) (1) with chassis ground
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

4
64
Hot short (Short circuit with Wiring harness between TMCN2 (female)
24V circuit) in wiring harness (30) TM1 (female) (1) with chassis ground
Voltage
Max. 1 V

Voltage
Max. 1 V

carried out.)
D275AX-5E0
40 Troubleshooting
SEN01659-00
D275AX-5E0
65
SEN01659-00
40 Troubleshooting
Failure code [DLT3KB] Transmission out-speed sensor abnormal

Action code
Failure code
E01
DLT3KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Transmission out-speed sensor abnormal

While machine is traveling, signal from transmission bevel speed sensor does not change.
Recognizes that transmission bevel speed is 0 rpm.
Transmission bevel speed cannot be monitored.

Traction force cannot be calculated.
Auto shift down function does not work normally.
Gear shift shock is large.
Transmission bevel speed can be checked with real-time monitoring mode.

(Code: 31400 Transmission output speed)
Method of reproducing failure code: Turn starting switch ON + Drive machine (actually or with no
load).
Cause
Defective installation of
1 transmission output speed
sensor
Possible causes
and standard
value in normal
state
Defective transmission bevel

2 speed sensor (Internal disconnection or short circuit)

circuit)

Carry out Testing and adjusting, "Adjusting transmission speed
sensor".
TM1 (male)
Resistance
Between (1) (2)
500 1,000 z
Min. 1 Mz
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

carried out.)
66
D275AX-5E0
40 Troubleshooting
SEN01659-00
Failure code [DV00KB] Caution buzzer short circuit

Action code
Failure code
DV00KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Caution buzzer short circuit

Abnormal current flowed when caution buzzer circuit output ground signal.
Flashes caution lamp.
Stops caution buzzer circuit from outputting ground signal.
Caution buzzer does not sound.
Method of reproducing failure code: Turn starting switch ON (When it is turned ON, buzzer sounds
for 1 second).
Cause
Defective caution buzzer
1
Possible causes
and standard
value in normal
state

217 (male)
Resistance
Between (1) (2)
200 z


24V circuit) in wiring harness Short circuit of wiring harness between 217
(female) (1) S03 (female) (18) with chassis ground
Voltage
Max. 1 V
If causes 1 and 2 are not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried
out.)
D275AX-5E0
67
SEN01659-00
40 Troubleshooting
Failure code [DW59KA] Blade dual selector solenoid disconnection

Action code
Failure code
E01
DW59KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Blade dual selector solenoid disconnection

When signal is output to blade dual selector solenoid circuit, any current does not flow.
Stops outputting to blade dual selector solenoid circuit.
Blade dual tilt mechanism does not work (When it is operated, single tilt mechanism works).
Output (Current) to blade dual selector solenoid can be checked in real-time monitoring mode.
(Code 70600: Blade dual solenoid drive current)
Method of reproducing failure code: Turn starting switch ON and perform blade dual tilt operation.
Cause
a Prepare with starting switch OFF, then carry out troubleshootDefective blade dual selector
ing without turning starting switch ON.
1 solenoid (Internal short cirPA (male)
Resistance
cuit)
Between (1) (2)
10 40 z
Possible causes
and standard
value in normal
state
2
or defective contact in con- (27) PA (female) (1)
nector)
(23) PA (female) (2)
3
Resistance
Max. 1 z
Resistance
Max. 1 z
If causes 1 and 2 are not detected, transmission controller may be

carried out.)
68
D275AX-5E0
SEN01659-00
40 Troubleshooting
Failure code [DW59KB] Blade dual selector solenoid short circuit

Action code
Failure code
E01
DW59KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Stops outputting to blade dual selector solenoid circuit.

Blade dual tilt mechanism does not work (When it is operated, single tilt mechanism works).
Output (Current) to blade dual selector solenoid can be checked in real-time monitoring mode.
Method of reproducing failure code: Turn starting switch ON and perform blade dual tilt operation.
Defective blade dual selector

1 solenoid (Internal short circuit)

PA (male)
Resistance
Between (1) (2)
10 40 z
Min. 1 Mz
Resis(Contact with ground circuit) TMCN3 (female) (27) PA (female) (1) with
Min. 1 Mz
tance
chassis ground
harness)
70
Blade dual selector solenoid short circuit

When signal is output to blade dual selector solenoid circuit, abnormal current flowed.
Cause
Possible causes
and standard
value in normal
state
(23) PA (female) (2), TMCN3 (female) (29)
PA (female) (1)
Resistance
Min. 1 Mz
If cause 1 3 is not detected, transmission controller may be

carried out.)
D275AX-5E0
40 Troubleshooting
SEN01659-00
D275AX-5E0
71
SEN01659-00
40 Troubleshooting
Failure code [DW59KY] Blade dual selector solenoid hot short

Action code
Failure code
E01
DW59KY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Blade dual selector solenoid hot short

Some current keeps flowing to blade dual selection solenoid circuit.

Stops outputting signal to blade dual selection solenoid circuit.
Blade dual tilt mechanism keeps operation.
Output (Current) to blade dual selection solenoid can be checked in real-time monitoring mode.
Method of reproducing failure code: Turn starting switch ON + (Perform blade pitch).
Cause
Possible causes
and standard
value in normal
state
Defective blade dual selec1 tion solenoid (Internal short

circuit)


PPA (male)
Resistance
Between (1) (2)
10 40 z

(27) DUL (female) (1)
Voltage
Max. 1 V

carried out.)
72
D275AX-5E0
40 Troubleshooting
SEN01659-00
Failure code [DW5AKA] Blade pitch selector solenoid disconnection

Action code
Failure code
E02
DW5AKA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Blade pitch selector solenoid disconnection

When signal is output to blade pitch selector solenoid circuit, any current does not flow.
Stops outputting to blade pitch selector solenoid circuit.
Blade pitch mechanism does not work (When it is operated, blade tilt mechanism works).
Output (Current) to blade pitch selector solenoid can be checked in real-time monitoring mode.
(Code 31625: Blade pitch solenoid drive current)
Method of reproducing failure code: Turn starting switch ON and perform blade pitch operation.
Cause
Defective blade pitch selec1 tor solenoid (Internal short
circuit)
Possible causes
and standard
value in normal
state

PB (male)
Resistance
Between (1) (2)
10 40 z
2
or defective contact in con- (37) PB (female) (1)
nector)
(23) PB (female) (2)
3
Resistance
Max. 1 z
Resistance
Max. 1 z

carried out.)
D275AX-5E0
73
SEN01659-00
40 Troubleshooting
Failure code [DW5AKB] Blade pitch selector solenoid short circuit

Action code
Failure code
E02
DW5AKB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

Stops outputting to blade pitch selector solenoid circuit.
Blade pitch mechanism does not work (When it is operated, blade tilt mechanism works).
Output (Current) to blade pitch selector solenoid can be checked in real-time monitoring mode.
Method of reproducing failure code: Turn starting switch ON and perform blade pitch operation.
Defective blade pitch selec1 tor solenoid (Internal short

circuit)

PB (male)
Resistance
Between (1) (2)
10 40 z
Min. 1 Mz
Resis(Contact with ground circuit) TMCN3 (female) (37) PB (female) (1) with
Min. 1 Mz
tance
chassis ground
harness)
74
Blade pitch selector solenoid short circuit

When signal was output to blade pitch selector solenoid circuit, abnormal current flowed.
Cause
Possible causes
and standard
value in normal
state
(23) PB (female) (1), TMCN3 (female) (37)
- PB (female) (2)
Resistance
Min. 1 Mz

carried out.)
D275AX-5E0
40 Troubleshooting
SEN01659-00
D275AX-5E0
75
SEN01659-00
40 Troubleshooting
Failure code [DW5AKY] Blade pitch selection solenoid hot short

circuit
Action code
Failure code
E02
DW5AKY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Blade pitch selection solenoid hot short circuit

Some current keeps flowing to blade pitch selection solenoid circuit.

Stops outputting signal to blade pitch selection solenoid circuit.
Blade pitch selector solenoid keeps operation.
Output state (Current) to blade pitch selection solenoid can be checked in real-time monitoring
mode. (Code 31625: Blade pitch solenoid drive current)
Method of reproducing failure code: Turn starting switch ON + (Perform blade pitch)
Cause
Possible causes
and standard
value in normal
state
Defective blade pitch selec1 tion solenoid (Internal short

circuit)

2

PTH (male)
Resistance
Between (1) (2)
10 40 z

(37) PB (female) (1)
Voltage
Max. 1 V

carried out.)
76
D275AX-5E0
SEN01659-00
40 Troubleshooting
78
D275AX-5E0
SEN01878-00
BULLDOZER
1SHOP MANUAL
D275AX-5E0
Machine model
Serial number
D275AX-5E0
30001 and up
40 Troubleshooting

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 [DWN1KA] HSS pump solenoid right disconnection .................................................................. 6
Failure code [DWN1KB] HSS pump solenoid right short circuit...................................................................... 8
Failure code [DWN1KY] HSS pump solenoid right hot short ........................................................................ 10
Failure code [DWN2KA] HSS pump solenoid left disconnection .................................................................. 12
Failure code [DWN2KB] HSS pump solenoid left short circuit ...................................................................... 14
Failure code [DWN2KY] HSS pump solenoid left short circuit ...................................................................... 16
Failure code [DWN3KA] Sudden stop prevention solenoid disconnection ................................................... 18
Failure code [DWN3KB] Sudden stop prevention solenoid short circuit ....................................................... 20
Failure code [DWN3KY] Sudden stop prevention solenoid hot short circuit ................................................. 22
Failure code [DWN4KA] HSS motor free solenoid disconnection................................................................. 23
Failure code [DWN4KB] HSS motor free solenoid short circuit .................................................................... 24
D275AX-5E0
SEN01878-00
40 Troubleshooting
Failure code [DWN5KA] Fan pump solenoid disconnection ......................................................................... 26

Failure code [DWN5KB] Fan pump solenoid short circuit ............................................................................. 28
Failure code [DWN5KY] Fan pump solenoid hot short circuit ....................................................................... 30
Failure code [DXH1KA] Lock-up solenoid disconnection.............................................................................. 32
Failure code [DXH1KB] Lock-up solenoid short circuit ................................................................................. 34
Failure code [DXH1KY] Lock-up solenoid hot short...................................................................................... 36
Failure code [DXH4KA] 1st clutch ECMV disconnection .............................................................................. 38
Failure code [DXH4KB] 1st clutch ECMV short circuit .................................................................................. 40
Failure code [DXH4KY] 1st clutch ECMV hot short circuit ............................................................................ 42
Failure code [DXH5KA] 2nd clutch ECMV disconnection ............................................................................. 44
Failure code [DXH5KB] 2nd clutch ECMV short circuit................................................................................. 46
Failure code [DXH5KY] 2nd clutch ECMV hot short circuit........................................................................... 48
Failure code [DXH6KA] 3rd clutch ECMV disconnection .............................................................................. 50
Failure code [DXH6KB] 3rd clutch ECMV short circuit.................................................................................. 52
Failure code [DXH6KY] 3rd clutch ECMV hot short circuit............................................................................ 54
Failure code [DXH7KA] Reverse clutch ECMV disconnection...................................................................... 56
Failure code [DXH7KB] Reverse clutch ECMV short circuit ......................................................................... 58
Failure code [DXH7KY] R clutch ECMV hot short circuit .............................................................................. 60
Failure code [DXH8KA] Forward clutch ECMV disconnection ...................................................................... 62
Failure code [DXH8KB] Forward clutch ECMV short circuit.......................................................................... 64
Failure code [DXH8KY] F clutch ECMV hot short circuit............................................................................... 66
Failure code [DXHBKA] Right brake ECMV disconnection........................................................................... 68
Failure code [DXHBKB] Right brake ECMV short circuit .............................................................................. 70
Failure code [DXHBKY] Right brake ECMV hot short circuit ........................................................................ 72
Failure code [DXHCKA] Left brake ECMV disconnection ............................................................................. 74
Failure code [DXHCKB] Left brake ECMV short circuit................................................................................. 76
Failure code [DXHCKY] Left brake ECMV hot short circuit........................................................................... 78
D275AX-5E0
40 Troubleshooting
SEN01878-00
Failure code [DW7BKA] Fan rev EPC disconnection

Action code
Failure code
E01
DW7BKA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Fan rev EPC disconnection

When signal is output to fan reverse solenoid circuit, no current flows.

Turns signal to fan reverse solenoid circuit OFF.
Fan reverse function cannot be used.
Output state (ON/OFF) to fan reverse solenoid can be checked in real-time monitoring mode.
(Code 40914: Steering controller output signal 1)
Method of reproducing failure code: Turn starting switch ON + Select fan reverse mode.
Cause
Possible causes
and standard
value in normal
state
Defective fan reverse solenoid (Internal disconnection)

FAR (male)
Resistance
Between (1) (2)
34 44 z
2
or defective contact in con- (17) FAR (female) (1)
nector)
(13) FAR (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
out.)
D275AX-5E0
SEN01878-00
40 Troubleshooting
Failure code [DW7BKB] Fan rev EPC short circuit

Action code
Failure code
E01
DW7BKB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Fan rev EPC short circuit

When signal was output to fan reverse solenoid circuit, abnormal current flowed.
Turns signal to fan reverse solenoid circuit OFF.
Fan reverse function cannot be used.
Method of reproducing failure code: Turn starting switch ON + Select fan reverse mode.
Cause

Possible causes
and standard
value in normal
state
Defective fan reverse solenoid (Internal short circuit)

circuit)

harness)
FAR (male)
Resistance
Between (1) (2)
34 44 z
Min. 1 Mz
(17) FAR (female) (1) and chassis ground
Resistance
Min. 1 Mz
(17) FAR (female) (1) and between
STCN3 (female) (13) FAR (female) (2)
Resistance
Min. 1 Mz
out.)
D275AX-5E0
40 Troubleshooting
SEN01878-00
Failure code [DW7BKY] Fan reverse solenoid hot short circuit

Action code
Failure code
E02
DW7BKY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Fan reverse solenoid short hot circuit

Some current keeps flowing to fan reverse solenoid circuit.

Stops outputting signal to fan reverse solenoid circuit.
Fan keeps running in reverse.
Method of reproducing failure code: Turn starting switch ON (+ Perform fan reverse operation).
Cause
1
Possible causes
and standard
value in normal
state
Defective fan reverse solenoid (Internal short circuit)


FAR2 (male)
Resistance
Between (1) (2)
34 44 z

Wiring harness between STC3 (female) (17)
FAR2 (female) (1)
Voltage
Max. 1 V

carried out.)
D275AX-5E0
SEN01878-00
40 Troubleshooting
Failure code [DWN1KA] HSS pump solenoid right disconnection

Action code
Failure code
CALL E03
DWN1KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
HSS pump solenoid right disconnection

When signal is output to HSS pump solenoid right circuit, any current does not flow.
Stops outputting to HSS pump solenoid right circuit.
Output (Current) to HSS pump solenoid left can be checked in real-time monitoring mode.
(Code 50601: Right HSS solenoid output current, 50603: Right HSS solenoid command current)
Method of reproducing failure code: Turn starting switch ON and operate PCCS lever (for steering
to right).
Cause
Defective HSS pump sole1 noid right (Internal disconnection)
Possible causes
and standard
value in normal
state

PUPA (male)
Resistance
Between (1) (2)
10 20 z
2
or defective contact in con- (35) PUPA (female) (1)
nector)
(3) PUPA (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
If causes 1 and 2 are not detected, steering controller may be

3 Defective steering controller defective. (Since trouble is in system, troubleshooting cannot be
carried out.)
D275AX-5E0
40 Troubleshooting
SEN01878-00
D275AX-5E0
SEN01878-00
40 Troubleshooting
Failure code [DWN1KB] HSS pump solenoid right short circuit

Action code
Failure code
CALL E03
DWN1KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
HSS pump solenoid right short circuit

When signal was output to HSS pump solenoid right circuit, abnormal current flowed.
Stops outputting to HSS pump solenoid right circuit.
Output (Current) to HSS pump solenoid left can be checked in real-time monitoring mode.
(Code 50601: Right HSS solenoid output current, 50603: Right HSS solenoid command current)
to right).
Cause
Defective HSS pump sole1 noid right (Internal short circuit)
Possible causes
and standard
value in normal
state

PUPA (male)
Resistance
Between (1) (2)
10 20 z
Min. 1 Mz
Resis(Contact with ground circuit) STCN3 (female) (35) PUPA (female) (1)
Min. 1 Mz
tance
with chassis ground

harness)
Short circuit in wiring harness between
STCN3 (female) (35) PUPA (female) (1)
with wiring harness between STCN3
(female) (3) PUPA (female) (2)
Resistance
Min. 1 Mz
out.)
D275AX-5E0
40 Troubleshooting
SEN01878-00
D275AX-5E0
SEN01878-00
40 Troubleshooting
Failure code [DWN1KY] HSS pump solenoid right hot short

Action code
Failure code
CALL E03
DWN1KY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
HSS pump solenoid right hot short

When signal is output to right HSS pump solenoid circuit, some current keeps flowing.
Stops outputting signal to HSS pump solenoid right circuit.
Machine keeps turning to right (Stop with pedal brake or parking brake lever).
Output state to HSS pump solenoid left can be checked with real-time monitoring mode.
(Code: 50601 Right HSS solenoid output current, 50603: Right HSS solenoid command current)
Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (Left steering).
Cause
Defective HSS pump sole1 noid left (Internal short circuit)
Possible causes
and standard
value in normal
state

PUPA (male)
Resistance
Between (1) (2)
10 20 z
Min. 1 Mz


(35) PUPA (female) (1) and chassis
ground
Voltage
Max. 1 V
If causes 1, 2 are not detected, steering controller may be defec3 Defective steering controller tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
10
D275AX-5E0
40 Troubleshooting
SEN01878-00
D275AX-5E0
11
SEN01878-00
40 Troubleshooting
Failure code [DWN2KA] HSS pump solenoid left disconnection

Action code
Failure code
CALL E03
DWN2KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
HSS pump solenoid left disconnection

When signal is output to HSS pump solenoid left circuit, any current does not flow.
Stops outputting to HSS pump solenoid left circuit.
Output (Current) to HSS pump solenoid right can be checked in real-time monitoring mode.
(Code: 50600: Left HSS solenoid output current, 50602: Left HSS solenoid command current)
to left).
Cause
Defective HSS pump sole1 noid left (Internal disconnection)
Possible causes
and standard
value in normal
state

PUPB (male)
Resistance
Between (1) (2)
10 20 z
2
or defective contact in con- (25) PUPB (female) (1)
nector)
(3) PUPB (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
out.)
12
D275AX-5E0
40 Troubleshooting
SEN01878-00
D275AX-5E0
13
SEN01878-00
40 Troubleshooting
Failure code [DWN2KB] HSS pump solenoid left short circuit

Action code
Failure code
CALL E03
DWN2KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
HSS pump solenoid left short circuit

When signal was output to HSS pump solenoid left circuit, abnormal current flowed.
Stops outputting to HSS pump solenoid left circuit.
Output (Current) to HSS pump solenoid right can be checked in real-time monitoring mode.
to left).
Cause
Possible causes
and standard
value in normal
state

PUPB (male)
Resistance
Between (1) (2)
10 20 z
Min. 1 Mz
Resis(Contact with ground circuit) STCN3 (female) (25) PUPB (female) (1)
Min. 1 Mz
tance
with chassis ground

harness)
STCN3 (female) (25) PUPB (female) (1)
(female) (3) PUPB (female) (2)
Resistance
Min. 1 Mz
out.)
14
D275AX-5E0
40 Troubleshooting
SEN01878-00
D275AX-5E0
15
SEN01878-00
40 Troubleshooting
Failure code [DWN2KY] HSS pump solenoid left short circuit

Action code
Failure code
E03
DWN2KY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
HSS pump solenoid left short circuit

When signal is output to HSS pump solenoid left circuit, some current keeps flowing.
Stops outputting signal to HSS pump solenoid right circuit.
Machine keeps turning to left (Stop with pedal brake or parking brake lever).
Output state to HSS pump solenoid right can be checked with real-time monitoring mode.
Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (Left steering).
Cause
Possible causes
and standard
value in normal
state

PUPB (male)
Resistance
Between (1) (2)
10 20 z
Min. 1 Mz


(25) PUPB (female) (1) and chassis
ground
Voltage
Max. 1 V
out.)
16
D275AX-5E0
40 Troubleshooting
SEN01878-00
D275AX-5E0
17
SEN01878-00
40 Troubleshooting
Failure code [DWN3KA] Sudden stop prevention solenoid

disconnection
Action code
Failure code
CALL E04
DWN3KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Sudden stop prevention solenoid disconnection

When signal is output to sudden stop prevention solenoid circuit, any current does not flow.
Output (Current) to sudden stop prevention solenoid can be checked in real-time monitoring mode.
(Code 31628: Sudden stop prevention solenoid drive current)
Cause
Defective sudden stop pre1 vention solenoid (Internal
disconnection)
Possible causes
and standard
value in normal
state

ST8 (male)
Resistance
Between (1) (2)
5 25 z
2
or defective contact in con- (7) ST8 (female) (1)
nector)
(23) ST8 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
out.)
18
D275AX-5E0
SEN01878-00
40 Troubleshooting
Failure code [DWN3KB] Sudden stop prevention solenoid short circuit1

Action code
Failure code
CALL E04
DWN3KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal was output to sudden stop prevention solenoid circuit, abnormal current flowed.
Output (Current) to sudden stop prevention solenoid can be checked in real-time monitoring mode.
Cause
Defective sudden stop pre1 vention solenoid (Internal
short circuit)
Possible causes
and standard
value in normal
state
Sudden stop prevention solenoid short circuit


ST8 (male)
Resistance
Between (1) (2)
5 25 z
Min. 1 Mz
Resis(Contact with ground circuit) STCN3 (female) (7) ST8 (female) (1) with
Min. 1 Mz
tance
chassis ground

harness)
STCN3 (female) (7) ST8 (female) (1) with
wiring harness between STCN3 (female)
(23) ST8 (female) (2)
Resistance
Min. 1 Mz
out.)
20
D275AX-5E0
40 Troubleshooting
SEN01878-00
D275AX-5E0
21
SEN01878-00
40 Troubleshooting
Failure code [DWN3KY] Sudden stop prevention solenoid hot short

circuit
Action code
Failure code
CALL E04
DWN3KY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Sudden stop prevention solenoid hot short circuit

Some current keeps flowing in sudden stop prevention solenoid circuit.

Sudden stop prevention valve does not operate in emergency.
Output to sudden stop prevent solenoid can be checked with real-time monitoring mode.
Cause
Defective sudden stop pre1 vent solenoid (Internal short
circuit)
Possible causes
and standard
value in normal
state

ST8 (male)
Resistance
Between (1) (2)
5 25 z
Min. 1 Mz

2
24V circuit) in wiring harness (7) ST8 (female) (1) with chassis ground
(23) ST8 (female) (2) with chassis ground
Voltage
Max. 1 V
Voltage
Max. 1 V
out.)
22
D275AX-5E0
40 Troubleshooting
SEN01878-00
Failure code [DWN4KA] HSS motor free solenoid disconnection

Action code
Failure code
E01
DWN4KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
HSS motor free solenoid disconnection

No current flows or some current keeps flowing in HSS motor free solenoid circuit.
Stops outputting to HSS motor free solenoid circuit.
Turning performance may lower.
Output (Voltage) to HSS motor free solenoid can be checked in real-time monitoring mode.
(Code 31626: HSS motor free solenoid drive current)
Method of reproducing failure code: Start engine and turn pivot turn switch ON and travel and steer
fully.
Cause
Defective HSS motor free
1 solenoid (Internal disconnection)

MFR (male)
Resistance
Between (1) (2)
5 25 z
Possible causes
and standard
value in normal
state
2
or defective contact in con- (8) MFR (female) (1)
nector)
(3) MFR (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z


STCN3 (female) (8) MFR (female) (1) with
chassis ground
Voltage
Max. 1V

chassis ground
Voltage
Max. 1V
out.)
D275AX-5E0
23
SEN01878-00
40 Troubleshooting
Failure code [DWN4KB] HSS motor free solenoid short circuit

Action code
Failure code
E01
DWN4KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
HSS motor free solenoid short circuit

When signal was output to HSS motor free solenoid circuit, abnormal current flowed.
Stops outputting to HSS motor free solenoid circuit.
Turning performance may lower.
Output (Voltage) to HSS motor free solenoid can be checked in real-time monitoring mode.
(Code 31626: HSS motor free solenoid drive current)
Method of reproducing failure code: Start engine and turn pivot turn switch ON and travel and steer
fully.
Cause
Defective HSS motor free
Possible causes
and standard
value in normal
state

MFR (male)
Resistance
Between (1) (2)
5 25 z
Min. 1 Mz
Resis(Contact with ground circuit) STCN3 (female) (8) MFR (female) (1) with
Min. 1 Mz
tance
chassis ground

harness)
wiring harness between STCN3 (female) (3)
MFR (female) (2)
Resistance
Min. 1 Mz
out.)
24
D275AX-5E0
SEN01878-00
40 Troubleshooting
Failure code [DWN5KA] Fan pump solenoid disconnection

Action code
Failure code
E01
DWN5KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Fan pump solenoid disconnection

When signal is output to fan pump solenoid circuit, any current does not flow.
Stops outputting to fan pump solenoid circuit.
Fan pump output is kept at its maximum.
Output (Current) to fan pump solenoid can be checked in real-time monitoring mode.
(Code 31623, 31624: Cooling fan solenoid command current, output current)
Cause
Defective fan pump solenoid
1
FAC (male)
Resistance
Between (1) (2)
Possible causes
and standard
value in normal
state
2
or defective contact in con- (17) FAC (female) (1)
nector)
(23) FAC (female) (2)
3
26
15 25 z
Resistance
Max. 1 z
Resistance
Max. 1 z
If causes 1, 2 are not detected, transmission controller may be

carried out.)
D275AX-5E0
40 Troubleshooting
SEN01878-00
D275AX-5E0
27
SEN01878-00
40 Troubleshooting
Failure code [DWN5KB] Fan pump solenoid short circuit

Action code
Failure code
E01
DWN5KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Fan pump solenoid short circuit

When signal was output to fan pump solenoid circuit, abnormal current flowed.
Stops outputting to fan pump solenoid circuit.
Method of reproducing service code: Turn starting switch ON.
Cause

Possible causes
and standard
value in normal
state

Resistance
Between (1) (2)
15 25 z
Min. 1 Mz
Resis(Contact with ground circuit) TMCN3 (female) (17) FAC (female) (1)
Min. 1 Mz
tance
with chassis ground

harness)
28
FAC (male)
TMCN3 (female) (17) FAC (female) (1)
with wiring harness between TMCN3
(female) (23) FAC (female) (2)
Resistance
Min. 1 Mz
If causes 1 - 3 are not detected, transmission controller may be

carried out.)
D275AX-5E0
40 Troubleshooting
SEN01878-00
D275AX-5E0
29
SEN01878-00
40 Troubleshooting
Failure code [DWN5KY] Fan pump solenoid hot short circuit

Action code
Failure code
E02
DWN5KY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Fan pump solenoid hot short circuit

Some current keeps flowing to fan pump solenoid circuit.

Stops outputting signal to fan pump solenoid circuit.
Fan speed does not increase.
Cause

Possible causes
and standard
value in normal
state
FAC (male)
Resistance
Between (1) (2)
15 25 z
Between (1) ground
Min. Mz

2
30



(17) FAC (female) (1) with chassis ground
Voltage
Max. 1 V

(23) FAC (female) (2) with chassis ground
Voltage
Max. 1 V

carried out.)
D275AX-5E0
40 Troubleshooting
SEN01878-00
D275AX-5E0
31
SEN01878-00
40 Troubleshooting
Failure code [DXH1KA] Lock-up solenoid disconnection

Action code
Failure code
E01
DXH1KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Stops outputting to torque converter lock-up solenoid circuit.

Torque converter is not locked-up.
Output (Current) to torque converter lock-up solenoid can be checked in real-time monitoring mode.
(Code 31627: Torque converter lock-up solenoid drive current)
Method of reproducing failure code: Start engine and turn lock-up switch ON and drive machine.

1 lock-up solenoid (Internal
short circuit)

653 (male)
Resistance
Between (1) (2)
30 80 z
2
or defective contact in con- (38) 653 (female) (1)
nector)
(23) 653 (female) (2)
3
32
Lock-up solenoid disconnection

When signal is output to torque converter lock-up solenoid circuit, any current does not flow.
Cause
Possible causes
and standard
value in normal
state
Resistance
Max. 1 z
Resistance
Max. 1 z

carried out.)
D275AX-5E0
40 Troubleshooting
SEN01878-00
D275AX-5E0
33
SEN01878-00
40 Troubleshooting
Failure code [DXH1KB] Lock-up solenoid short circuit

Action code
Failure code
E01
DXH1KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Stops outputting to torque converter lock-up solenoid circuit.

Torque converter is not locked-up.
Output (Current) to torque converter lock-up solenoid can be checked in real-time monitoring mode.
(Code 31627: Torque converter lock-up solenoid drive current)

1 lock-up solenoid (Internal
short circuit)

653 (male)
Resistance
Between (1) (2)
30 80 z
Min. 1 Mz
Resis(Contact with ground circuit) TMCN3 (female) (38) 653 (female) (1)
Min. 1 Mz
tance
with chassis ground

harness)
34
Lock-up solenoid short circuit

When signal was output to torque converter lock-up solenoid circuit, abnormal current flowed.
Cause
Possible causes
and standard
value in normal
state
TMCN3 (female) (38) 653 (female) (1)
(female) (23) 653 (female) (2)
Resistance
Min. 1 Mz

carried out.)
D275AX-5E0
40 Troubleshooting
SEN01878-00
D275AX-5E0
35
SEN01878-00
40 Troubleshooting
Failure code [DXH1KY] Lock-up solenoid hot short

Action code
Failure code
E03
DXH1KY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Lock-up solenoid hot short

Some current keeps flowing in torque converter lock-up solenoid circuit.

Stops outputting signal to torque converter lockup solenoid circuit.
Torque converter is kept locked up.

Once machine is stopped, gear speed is limited to F1 and R1.
Engine may stall during travel.
Output (Current) to torque converter lockup solenoid can be checked with real-time monitoring
mode. (Code 31627: Torque converter lock-up solenoid drive current)
Cause

1
Possible causes
and standard
value in normal
state
653 (male)
Resistance
Between (1) (2)
3.5 12.5 z
Min. 1 Mz

2
Voltage Max. 1 V
(38) 653 (female) (1) and chassis ground
3
36

lockup solenoid

carried out.)
D275AX-5E0
40 Troubleshooting
SEN01878-00
D275AX-5E0
37
SEN01878-00
40 Troubleshooting
Failure code [DXH4KA] 1st clutch ECMV disconnection

Action code
Failure code
CALL E03
DXH4KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

Stops outputting to transmission 1st clutch ECMV solenoid circuit.
Output (Current) to 1st clutch ECMV solenoid can be checked in real-time monitoring mode.
(Code 31602, 31612: Output current of 1st clutch ECMV)
Method of reproducing failure code: Start engine and drive machine in F1 or R1.
Defective 1st clutch ECMV


S1T (male)
Resistance
Between (1) (2)
5 15 z
2
or defective contact in con- (15) S1T (female) (1)
nector)
(3) S1T (female) (2)
3
38
1st clutch ECMV disconnection

When signal is output to 1st clutch ECMV solenoid circuit, any current does not flow.
Cause
Possible causes
and standard
value in normal
state
Resistance
Max. 1 z
Resistance
Max. 1 z

carried out.)
D275AX-5E0
40 Troubleshooting
SEN01878-00
D275AX-5E0
39
SEN01878-00
40 Troubleshooting
Failure code [DXH4KB] 1st clutch ECMV short circuit

Action code
Failure code
CALL E03
DXH4KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

Stops outputting to transmission 1st clutch ECMV solenoid circuit.
Output (Current) to 1st clutch ECMV solenoid can be checked in real-time monitoring mode.


S1T (male)
Resistance
Between (1) (2)
5 15 z
Min. 1 Mz
Resis(Contact with ground circuit) TMCN3 (female) (15) S1T (female) (1)
Min. 1 Mz
tance
with chassis ground

harness)
40
1st clutch ECMV short circuit

When signal was output to transmission 1st clutch ECMV solenoid circuit, abnormal current flowed.
Cause
Possible causes
and standard
value in normal
state
TMCN3 (female) (15) S1T (female) (1)
(female) (3) S1T (female) (2)
Resistance
Min. 1 Mz

carried out.)
D275AX-5E0
40 Troubleshooting
SEN01878-00
D275AX-5E0
41
SEN01878-00
40 Troubleshooting
Failure code [DXH4KY] 1st clutch ECMV hot short circuit

Action code
Failure code
CALL E03
DXH4KY
Contents of
trouble
Trouble
1st clutch ECMV hot short circuit

Some current keeps flowing in transmission 1st clutch ECMV solenoid circuit.
Action of
controller

Turns signal to transmission 1st clutch ECMV solenoid circuit OFF.
Problem that
appears on
machine

Related
information
Output to 1st clutch ECMV solenoid can be checked with real-time monitoring mode.
Method of reproducing failure code: Start engine + Set gear to F2 or R2.
Cause
Possible causes
and standard
value in normal
state

S1T (male)
Resistance
Between (1) (2)
5 15 z
Min. 1 Mz

2
24V circuit) in wiring harness (15) S1T (female) (1) with chassis ground
(3) S1T (female) (2) with chassis ground
42
Voltage
Max. 1 V
Voltage
Max. 1 V

carried out.)
D275AX-5E0
40 Troubleshooting
SEN01878-00
D275AX-5E0
43
SEN01878-00
40 Troubleshooting
Failure code [DXH5KA] 2nd clutch ECMV disconnection

Action code
Failure code
CALL E03
DXH5KA
Contents of
trouble
Trouble
2nd clutch ECMV disconnection

When signal is output to 2nd clutch ECMV solenoid circuit, any current does not flow.
Action of
controller

Stops outputting to transmission 2nd clutch ECMV solenoid circuit.
Problem that
appears on
machine

Related
information
Output (Current) to 2nd clutch ECMV solenoid can be checked in real-time monitoring mode.
(Code 31603, 31613: Output current of 2nd clutch ECMV)
Cause
Defective 2nd clutch ECMV
Possible causes
and standard
value in normal
state

S2T (male)
Resistance
Between (1) (2)
5 15 z
2
nector)
(13) S2T (female) (2)
3
44
Resistance
Max. 1 z
Resistance
Max. 1 z

carried out.)
D275AX-5E0
40 Troubleshooting
SEN01878-00
D275AX-5E0
45
SEN01878-00
40 Troubleshooting
Failure code [DXH5KB] 2nd clutch ECMV short circuit

Action code
Failure code
CALL E03
DXH5KB
Contents of
trouble
Trouble
2nd clutch ECMV short circuit

When signal was output to transmission 2nd clutch ECMV solenoid circuit, abnormal current flowed.
Action of
controller

Stops outputting to transmission 2nd clutch ECMV solenoid circuit.
Problem that
appears on
machine

Related
information
Output (Current) to 2nd clutch ECMV solenoid can be checked in real-time monitoring mode.
Cause
Possible causes
and standard
value in normal
state

S2T (male)
Resistance
Between (1) (2)
5 15 z
Min. 1 Mz
Resis(Contact with ground circuit) TMCN3 (female) (36) S2T (female) (1)
Min. 1 Mz
tance
with chassis ground

harness)
46
TMCN3 (female) (36) S2T (female) (1)
(female) (13) S2T (female) (2)
Resistance
Min. 1 Mz

carried out.)
D275AX-5E0
40 Troubleshooting
SEN01878-00
D275AX-5E0
47
SEN01878-00
40 Troubleshooting
Failure code [DXH5KY] 2nd clutch ECMV hot short circuit

Action code
Failure code
CALL E03
DXH5KY
Contents of
trouble
Trouble
2nd clutch ECMV hot short circuit

Some current keeps flowing in transmission 2nd clutch ECMV solenoid circuit.
Action of
controller

Turns signal to transmission 2nd clutch ECMV solenoid circuit OFF.
Problem that
appears on
machine

Related
information
Output to 2nd clutch ECMV solenoid can be checked with real-time monitoring mode.
Cause
Possible causes
and standard
value in normal
state


S2T (male)
Resistance
Between (1) (2)
5 15 z
Min. 1 Mz

2
Voltage Max. 1 V
(36) S2T (female) (1) and chassis ground
3
48

carried out.)
D275AX-5E0
40 Troubleshooting
SEN01878-00
D275AX-5E0
49
SEN01878-00
40 Troubleshooting
Failure code [DXH6KA] 3rd clutch ECMV disconnection

Action code
Failure code
CALL E03
DXH6KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

Stops outputting to transmission 3rd clutch ECMV solenoid circuit.
Output (Current) to 3rd clutch ECMV solenoid can be checked in real-time monitoring mode.
(Code 31604, 31614: Output current of 3rd clutch ECMV)
Defective 3rd clutch ECMV


S3T (male)
Resistance
Between (1) (2)
5 15 z
2
nector)
3
50
3rd clutch ECMV disconnection

When signal is output to 3rd clutch ECMV solenoid circuit, any current does not flow.
Cause
Possible causes
and standard
value in normal
state
Resistance
Max. 1 z
Resistance
Max. 1 z

carried out.)
D275AX-5E0
40 Troubleshooting
SEN01878-00
D275AX-5E0
51
SEN01878-00
40 Troubleshooting
Failure code [DXH6KB] 3rd clutch ECMV short circuit

Action code
Failure code
CALL E03
DXH6KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

Stops outputting to transmission 3rd clutch ECMV solenoid circuit.
Output (Current) to 3rd clutch ECMV solenoid can be checked in real-time monitoring mode.


S3T (male)
Resistance
Between (1) (2)
5 15 z
Min. 1 Mz
Resis(Contact with ground circuit) TMCN3 (female) (5) S3T (female) (1) with
Min. 1 Mz
tance
chassis ground

harness)
52
3rd clutch ECMV short circuit

When signal was output to transmission 3rd clutch ECMV solenoid circuit, abnormal current flowed.
Cause
Possible causes
and standard
value in normal
state
TMCN3 (female) (5) S3T (female) (1) with
wiring harness between TMCN3 (female)
Resistance
Min. 1 Mz

carried out.)
D275AX-5E0
40 Troubleshooting
SEN01878-00
D275AX-5E0
53
SEN01878-00
40 Troubleshooting
Failure code [DXH6KY] 3rd clutch ECMV hot short circuit

Action code
Failure code
E03
DXH6KY
Contents of
trouble
Trouble
3rd clutch ECMV hot short circuit

Some current keeps flowing in transmission 3rd solenoid circuit.
Action of
controller

Turns signal to transmission 3rd clutch ECMV solenoid circuit OFF.
Problem that
appears on
machine

Related
information
Output to 3rd clutch ECMV solenoid can be checked with real-time monitoring mode.
Cause
Possible causes
and standard
value in normal
state

S3T (male)
Resistance
Between (1) (2)
5 15 z
Min. 1 Mz

2
54
24V circuit) in wiring harness (5) S3T (female) (1) with chassis ground
Voltage
Max. 1 V

(3) S3T (female) (2) with chassis ground
Voltage
Max. 1 V

carried out.)
D275AX-5E0
40 Troubleshooting
SEN01878-00
D275AX-5E0
55
SEN01878-00
40 Troubleshooting
Failure code [DXH7KA] Reverse clutch ECMV disconnection

Action code
Failure code
CALL E03
DXH7KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

Stops outputting to transmission reverse clutch ECMV solenoid circuit.
Once machine is stopped, travel is limited to F1.
Output (Current) to reverse clutch ECMV solenoid can be checked in real-time monitoring mode.
(Code 31606, 31616: Output current of reverse clutch ECMV)
Method of reproducing failure code: Start engine and drive machine in reverse.
Defective reverse clutch

1 ECMV solenoid (Internal
short circuit)

SRT (male)
Resistance
Between (1) (2)
5 15 z
2
or defective contact in con- (25) SRT (female) (1)
nector)
(13) SRT (female) (2)
3
56
Reverse clutch ECMV disconnection

When signal is output to reverse clutch ECMV solenoid circuit, any current does not flow.
Cause
Possible causes
and standard
value in normal
state
Resistance
Max. 1 z
Resistance
Max. 1 z

carried out.)
D275AX-5E0
40 Troubleshooting
SEN01878-00
D275AX-5E0
57
SEN01878-00
40 Troubleshooting
Failure code [DXH7KB] Reverse clutch ECMV short circuit

Action code
Failure code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
DXH7KB
Trouble

Stops outputting to transmission reverse clutch ECMV solenoid circuit.
Output (Current) to reverse clutch ECMV solenoid can be checked in real-time monitoring mode.
(Code 31606, 31616: Output current of reverse clutch ECMV)
Defective reverse clutch

short circuit)

SRT (male)
Resistance
Between (1) (2)
5 15 z
Min. 1 Mz
Resis(Contact with ground circuit) TMCN3 (female) (25) SRT (female) (1)
Min. 1 Mz
tance
with chassis ground

harness)
58
Reverse clutch ECMV short circuit

When signal was output to transmission reverse clutch ECMV solenoid circuit, abnormal current
flowed.
Cause
Possible causes
and standard
value in normal
state
TMCN3 (female) (25) SRT (female) (1)
(female) (13) SRT (female) (2)
Resistance
Min. 1 Mz

carried out.)
D275AX-5E0
40 Troubleshooting
SEN01878-00
D275AX-5E0
59
SEN01878-00
40 Troubleshooting
Failure code [DXH7KY] R clutch ECMV hot short circuit

Action code
Failure code
CALL E03
DXH7KY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

Turns signal to transmission R clutch ECMV solenoid circuit OFF.
Once machine is stopped, travel is limited to R1.
Output to R clutch ECMV solenoid can be checked with real-time monitoring mode.
(Code 31606, 31616: Output current of reverse clutch ECMV))
Method of reproducing failure code: Start engine and drive machine forward.
Defective R clutch ECMV


SRT (male)
Resistance
Between (1) (2)
5 15 z
Min. 1 Mz

2
60
R clutch ECMV hot short circuit

Some current keeps flowing in transmission R clutch ECMV solenoid circuit.
Cause
Possible causes
and standard
value in normal
state
24V circuit) in wiring harness (25) SRT (female) (1) with chassis ground
Voltage
Max. 1 V

(13) SRT (female) (2) with chassis ground
Voltage
Max. 1 V

carried out.)
D275AX-5E0
40 Troubleshooting
SEN01878-00
D275AX-5E0
61
SEN01878-00
40 Troubleshooting
Failure code [DXH8KA] Forward clutch ECMV disconnection

Action code
Failure code
CALL E03
DXH8KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

Stops outputting to transmission forward clutch ECMV solenoid circuit.
Output (Current) to forward clutch ECMV solenoid can be checked in real-time monitoring mode.
(Code 31608, 31622: Output current of forward clutch ECMV)
Defective forward clutch

short circuit)

SFT (male)
Resistance
Between (1) (2)
5 15 z
2
or defective contact in con- (35) SFT (female) (1)
nector)
(13) SFT (female) (2)
3
62
Forward clutch ECMV disconnection

When signal is output to forward clutch ECMV solenoid circuit, any current does not flow.
Cause
Possible causes
and standard
value in normal
state
Resistance
Max. 1 z
Resistance
Max. 1 z

carried out.)
D275AX-5E0
40 Troubleshooting
SEN01878-00
D275AX-5E0
63
SEN01878-00
40 Troubleshooting
Failure code [DXH8KB] Forward clutch ECMV short circuit

Action code
Failure code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
DXH8KB
Trouble

Stops outputting to transmission forward clutch ECMV solenoid circuit.
Output (Current) to forward clutch ECMV solenoid can be checked in real-time monitoring mode.
Defective forward clutch

short circuit)

SFT (male)
Resistance
Between (1) (2)
5 15 z
Min. 1 Mz
Resis(Contact with ground circuit) TMCN3 (female) (35) SFT (female) (1)
Min. 1 Mz
tance
with chassis ground

harness)
64
Forward clutch ECMV short circuit

When signal was output to transmission forward clutch ECMV solenoid circuit, abnormal current
flowed.
Cause
Possible causes
and standard
value in normal
state
TMCN3 (female) (35) SFT (female) (1)
(female) (13) SFT (female) (2)
Resistance
Min. 1 Mz

carried out.)
D275AX-5E0
40 Troubleshooting
SEN01878-00
D275AX-5E0
65
SEN01878-00
40 Troubleshooting
Failure code [DXH8KY] F clutch ECMV hot short circuit

Action code
Failure code
CALL E03
DXH8KY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
F clutch ECMV hot short circuit

Some current keeps flowing in transmission F clutch ECMV solenoid circuit.

Turns signal to transmission F clutch ECMV solenoid circuit OFF.
Output to F clutch ECMV solenoid can be checked with real-time monitoring mode.
Cause
Defective F clutch ECMV
Possible causes
and standard
value in normal
state

SFT (male)
Resistance
Between (1) (2)
5 15 z
Min. 1 Mz

2
24V circuit) in wiring harness (35) SFT (female) (1) with chassis ground
(3) SFT (female) (2) with chassis ground
66
Voltage
Max. 1 V
Voltage
Max. 1 V

carried out.)
D275AX-5E0
40 Troubleshooting
SEN01878-00
D275AX-5E0
67
SEN01878-00
40 Troubleshooting
Failure code [DXHBKA] Right brake ECMV disconnection

Action code
Failure code
CALL E04
DXHBKA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Right brake ECMV disconnection

When signal is output to right steering brake ECMV solenoid circuit, any current does not flow.

Stops outputting to right steering brake ECMV solenoid circuit.
Limits operation of engine, transmission and brake.
Operates sudden stop prevention valve.
Right brake keeps operating.

Output (Current) to right steering brake ECMV solenoid can be checked in real-time monitoring
mode. (Code 31620, 31618: Output current of right steering brake ECMV)
Method of reproducing failure code: Turn starting switch ON and release parking brake lever.
Cause
1 brake ECMV solenoid (Internal short circuit)
Possible causes
and standard
value in normal
state

SRB (male)
Resistance
Between (1) (2)
5 15 z
2
or defective contact in con- (15) SRB (female) (1)
nector)
(13) SRB (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
out.)
68
D275AX-5E0
40 Troubleshooting
SEN01878-00
D275AX-5E0
69
SEN01878-00
40 Troubleshooting
Failure code [DXHBKB] Right brake ECMV short circuit

Action code
Failure code
CALL E04
DXHBKB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Right brake ECMV short circuit

When signal was output to right steering brake ECMV solenoid circuit, abnormal current flowed.

Stops outputting to right steering brake ECMV solenoid circuit.

Output (Current) to right steering brake ECMV solenoid can be checked in real-time monitoring
mode. (Code 31620, 31618: Output current of right steering brake ECMV)
Method of reproducing failure code: Start engine and release parking brake lever.
Cause
1 brake ECMV (Internal short
circuit)
Possible causes
and standard
value in normal
state

SRB (male)
Resistance
Between (1) (2)
5 15 z
Min. 1 Mz
Resis(Contact with ground circuit) STCN3 (female) (15) SRB (female) (1)
Min. 1 Mz
tance
with chassis ground

harness)
STCN3 (female) (15) SRB (female) (1)
(female) (13) SRB (female) (2)
Resistance
Min. 1 Mz
If causes 1 - 3 are not detected, steering controller may be defec4 Defective steering controller tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
70
D275AX-5E0
40 Troubleshooting
SEN01878-00
D275AX-5E0
71
SEN01878-00
40 Troubleshooting
Failure code [DXHBKY] Right brake ECMV hot short circuit

Action code
Failure code
CALL E04
DXHBKY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

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.
(Code 31620, 31618: Output current of right steering brake ECMV)
Method of reproducing failure code: Turn starting switch ON + Operate parking brake lever (Lock).
Defective right steering1 brake ECMV solenoid (Internal short circuit)

SRB (male)
Resistance
Between (1) (2)
5 15 z
Min. 1 Mz

2
72
Right brake ECMV hot short circuit

Some current keeps flowing in right brake ECMV solenoid circuit.
Cause
Possible causes
and standard
value in normal
state
24V circuit) in wiring harness (15) SRB (female) (1) with chassis ground
Voltage
Max. 1 V

(13) SRB (female) (2) with chassis ground
Voltage
Max. 1 V
Defective power train controller
If causes 1, 2 are not detected, power train controller may be

carried out.)
D275AX-5E0
40 Troubleshooting
SEN01878-00
D275AX-5E0
73
SEN01878-00
40 Troubleshooting
Failure code [DXHCKA] Left brake ECMV disconnection

Action code
Failure code
CALL E04
DXHCKA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Left brake ECMV disconnection

When signal is output to left steering brake ECMV solenoid circuit, any current does not flow.

Stops outputting to left steering brake brake ECMV solenoid circuit.
Limits operation of engine, transmission and brake.
Left brake keeps operating.

Output (Current) to left steering brake ECMV solenoid can be checked in real-time monitoring
mode. (Code 31621, 31619: Output current of left steering brake ECMV)
Method of reproducing failure code: Turn starting switch ON and release parking brake lever.
Cause
Defective steering case left
1 brake ECMV solenoid (Internal short circuit)
Possible causes
and standard
value in normal
state

SLB (male)
Resistance
Between (1) (2)
5 15 z
2
or defective contact in con- (5) SLB (female) (1)
nector)
(13) SLB (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z

3 Defective steering controller defective. (Since trouble is in system, troubleshooting cannot be
carried out.)
74
D275AX-5E0
40 Troubleshooting
SEN01878-00
D275AX-5E0
75
SEN01878-00
40 Troubleshooting
Failure code [DXHCKB] Left brake ECMV short circuit

Action code
Failure code
CALL E04
DXHCKB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Left brake ECMV short circuit

When signal was output to left steering brake ECMV solenoid circuit, abnormal current flowed.

Stops outputting to left steering brake ECMV solenoid circuit.
Left brake keeps operating.

Output (Current) to left steering brake ECMV solenoid can be checked in real-time monitoring
mode. (Code 31621, 31619: Output current of left steering brake ECMV)
Method of reproducing failure code: Start engine and release parking brake lever.
Cause
short circuit)
Possible causes
and standard
value in normal
state

SLB (male)
Resistance
Between (1) (2)
5 15 z
Min. 1 Mz
Resis(Contact with ground circuit) STCN3 (female) (5) SLB (female) (1) with
Min. 1 Mz
tance
chassis ground

harness)
STCN3 (female) (5) SLB (female) (1) with
wiring harness between STCN3 (female)
(13) SLB (female) (2)
Resistance
Min. 1 Mz
If causes 1 - 3 are not detected, steering controller may be defec4 Defective steering controller tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
76
D275AX-5E0
40 Troubleshooting
SEN01878-00
D275AX-5E0
77
SEN01878-00
40 Troubleshooting
Failure code [DXHCKY] Left brake ECMV hot short circuit

Action code
Failure code
CALL E04
DXHCKY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Left brake ECMV hot short circuit

Some current keeps flowing in left steering brake ECMV solenoid circuit.

Turns signal to left steering brake ECMV solenoid circuit OFF.
Limits operation of engine and transmission, brake.
Left brake does not operate.

Output to left steering brake ECMV solenoid can be checked with real-time monitoring mode.
(Code 31621, 31619: Output current of left steering brake ECMV)
Method of reproducing failure code: Turn starting switch ON + Operate parking brake lever (Lock).
Cause
short circuit)
Possible causes
and standard
value in normal
state

SLB (male)
Resistance
Between (1) (2)
5 15 z
Min. 1 Mz

2
24V circuit) in wiring harness (5) SLB (female) (1) with chassis ground
(13) SLB (female) (2) with chassis ground
78
Defective power train controller
Voltage
Max. 1 V
Voltage
Max. 1 V
If causes 1, 2 are not detected, power train controller may be

carried out.)
D275AX-5E0
40 Troubleshooting
SEN01878-00
D275AX-5E0
79
SEN01878-00
40 Troubleshooting
80
D275AX-5E0
SEN01646-00
BULLDOZER
1SHOP MANUAL
D275AX-5E0
Machine model
Serial number
D275AX-5E0
30001 and up
40 Troubleshooting
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
D275AX-5E0
SEN01646-00
40 Troubleshooting
E-11 At the locking-up of the torque converter, the torque converter lock-up display lamp does not come
on ........................................................................................................................................................... 26
E-12 The engine coolant temperature gauge does not indicate normally..................................................... 26
E-13 Indication of the power train temperature gauge is abnormal .............................................................. 27
E-14 The hydraulic oil temperature gauge does not indicate normally ......................................................... 27
E-15 Indication of the fuel gauge is abnormal............................................................................................... 28
E-16 Indications of gear speed and engine speed are abnormal.................................................................. 29
E-17 Indication of the shift mode service meter is abnormal ........................................................................ 29
E-18 The switch module cannot be operated................................................................................................ 30
E-19 The warning lamp does not flash or does not go out............................................................................ 31
E-20 The alarm buzzer does not sound or does not stop ............................................................................. 32
E-21 Auto shift down is not possible or is not released................................................................................. 33
E-22 Pivot turn is not possible or is not released .......................................................................................... 34
E-23 The alarm buzzer cannot be cancelled................................................................................................. 35
E-24 The operator mode cannot be operated ............................................................................................... 36
E-25 The service mode cannot be operated ................................................................................................. 38
E-26 The back-up alarm does not sound ...................................................................................................... 40
E-27 The night light, the headlamp, the working lamp and the rear lamp on the panel do not come on ...... 42
E-28 The air conditioner does not operate.................................................................................................... 48
E-29 KOMTRAX system does not operate normally..................................................................................... 54
D275AX-5E0
40 Troubleshooting
SEN01646-00
Information in troubleshooting table
a The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully.
Trouble
Related
information
Trouble which occurred in the machine

Information related to detected trouble or troubleshooting
Cause

<Contents of description>
Standard value in normal state to judge possible causes
Remarks on judgment
<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
V) circuit is in contact with power source (24 V) circuit.
Short circuit
Independent wiring harnesses are in contact with each
other abnormally.
2
Possible causes
and standard
value in normal
state
Possible causes of trouble

(Given numbers are refer<Precautions for troubleshooting>
ence numbers, which do
(1) Method of indicating connector No. and handling of Tnot indicate priority)
adapter
Insert or connect T-adapter as explained below for troubleshooting, 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", disconnect 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 (i
o): Roughly shows the location on the machine.
D275AX-5E0
SEN01646-00
40 Troubleshooting
E-1 The engine does not start

Trouble
Related
information
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.
If "the machine monitor does not come on" or "the battery relay does not cause operating sound"
when the starting switch is set to ON, the main electric power supply system is supposed to be out
of order. So, inspect the main electric power supply system.
Cause
1 Insufficient battery capacity

Battery voltage
Battery specific gravity
Min. 24 V
Min. 1.26
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON.
2
Defective starting switch

Key SW terminal
Switch position
Resistance
Between terminal
250 and terminal 280
OFF
Min. 1 Mz
START
Max. 1 z
a Prepare with the starting switch OFF, then start the engine and

If the engine starts in accordance with the engine starting arrange(Internal disconnection)
ment after the neutral safety relay (NSF) is replaced with another
one while the starting switch is set to OFF, the relay is defective.
a Prepare with the starting switch OFF, then turn the starting
switch ON and carry out troubleshooting.
Defective alternator (Internal
4
short-circuit)
Alternator
Voltage
Between Terminal R and ground
Max. 1 V
Possible causes
and standard
value in normal
state
Detective starting motor

(Internal defect)
Starting motor
Voltage
Electric power supply : between

Terminal ST/B and ground
20 30 V
Charge: between ST (2) and

ground
Max. 1 V
Starting: between ST (1) and

ground
20 30 V
When the voltages of electric power supply, for charging and starting are normal but the starting motor does not rotate, the starting
motor is defective.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between terminal 280 and
Resis6
Max. 1 z
or defective contact in con- NFS (female) (3)
tance
nector)
ResisMax. 1 z
and ST (female) (1)
tance
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)
STCN1 (female) (15) KOM1 (female) (28)
RSD (female) (2) with ground
8
Defective diode
Voltage
Max. 1 V
If diode CN-RSD is shorted, starting motor R terminal voltage is 20

30 V and the starting motor does not operate.
D275AX-5E0
40 Troubleshooting
SEN01646-00
Cause
Possible causes
and standard
value in normal
state
D275AX-5E0

circuit)
ST (female) (1) and ground
Resistance
Min. 1 Mz
Wiring harness between terminal 280 NSF

(female) (3) and ground
Resistance
Min. 1 Mz
SEN01646-00
40 Troubleshooting
D275AX-5E0
40 Troubleshooting
SEN01646-00
E-2 The preheater does not operate (Manual preheating function)

Trouble
Related
information
The preheater does not operate. (Manual preheating function)

a This troubleshooting describes the procedures to be followed when the manual preheating function cannot heat the electrical intake air heater mounting section. (When the preheating lamp only
does not come on, carry out the troubleshooting of "The preheating lamp does not come on.")
For preheating, both the "Automatic preheating function" and the "Manual preheating function" are
available. When either function is performed, the preheating lamp comes on.
If "the machine monitor does not come on" or "the battery relay does not cause operating sound"
hen the starting switch is turned ON, the main electric power supply system supposed to be out of
order. So, inspect the main electric power supply system.
Cause

2 Defective fuse (FS22-2)

3

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 defective.
Key SW terminal
Switch position
Resistance
Between terminal
250 and terminal 255
OFF
Min. 1 Mz
HEAT
Max. 1 z
If fuse is broken, circuit probably has ground fault etc.

(CB105H)

etc.
Defective preheater relay

Prepare with starting switch OFF, then turn it to HEAT and carry out
troubleshooting in each case.
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
and standard
value in normal
state
Defective heater relay (Inter5

nal defect)
Heater relay
Voltage
Electric power supply : between

Terminal HT/A (A) and ground
20 30 V
Signal : between Terminal HT

(C) and ground
20 30 V
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
6
heater (Internal defect)
Electrical intake air heater
Continuity
Between terminals
Continue
Wiring harness between FS22-2 output
PHR (female) (5)
Disconnection in wiring harness (Disconnection in wiring Wiring harness between PHR (female) (3)
7
or defective contact in con- and terminal 255 or terminal heater relay HT
nector)
Wiring harness between battery relay BRC
terminal or heater relay HVA terminal
Wiring harness between heater relay HT/B
terminal and electrical intake air heater
D275AX-5E0
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
SEN01646-00
40 Troubleshooting
Cause

Possible causes
and standard
value in normal
state

circuit)
Defective diode HTD (Internal short circuit)
Wiring harness between FS22-2 (outlet

side) PHR (female) (5) and ground
Resistance
Min. 1 Mz
Wiring harness between PHR (female) (3)

heater relay HT terminal and ground
Resistance
Min. 1 Mz
Wiring harness between heater relay HT

terminal HTD (female) (1) and ground
Resistance
Min. 1 Mz
If diode HTD is shorted, circuit has ground fault and heater does
not operate probably.
D275AX-5E0
40 Troubleshooting
SEN01646-00
D275AX-5E0
SEN01646-00
40 Troubleshooting
E-3 The ripper pin puller cylinder does not operate

Trouble
The ripper pin puller cylinder does not operate.
Related
information
Cause
Defective pin puller switch

short circuit)
Defective pin puller solenoid

short circuit)

When the fuse is blown, a ground fault may have possibly occurred
to the circuit.
263 (male)
Between (1) and (2)
Switch
Resistance
Pull
Max. 1 z
Press
Min. 1 Mz
PPL (male)
Resistance
Between (1) and (2)
10 80 z
Min. 1 Mz
Possible causes
and standard
value in normal
state
Disconnection of wiring harness (Disconnection in wiring

4
Wiring harness between FS22-2 outlet and

263 (female) (1)
Resistance
Max. 1 z
Wiring harness between 263 (female) (2)

and PPL (female) (1)
Resistance
Max. 1 z
Wiring harness between PPL (female) (2)

and ground
Resistance
Max. 1 z
Ground fault of wiring har5 ness (Contact with ground
circuit)
Between wiring harness between FS22-2

(outlet side) and 263 (female) and ground
Resistance
Min. 1 Mz
Between wiring harness between 263

(female) (2) and PPL (female) (1) and
ground
Resistance
Min. 1 Mz
switch ON and carry out troubleshooting. (Push on the switch)
10
Hot short circuit of wiring har- Between wiring harness between 263
6 ness (Contact with 24V cir- (female) (2) and PPL (female) (1) and
cuit)
ground
Voltage
Max. 1 V
Between wiring harness between PPL

(female) (2) and ground and ground
Voltage
Max. 1 V
D275AX-5E0
40 Troubleshooting
SEN01646-00
D275AX-5E0
11
SEN01646-00
40 Troubleshooting
E-4 The machine monitor does not come on at all when the starting
switch is turned ON
Trouble
Related
information
The machine monitor does not come on at all when the starting switch is turned ON.
When the starting switch is turned ON, the gear speed indicator, the multi information section, the
gauge section and the lamp section come on for 3 sec.
Cause
1

(CB2, CB6)

When the circuit breaker is cut off, the circuit may have possibly
been short-circuited with ground.
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON .

2
Possible causes
and standard
value in normal
state

(2) and CB2 outlet
Resistance
Max. 1 z

(4) and ground
Resistance
Max. 1 z

(6) and CB6 outlet
Resistance
Max. 1 z

and CB2 outlet
Resistance
Max. 1 z

and ground
Resistance
Max. 1 z
circuit)
Between wiring harness CB2 (outlet side)

and S03 (female) (2) and S01 (female) (1)
and ground
Resistance
Min. 1 Mz
Between wiring harness CB6 (outlet side)

and S03 (female) (5) (6) and ground
Resistance
Min. 1 Mz

(Gauge/lamp module)
S03
Voltage
Between (1), (2) and (3), (4)
20 30 V
S01
Voltage
Between (1) and (2)
20 30 V
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON and OFF.
5 CAN communication error
12
S03
Voltage
Between (5) (6) and (3) (4)
20 30 V
If failure code [DAFRKR] of CAN communication error is displayed, carry out troubleshooting for it.
D275AX-5E0
40 Troubleshooting
SEN01646-00
D275AX-5E0
13
SEN01646-00
40 Troubleshooting
E-5 When the starting switch is turned ON, the machine monitor
completely remains lighted and does not go out
Trouble
When the starting switch is turned ON, the machine monitor completely remains lighted and does
not go out.
Related
information
When the starting switch is turned ON, the gear speed indicator, the multi information section, the
gauge section and the lamp section come on for 3 sec. and go out.
Possible causes
and standard
value in normal
state
14
Cause
1

(Gauge/lamp module)

This internal defect cannot be diagnosed.
D275AX-5E0
40 Troubleshooting
SEN01646-00
E-6 When the starting switch is turned ON, the basic check items flash1
Trouble
Related
information
The radiator coolant level caution lamp flashes.

When any basic check items are detected to be abnormal before the engine starts, they will flash.
Cause
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 specified level.)
The radiator coolant level
2 sensor is defective.
WLV (male)
Between (1) and (2)
Possible causes
and standard
value in normal
state
Radiator coolant
level
Resistance
Normal level
Max. 1 z
Lower level
Min. 1 Mz
Disconnection of wiring harness (Disconnection in wiring Wiring harness between S03 (female) (11)
3
or defective contact in con- and WLV (female) (1)
nector)
Wiring harness between WLV (female) (2)
and ground
Resistance
Max. 1 z
Resistance
Max. 1 z
4

(Gauge/lamp module)
S03
Between (11) and
ground
Radiator coolant
level
Voltage
Normal level
Max. 1 V
Lower level
20 20 V
D275AX-5E0
15
SEN01646-00
40 Troubleshooting
E-7 While the engine is operating, any caution item flashes
Trouble (1)
The battery charge level caution lamp flashes.
Related
information
When any abnormality is detected during engine operation, the relevant caution item will flash.
Cause
Possible causes
and standard
value in normal
state
Alternator
Engine speed
Voltage
Between Terminal R
and ground
Min. medium speed

(half)
20 30 V
Disconnection of wiring har- a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON.
2
or defective contact in con- Wiring harness between S04 (female) (9)
ResisMax. 1 z
nector)
and alternator R terminal
tance
circuit)
16
Defective alternator (Insufficient power generation)


(Gauge/lamp module)
Between wiring harness between S04

(female) (9) and alternator R terminal, or
starting motor R terminal or STCN1 (female)
(5) or TMCN1 (female) (15) or KOM1
Resistance
Min. 1 Mz
S04
Engine speed
Voltage
Between (9) and

ground
Min. medium speed

(half)
20 30 V
D275AX-5E0
40 Troubleshooting
SEN01646-00
D275AX-5E0
17
SEN01646-00
40 Troubleshooting
Trouble (2)
The air cleaner clogging caution lamp flashes. (If equipped spec.)
Related
information
If abnormality is detected while the engine is running, the caution item lamp flashes.
Cause
Possible causes
and standard
value in normal
state
1 Clogged air cleaner
Clean or replace the air cleaner.
Disconnection in wiring
harness (Disconnection in
2
wiring harness or defective
contact in connector)
and AF1 (female) (1)
Resistance
Max. 1 z

(Contact with ground circuit) (female) (13) and AF1 (female) (1) and chassis ground
Resistance
Min. 1 Mz

4

(gauge, lamp module)
S03
Air cleaner
Voltage
Between (13) and

chassis ground
When normal
Max. 1 V
When clogged
20 30 V
18
D275AX-5E0
40 Troubleshooting
SEN01646-00
E-8 While the engine is operating, the emergency warning item flashes1
Trouble (1)
The engine oil pressure caution lamp flashes.
Related
information
If abnormality is detected while the engine is running, the emergency calculation item flashes and
the caution buzzer sounds.
Engine oil pressure is checked by engine controller.
Cause
Possible causes
and standard
value in normal
state
Check the engine oil pressure, as the drop of engine oil pressure is
Reduction of engine oil presdetected.
sure
Carry out the engine troubleshooting of "S-12 Oil pressure drops."
Defective engine hydraulic

2
system
If no problem is found in cause 1, the engine oil pressure sensor circuit can be suspected to be defective. So, carry out the troubleshooting of "Failure codes [CA135] and [CA141] Abnormal engine
oil pressure sensor."
Since this is an internal defect, it cannot be diagnosed.
D275AX-5E0
19
SEN01646-00
40 Troubleshooting
Trouble (2)
The engine coolant temperature caution lamp flashes.
Related
information
When any abnormality is detected during engine operation, the relevant emergency warning item
will sound the alarm buzzer.
The engine coolant temperature caution lamp flashes or goes out as it links with indication on the
engine coolant temperature gauge.
Failure code [B@BCNS] may be displayed, too.
Engine coolant temperature is checked by engine controller.
Cause
Overheated engine coolant
1
temperature

As overheated engine coolant was detected, check the engine
coolant temperature. (When the coolant temperature is over
102C, the lamp flashes. When the coolant temperature is over
105C, the lamp flashes and the buzzer sounds.)
Check the indication on the engine coolant temperature gauge. If
the indication is abnormal, carry out the troubleshooting of "Indication on the engine coolant temperature gauge is abnormal."
a Coolant temperatures are guides for
selecting indications.
Possible causes
and standard
value in normal
state
The engine coolant temperature sensor system is defec- Coolant temperature

2
gauge
tive. (Engine controller
system)
Coolant temperature
lamp
20

(Gauge/lamp module)
White range/
Green range
Red range
Goes out
Flashes
When Causes 1 and 2 are not applicable, the machine monitor is

supposed to be defective. (This is an internal defect, which cannot
be troubleshot.)
D275AX-5E0
40 Troubleshooting
SEN01646-00
Trouble (3)
The power train oil temperature caution lamp flashes.
Related
information
The power train oil temperature caution lamp flashes or goes out as it links with indication on the
power train oil temperature gauge.
Failure code [B@CENS] may be displayed, too.
Cause
1
Overheated oil temperature

of power train

As an overheated power train oil temperature was detected, check
the power train oil temperature. (When the oil temperature is over
120C, the lamp flashes. When the oil temperature is over 130C,
the lamp flashes and the buzzer sounds.)
Check the indication on the power train oil temperature gauge. If
the indication is abnormal, carry out the troubleshooting of "Indication on the power train oil temperature gauge is abnormal."
a Oil temperatures are guides for selecting indications.
Possible causes
and standard
value in normal
state
The power train oil temperature sensor system is defec2

tive. (Machine monitor
system)
Oil temperature
gauge
Oil temperature lamp
D275AX-5E0

(Gauge/lamp module)
White range/
Green range
Red range
Goes out
Flashes

be troubleshot.)
21
SEN01646-00
40 Troubleshooting
Trouble (4)
The hydraulic oil temperature caution lamp flashes.
Related
information
The hydraulic oil temperature caution lamp flashes or goes out as it links with indication on the
hydraulic oil temperature gauge.
Failure code [B@HANS] may be displayed, too.
Cause
Overheated hydraulic oil

temperature
As an overheated hydraulic oil temperature was detected, check

the hydraulic oil temperature. (When the oil temperature is over
100C, the lamp flashes. When the oil temperature is over 110C,
the lamp flashes and the buzzer sounds.)
Check the indication on the engine coolant temperature gauge. If
the indication is abnormal, carry out the troubleshooting of "Indication on the hydraulic oil temperature gauge is abnormal."
a Oil temperatures are guides for selecting indications.
Possible causes
and standard
value in normal
state
The hydraulic oil temperature

2 sensor system is defective.
Oil temperature
gauge
Oil temperature lamp
22

(Gauge/lamp module)
White range/
Green range
Red range
Goes out
Flashes

be troubleshot.)
D275AX-5E0
40 Troubleshooting
SEN01646-00
Trouble (5)
The HSS charge pressure caution lamp flashes.
Related
information
Failure code [B@CHZG] may be displayed, too.
Cause
1
Drop of HSS charge pressure

Check the HSS charge pressure as the drop of HSS charge pressure is detected.
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the switch ON or after starting the
engine.
The HSS charge oil pressure

2 switch is defective.
406 (male)
Between (1) and (2)

Possible causes
and standard
value in normal
state

circuit)
HSS charge pressure
Resistance
Less than 0.8 MPa

{Less than 8 kg/cm2}
Min. 1 Mz
Min. 1.4 MPa

{Min. 14 kg/cm2}
Max. 1 z
and 406 (female) (1) and ground.
Resistance
Min. 1 Mz
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the switch ON or after starting the
engine.
4

(Gauge/lamp module)
S03
Between (15) and
ground
HSS charge pressure
Voltage
Less than 0.8 MPa

{Less than 8 kg/cm2}
20 30 V
Min. 1.4 MPa

{Min. 14 kg/cm2}
Max. 1 V
D275AX-5E0
23
SEN01646-00
40 Troubleshooting
E-9 While the preheater is operating, the preheating pilot lamp does not
come on
1
Trouble
Related
information
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 troubleshooting of "The electrical intake air heater does not work.")
For preheating, both the "Automatic preheating function" and the "Manual preheating function" are
available. Even when either function is performed, the preheating lamp comes on.
Cause
Disconnection of wiring har- a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON.
1
ResisMax. 1 z
nector)
and heater relay HT terminal
tance
Possible causes
and standard
value in normal
state

circuit)
(female) (9) and heater relay HT terminal
and ground
Resistance
Min. 1 Mz
3
24
Defective machine monitorl

(Gauge/lamp module)
S03
Starting switch
Voltage
Between (9) and

ground
ON
Max. 1V
HEAT
20 30 V
D275AX-5E0
40 Troubleshooting
SEN01646-00
D275AX-5E0
25
SEN01646-00
40 Troubleshooting
E-10 At the selecting time of dual tilt, the dual/single tilt selector lamp
does not come on (Dual tilt-mounted machine)
1
Trouble
Related
information
Possible causes
and standard
value in normal
state
At the selecting time of dual tilt, the dual/single tilt selector lamp does not come on. (Dual tiltmounted machine)
Before troubleshooting the blade, make sure that the dual tilt can operate. (When the blade does
not operate normally, the electrical system on the machine side or the hydraulic/mechanical system
is supposed to be out of order. So, troubleshoot the relevant system.)
Cause
1

(Gauge/lamp module)

This is an internal defect, which cannot be troubleshot.
E-11 At the locking-up of the torque converter, the torque converter

lock-up display lamp does not come on
Trouble
Related
information
Possible causes
and standard
value in normal
state
At the locking-up of the torque converter, the torque converter lock-up display lamp does not come
on.
Before troubleshooting the torque converter, make sure that the lock-up is operating. (When the
lock-up does not operate normally, the electrical system on the machine side or the hydraulic/
mechanical system is supposed to be out of order. So, troubleshoot the relevant system.)
Cause
1

(Gauge/lamp module)

E-12 The engine coolant temperature gauge does not indicate normally 1
Trouble (1)
The engine coolant temperature gauge does not indicate normally.
Related
information
Information of the engine coolant temperature sensor are received from the engine controller
through communication.
When any abnormality occurred in the engine coolant temperature sensor system, the failure code
[CA144], [CA145] are displayed sometimes.
Cause
Possible causes
and standard
value in normal
state
26

temperature sensor system
If failure code [CA144] or [CA145] is displayed, carry out troubleshooting for it.
Engine controller CAN com- If failure code [DB2RKR] is displayed, carry out troubleshooting for
munication error
it.

4
(Gauge/lamp module)
D275AX-5E0
40 Troubleshooting
SEN01646-00
E-13 Indication of the power train temperature gauge is abnormal

Trouble
Indication of the power train temperature gauge is abnormal.
Related
information
If power train oil temperature sensor system is abnormal, failure code [DGT1KX] or [DGT1KA] may
be displayed.
Possible causes
and standard
value in normal
state
Defective power train oil tem- If failure code [DGT1KX] or [DGT1KA] is displayed, carry out trou1
perature sensor system
bleshooting for it.
Cause
E-14 The hydraulic oil temperature gauge does not indicate normally 1
Trouble
Related
information
The hydraulic oil temperature gauge does not indicate normally.

Signals of the hydraulic oil temperature sensor are received from the transmission controller
through communication.
When any abnormality occurred in the hydraulic oil temperature sensor system, the failure code
[DGS1KX] is displayed sometimes.
Cause
Possible causes
and standard
value in normal
state
D275AX-5E0
Defective hydraulic oil temperature sensor system
If failure code [DGS1KX] is displayed, carry out troubleshooting for

it.
Transmission controller CAN If failure code [DAQRKR] is displayed, carry out troubleshooting
communication error
for it.

(Gauge/lamp module)
27
SEN01646-00
40 Troubleshooting
E-15 Indication of the fuel gauge is abnormal

Trouble
Indication of the fuel gauge is abnormal.
Related
information
Cause
Defective fuel level sensor.
short circuit)

FLV (male)
Remained fuel level
Resistance
Between (1) and (2)

(ground)
Full
About 4 z
Empty
About 85 z
Possible causes
and standard
value in normal
state
2
or defective contact in con- and FLV (female) (1)
nector)
Wiring harness between FLV (female) (2)
and ground
circuit)
Resistance
Max. 1 z
Resistance
Max. 1 z
(female) (10) and FLV (female) (1) and
ground
Resistance
Min. 1 Mz
Hot short circuit of wiring har4 ness (Contact with 24V cir- Between wiring harness between S04
cuit)
(female) (10) and FLV (female) (1) and
Voltage Max. 1 V
ground
5

(Gauge/lamp module)
S04 (female)
Remained fuel level
Resistance
Between (10) and

ground
Full
About 4 z
Empty
About 85 z
28
D275AX-5E0
40 Troubleshooting
SEN01646-00
E-16 Indications of gear speed and engine speed are abnormal

Trouble
Related
information
Indications of gear speed and engine speed are abnormal.

Signals of gear speed and engine speed are received from the transmission controller and the
engine controller through communication.
Cause
Possible causes
and standard
value in normal
state

1
(Gauge/lamp module)
Engine controller or travel

2 controller CAN communication error
If failure code [DB2RKR] or [DAQRKR] is displayed, carry out troubleshooting for it.
E-17 Indication of the shift mode service meter is abnormal

Trouble (1)
During engine operation, the service meter does not advance.
Related
information
The service meter measures time according to engine drive signals (alternator voltage).
Possible causes
and standard
value in normal
state
Trouble (2)
Cause
1 Defective alternator system
When the battery charge level caution lamp flashes during engine
operation, carry out the troubleshooting of "While the engine is
operating, caution items flash."

(Gauge/lamp module)
Shift mode and service meter are not displayed at all.
Related
information
Possible causes
and standard
value in normal
state
D275AX-5E0
Cause
1

(Gauge/lamp module)

29
SEN01646-00
40 Troubleshooting
E-18 The switch module cannot be operated

Trouble (1)
Though the switch is used, lamps do not change.
Related
information
Possible causes
and standard
value in normal
state
Cause
1

(Switch module)

Trouble (2)
Though the switch is used, the system setting does not change.
Related
information
Switch module signals are transmitted to each controller through communication.

Cause
Possible causes
and standard
value in normal
state
a Prepare with the starting switch OFF, then carry out troubleDisconnection of wiring harshooting without turning the starting switch ON.
1
Resisand STCN2 (female) (21), or TMCN2
Max. 1 z
nector)
tance
(female) (21)

(Switch module)
carry out the troubleshooting.
S01
Voltage
69V
30
D275AX-5E0
40 Troubleshooting
SEN01646-00
E-19 The warning lamp does not flash or does not go out
Trouble
The warning lamp does not flash or does not go out.
Related
information
Possible causes
and standard
value in normal
state
D275AX-5E0
Cause
1

(Gauge/lamp module)

31
SEN01646-00
40 Troubleshooting
E-20 The alarm buzzer does not sound or does not stop
Trouble
Related
information
The alarm buzzer does not sound or does not stop.

When a short circuit occurs in the alarm buzzer system, the failure code is displayed but no other
failure codes are displayed.
Cause
1
(CB2)
Defective alarm buzzer
short circuit)
Possible causes
and standard
value in normal
state

When the circuit breaker is cut off, a ground fault may have possibly occurred in the circuit.
217 (male)
Resistance
Between (1) and (2)
200 z
Min. 1 Mz
Resis3
Max. 1 z
or defective contact in con- and 217 (female) (1)
tance
nector)
Wiring harness between 217 (female) (2)
ResisMax. 1 z
and CB2 outlet
tance
circuit)
Between wiring harness related to CB2 (outlet side) and ground
Resistance
Min. 1 Mz
5

(Gauge/lamp module)
S03
Between (18) and
ground
Alarm buzzer
Voltage
At stop
20 30 V
At operation
(sounding)
Max. 3 V
32
D275AX-5E0
40 Troubleshooting
SEN01646-00
E-21 Auto shift down is not possible or is not released

Trouble
Auto shift down is not possible or is not released.
Related
information
Cause

Defective auto shift down

1 switch (Internal disconnection or short circuit)
ASD (male)
Between (2) and (3)
Auto shift down

switch
Resistance
OFF (0)
Min. 1 Mz
ON (1)
Max. 1 z
Possible causes
and standard
value in normal
state
Disconnection of wiring harness (Disconnection in wiring Wiring harness between TMCN3 (female)
2
or defective contact in con- (39) and ASD (female) (3)
nector)
Wiring harness between ASD (female) (2)
and ground
circuit)
Resistance
Max. 1 z
Resistance
Max. 1 z
(female) (39) and ASD (female) (3) and
ground
Resistance
Min. 1 Mz
Defective transmission control system
If causes 1 4 are not detected, transmission control system may

have another defect.
D275AX-5E0
33
SEN01646-00
40 Troubleshooting
E-22 Pivot turn is not possible or is not released

Trouble
Pivot turn is not possible or is not released.
Related
information
Cause
Defective pivot turn switch
short circuit)

FTU (male)
Between (2) and (3)
Pivot turn switch
Resistance
OFF (0)
Min. 1 Mz
ON (1)
Max. 1 z
Possible causes
and standard
value in normal
state
Disconnection of wiring harness (Disconnection in wiring Wiring harness between STCN2 (female)
2
or defective contact in con- (13) and FTU (female) (3)
nector)
Wiring harness between FTU (female) (2)
and ground
circuit)
Resistance
Max. 1 z
Resistance
Max. 1 z
Between wiring harness between STCN2
(female) (13) and FTU (female) (3) and
ground
Resistance
Min. 1 Mz
4 Defective steering controller This is an internal defect, which cannot be troubleshot.

5
Defective steering control

system
If causes 1 4 are not detected, steering control system may have

another defect.
34
D275AX-5E0
40 Troubleshooting
SEN01646-00
E-23 The alarm buzzer cannot be cancelled

Trouble
Related
information
The alarm buzzer cannot be cancelled.

Cancel signal is sent from steering controller to machine monitor through communication system.
Cause

Defective buzzer cancel

1 switch (Internal disconnection or short circuit)
BUZ (male)
Between (1) and (2)
Between (1) and (3)
Resistance
OFF (0)
Min. 1 Mz
Max. 1 z
OFF (0)
Min. 1 Mz
Max. 1 z
Possible causes
and standard
value in normal
state
Disconnection of wiring harness (Disconnection in

2
wiring or defective contact in
connector)

(36) and BUZ (female) (2)
Resistance
Max. 1 z

(26) and BUZ (female) (3)
Resistance
Max. 1 z
Wiring harness between BUZ (female) (1)

and ground
Resistance
Max. 1 z
circuit)
Machine monitor CAN communication error

(female) (36) and BUZ (female) (2) and
ground
Resistance
Min. 1 Mz

(female) (26) and BUZ (female) (3) and
ground
Resistance
Min. 1 Mz
If failure code [DAFRKR] is displayed, carry out troubleshooting for

it.
D275AX-5E0
35
SEN01646-00
40 Troubleshooting
E-24 The operator mode cannot be operated

Trouble
The operator mode cannot be operated.
Related
information
Cause

switch system
Since the buzzer cancel switch system is supposed to be out of

order, carry out the troubleshooting of "The alarm buzzer cannot be
cancelled."
Defective information switch

2 (Internal short circuit or disconnection)
CUR (male)
Between (1) and (2)
Between (1) and (3)
Possible causes
and standard
value in normal
state
Information switch
Resistance
OFF (0)
Min. 1 Mz
<
Max. 1 z
OFF (0)
Min. 1 Mz
>
Max. 1 z
3

(16) and CUR (female) (2)
Resistance
Max. 1 z

(6) and CUR (female) (3)
Resistance
Max. 1 z
Wiring harness between CUR (female) (1)

and ground
Resistance
Max. 1 z
circuit)

(female) (16) and CUR (female) (2) and
ground
Resistance
Min. 1 Mz

(female) (6) and CUR (female) (3) and
ground
Resistance
Min. 1 Mz
36
D275AX-5E0
40 Troubleshooting
SEN01646-00
D275AX-5E0
37
SEN01646-00
40 Troubleshooting
E-25 The service mode cannot be operated

Trouble
The service mode cannot be operated.
Related
information
Cause

switch system
Since the buzzer cancel switch system is supposed to be out of

order, carry out the troubleshooting of "The alarm buzzer cannot be
cancelled."
Since the information switch system is supposed to be out of order,

Defective information switch
carry out the troubleshooting of "The operator mode cannot be
system
cancelled."

(CB6)
Defective service switch

4 (Internal short circuit or disconnection)
S24
Service switch
Resistance
Between (2) and (3),

Between (5) and (6)
OFF
Min. 1 Mz
ON
Max. 1 z
Wiring harness between CB6 outlet and
S24 (3)
Possible causes
and standard
value in normal
state

5
Wiring harness between S24 (6) and ground
and S24 (2)
(6) and S24 (5)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z

circuit)
Between wiring harness between CB6 (outlet) S24 (3) with ground
Resistance
Min. 1 Mz
Between wiring harness between S24 (6)

ground with ground
Resistance
Min. 1 Mz

(female) (16) S24 (2) ground with ground
Resistance
Min. 1 Mz

(female) (6) S24 (5) ground with ground
Resistance
Min. 1 Mz
7

(Gauge/lamp module)
S03
Service switch
Voltage
Between (16) and

ground
OFF
Max. 1 V
ON
20 30 V
38
D275AX-5E0
40 Troubleshooting
SEN01646-00
D275AX-5E0
39
SEN01646-00
40 Troubleshooting
E-26 The back-up alarm does not sound

Trouble
Related
information
The back-up alarm does not sound.

When a failure occurs on the primary side (coil side) of the back-up alarm relay, a relevant failure
code is displayed, but in case of failure on the secondary side (contact side), no failure code is displayed.
Cause

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
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.
Possible causes
and standard
value in normal
state

3

BKA (female) (1), (3)
Resistance
Max. 1 z
Wiring harness between BKA (female) (5)

and BKAL (female) (1)
Resistance
Max. 1 z
Wiring harness between BKAL (female) (2)

and ground
Resistance
Max. 1 z

(8) and BKA (female) (2)
Resistance
Max. 1 z
circuit)
40

(Internal defect)

(outlet side) and BKA (female) (1), (3) and
ground
Resistance
Min. 1 Mz
Between wiring harness between BKA

(female) (5) and BKAL (female) (1) and
ground
Resistance
Min. 1 Mz
When Causes 1 to 4 are not applicable, the back-up alarm is supposed to be defective.
D275AX-5E0
40 Troubleshooting
SEN01646-00
D275AX-5E0
41
SEN01646-00
40 Troubleshooting
E-27 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
information
Headlamp and working lamp are operated with 1 switch.

If headlamp switch is operated, panel lighting is changed for night.
Cause

1 Defective circuit breaker CB5
etc.
Defective headlamp and
2 working lamp switch (International disconnection)
FWL (male)
Between (2) and (3)
Switch
Resistance
OFF
Min. 1 Mz
ON
Max. 1 z
Wiring harness between FWL (female) (3)
and CB5 outlet
Possible causes
and standard
value in normal
state
Max. 1 z
Disconnection of wiring harness (Disconnection in wiring Wiring harness between FWL (female) (2)
3
or defective contact in con- and LMFL (female) (1) and LMFR (female)
(1) and LMW (female) (1) and S01 (female)
nector)
(10) or S03 (female) (8)
Resistance
Resistance
Max. 1 z
Wiring harness between LMFL (female) (2)

and LMFR (female) (2) or LMW (female) (2)
and ground
Resistance
Max. 1 z

circuit)
42

CB5 outlet and ground
Resistance
Min. 1 Mz

LMFL (female) (1), LMFR (female) (1), LMW
(female) (1), S01 (female) (10) or S03
Resistance
Min. 1 Mz
Wiring harness between LMFL (female) (2),

LMFR (female) (2), or LMW (female) (2)
ground and ground
Resistance
Min. 1 Mz
D275AX-5E0
40 Troubleshooting
SEN01646-00
Trouble (2)
Only the night light on the panel does not comes on. (Whole or part)
Related
information
If headlamp switch is operated, panel lighting is changed for night.

Cause
1
Defective night lamp (S02)

(Blown)

The night lamp is supposed to be defective. Check if the bulb is
blown.
and FWL (female) (2)
Resistance
Max. 1 z

and ground
Resistance
Max. 1 z
2
or defective contact in con- and CB2 (outlet)
nector)
and ground
Resistance
Max. 1 z
Resistance
Max. 1 z

Resistance
Max. 1 z

(4) and ground
Resistance
Max. 1 z
Possible causes
and standard
value in normal
state
circuit)

Resistance
Min. 1 Mz

and CB2 (outlet)
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
4

(Switch module)
Between S01 (10)

and (2)
Between S02 (1) and
(2)

5
(Gauge/lamp module)
D275AX-5E0
Light switch ON
20 30 V
Between S03 (8) and
(3), (4)
Light switch ON
20 30 V
43
SEN01646-00
Trouble (3)
40 Troubleshooting
Only the headlamp does not comes on. (Both right and left, or one side only)
Related
information
Cause
1 Defective headlamp (Blown)
2

(CB5)

The headlamp is supposed to be defective. Check if the bulb is
blown.
Defective headlamp relay

When the relay is replace with another relay while the starting
switch is set to OFF and the headlamp comes on after the starting
switch is turned ON and the light switch is turned ON, the headlamp relay (LMFL, LMFR) are defective.
LMFL (female) (3) and LMFR (female) (3)
Possible causes
and standard
value in normal
state
Resistance
Max. 1 z
Disconnection of wiring harWiring harness between LMFL (female) (5)

4
LHDL (female) (1) and LMFR (female) (5)
or defective contact in con LHDR (female) (1)
nector)
ground
Resistance
Max. 1 z
Resistance
Max. 1 z
Wiring harness between LMFR (female) (2)

ground
Resistance
Max. 1 z
circuit)
Between wiring harness between CB5 (outlet side) and LMFL (female) (3) and LMFR
Resistance
Min. 1 Mz

LHDL (female) (1) and LMFR (female) (5)
LHDR (female) (1) and ground
Resistance
Min. 1 Mz
6
44

Between wiring harness between LMFL

Voltage
Max. 1 V
Between wiring harness between LMFR

Voltage
Max. 1 V
D275AX-5E0
40 Troubleshooting
Trouble (4)
SEN01646-00
Only the working lamp does not comes on. (Both right and left, or one side only)
Related
information
Cause
Defective working lamp

(Blown)
The working lamp is supposed to be defective. Check if the bulb is

blown.

Defective working lamp relay When the relay is replace with another relay while the starting
switch is set to OFF and the headlamp comes on after the starting
switch is turned ON and the light switch is turned ON, the working
lamp relay (LMW) is defective.
Possible causes
and standard
value in normal
state

4

LMW (female) (3)
Resistance
Max. 1 z
Wiring harness between LMW (female) (5)

and LMKL (female) (1) or 242 (female) (1)
Resistance
Max. 1 z
Wiring harness between LMW (female) (2)

and ground
Resistance
Max. 1 z
circuit)

6
D275AX-5E0

(outlet side) LMW (female) (3) and ground
Resistance
Min. 1 Mz
Between wiring harness between LMW

(female) (5) and LMKL (female) (1) or 242
Resistance
Min. 1 Mz
Between wiring harness between LMW
Voltage
Max. 1 V
45
SEN01646-00
Trouble (5)
40 Troubleshooting
Only the rear lamp does not comes on. (Both right and left, or one side only)
Related
information
Cause
1 Defective rear lamp (Blown)
The working lamp is supposed to be defective. Check if the bulb is

blown.

Defective rear lamp switch

(International disconnection)
RWL (male)
Between (2) and (3)
Possible causes
and standard
value in normal
state
Switch
Resistance
OFF
Min. 1 Mz
ON
Max. 1 z
Disconnection of wiring harness (Disconnection in wiring Wiring harness between RWL (female) (2)
Resis4
Max. 1 z
or defective contact in con- and FS22-5 (outlet side)
tance
nector)
Wiring harness between RWL (female) (3)
ResisMax. 1 z
and LRER (female) (1) or LREL (female) (1)
tance
circuit)
46

(outlet side) - RWL (female) (2) and ground
Resistance
Min. 1 Mz
Between wiring harness between RWL

(female) (3) - LRER (female) (1) and LREL
Resistance
Min. 1 Mz
D275AX-5E0
40 Troubleshooting
SEN01646-00
D275AX-5E0
47
SEN01646-00
40 Troubleshooting
E-28 The air conditioner does not operate

Trouble (1)
No air flow
Related
information
Cause
1
(CB4)
Defective blower main relay
2
(coil side)
Defective blower main relay

(contact side)
Defective blower Hi relay

4
(coil side)
Possible causes
and standard
value in normal
state
Defective blower Hi relay

(contact side)
Defective blower Mi relay

6
(coil side)
Defective blower Mi relay

(contact side)
8 Defective blower motor

CN-R1 (male)
Resistance
Between (1) and (2)
240 40 z
CN-R1
Voltage
Between (6C) and ground
20 30 V
CN-R2 (male)
Resistance
Between (1) and (2)
240 40 z
The relay is in order when the motor rotates after the starting
switch is turned ON and the blower Hi switch is turned ON.
CN-R3 (male)
Resistance
Between (1) and (2)
240 40 z
The relay is in order when the motor rotates after the starting
switch is turned ON and the blower Mi switch is turned ON.
The motor is in order when it rotates after the starting switch is
turned ON and the blower Lo switch is turned ON.

9
48
Wiring harness between CN-R3 (female)

(0B), CN-AC1 (female) (0C), CN-R (female)
(0D) or CN-R2 (female) (0E) and ground
Resistance
Max. 1 z
Wiring harness between CN-B(female)

(10A) and CN-R1 (female) (10B)
Resistance
Max. 1 z
Wiring harness between CN-B (female)

(11A) and CN-R2 (female) (11B) or CN-R
(female) (11C)
Resistance
Max. 1 z

CN-AC1 (female) (13C), CN-R1 (female)
(13D), CN-R2 (female) (13E) or CN-R3
(female) (13H)
Resistance
Max. 1 z

(14A) and CN-AC1 (female) (14B)
Resistance
Max. 1 z
D275AX-5E0
40 Troubleshooting
SEN01646-00
Cause

Possible causes
and standard
value in normal
state
Disconnection of wiring harness (Disconnection in wiring Wiring harness between CN-R3 (female)
9
or defective contact in con- (17A) and CN-AC1 (female) (17B)
nector)
10 Defective control panel
Resistance
Max. 1 z
Resistance
Max. 1 z
When Causes 1 to 9 are not applicable, the control panel is supposed 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."
D275AX-5E0
49
SEN01646-00
Trouble (2)
40 Troubleshooting
Cooling is not possible.
Related
information
Cause

1 Defective pressure switch
CN-P
Blower switch
Voltage
Between (26A) and

ground
ON
20 30 V
Defective compressor clutch
2
relay (coil side)
CN-R4 (male)
Resistance
Between (1) and (2)
Defective compressor clutch
3
relay (contact side)
Defective condenser relay

(contact side)
5 Defective thermistor
Possible causes
and standard
value in normal
state
Defective condenser blower

resistor
240 40 z
CN-R4
Voltage
Between (9B) and ground
20 30 V
CN-R5
Voltage
Between (7B) and ground
20 30 V
CN-AC1 (male)
Resistance
Between (15B) and (16C)
Max. 3,500 z
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
Defective compressor magnet clutch
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.
The compressor magnet clutch is supposed to be out of order, so
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.
CN-R5 (female) (6B) or CN-R4 (female)
(6D)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z

CN-R4 (female) (13I)
Resistance
Max. 1 z
Wiring harness between CN-T (female)

Resistance
Max. 1 z
Disconnection of wiring har- Wiring harness between CN-R5 (female)

ness (Disconnection in wiring (7B) and ARC (female) (2)
10
or defective contact in conWiring harness between CN-R4 (female)
nector)
(9B) and 351 (female) (1)
50
D275AX-5E0
40 Troubleshooting
SEN01646-00
Cause

Disconnection of wiring harPossible causes

and standard 10
or defective contact in convalue in normal
nector)
state
11 Defective control panel
D275AX-5E0
Wiring harness between CN-P (female)

(19A) and CN-R4 (female) (19C)
Resistance
Max. 1 z
Wiring harness between CN-P (female)

Resistance
Max. 1 z
Wiring harness between ARC (female) (1)

and ground
Resistance
Max. 1 z
When Causes 1 to 10 are not applicable, the control panel is supposed to be defective.
51
SEN01646-00
40 Troubleshooting
52
D275AX-5E0
SEN01646-00
40 Troubleshooting
E-29 KOMTRAX system does not operate normally

Trouble
Related
information
KOMTRAX system does not operate normally.

If KOMTRAX system administrator makes request for checking system on machine side for trouble,
carry out following troubleshooting.
Even if KOMTRAX system has trouble, it does not particularly appear on machine.
Cause

a Turn starting switch OFF, then carry out troubleshooting.
1 Defective power supply
LED (1)
Normal state
LED-A1
ON
KOM1
Signal
Voltage
Between (39), (40)

(37), (38)
Constant
power supply
20 30 V
a Turn starting switch ON and carry out troubleshooting.

2 Defective GPS
LED (2)
Normal state
LED-A2
ON
a Start engine and carry out troubleshooting.

3 ACC signal and alternator R
signal
Possible causes
and standard
value in normal
state
LED (6)
Normal state
LED-C1
ON
KOM1
Signal
Voltage
Between (36)
(37), (38)
Starting switch ACC
20 30 V
Between (28)
(37), (38)
Alternator R
20 30 V
Defective starting switch C

signal
LED (8)
Normal state
LED-C3
ON

KOM1
Signal
Voltage
Between (27)
(37), (38)
Starting switch C
Max. 1 V
5 State of CAN connection
54
Number of mails not transmitted yet
LED (9)
Normal state
LED-C4
ON
a Prepare with starting switch OFF and carry out trouble-shooting.

KOM1
Signal
Resistance
Between (7) (8)
CAN
40 80 z

LED (12)
Normal state
7-segment
09
D275AX-5E0
40 Troubleshooting
SEN01646-00
Cause
Possible causes
and standard
value in normal
state
7 State of positioning with GPS
LED display unit
D275AX-5E0

a Turn starting switch ON and carry out troubleshooting (See *)
LED (13)
Normal state
Dot
ON
* In an outdoor location within radio waves' penetration range, it

sometimes takes more than a minute from turning on of the starting
switch to completion of the positioning.
KOM1 connector
55
SEN01646-00
40 Troubleshooting
56
D275AX-5E0
SEN01647-00
BULLDOZER
1SHOP MANUAL
D275AX-5E0
Machine model
Serial number
D275AX-5E0
30001 and up
40 Troubleshooting
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 Machine does not turn (Not turned rightward or leftward) ........................................................................ 9
H-7 Steering speed or power is low .............................................................................................................. 10
H-8 Brake does not work ...............................................................................................................................11
H-9 Torque converter does not lock-up......................................................................................................... 12
H-10 Overheat of power train oil temperature............................................................................................... 13
H-11 Abnormal sound around HSS pump or HSS motor .............................................................................. 14
H-12 All work equipment speeds are slow.................................................................................................... 15
H-13 Work equipment does not move .......................................................................................................... 16
D275AX-5E0
SEN01647-00
40 Troubleshooting
H-14 Blade lift speed is slow or lacks power................................................................................................. 17

H-15 Blade tilt speed is slow or lacks power................................................................................................. 18
H-16 Ripper lift speed is slow or lacks power ............................................................................................... 19
H-17 Ripper tilt speed is slow or lacks power ............................................................................................... 20
H-18 Excessive hydraulic drift of blade lift .................................................................................................... 21
H-19 Excessive hydraulic drift of blade tilt .................................................................................................... 22
H-20 Excessive hydraulic drift of ripper lift .................................................................................................... 23
H-21 Ripper pin puller cylinder does not work (Giant ripper attachment machine) ....................................... 24
H-22 Blade pitch does not work (Dual tilt attachment machine) ................................................................... 25
H-23 Abnormal sound comes out from around work equipment pump......................................................... 26
H-24 Fan speed is abnormal (Sound and/or vibration of fan are/is abnormally large or engine overheats). 27
D275AX-5E0
40 Troubleshooting
SEN01647-00
Information in troubleshooting table
a The following information is summarized in the troubleshooting table. Before carrying out troubleshooting, understand that information fully.
Trouble
Related
information
Trouble which occurred in the machine

Information related to detected trouble or troubleshooting
Cause
Possible causes
and standard
value in normal
state
Possible causes of trouble

<Contents of description>
(Given numbers are refer Standard value in normal state to judge possible causes
ence numbers, which do
Remarks on judgment
not indicate priority)
D275AX-5E0
SEN01647-00
40 Troubleshooting
H-1 No travel power (No drawbar pull)

Trouble
Related
information
No travel power. (No drawbar pull)

Confirm that the oil quantity on the power train is normal before troubleshooting.
Cause

a Prepare with starting switch OFF, then drive the engine in high
idle mode for troubleshooting.
Defective engine or transmission
2 Defective power train pump
Number of engine rotations
F3 stall
1,510 rpm
Stall in F3 + Relief of work equipment system (Pitch back)
1,450 rpm
The power train pump is assumed to be defective; directly check it.

Internally defective torque

converter
PCCS lever
Original pressure of
torque converter
Torque converter
delivery pressure
Full neutral
0.49 1.0 MPa

{5 10 kg/cm2}
0.49 0.1 MPa

{5 1 kg/cm2}
Possible causes
and standard
value in normal
state
Defective set pressure of

4 transmission main relief
valve and internal defect
PCCS lever
Transmission main relief

pressure
Full neutral
Min. 2.94 MPa {Min. 30 kg/cm2}
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
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
FWD
REV
1ST
2ND
3RD
Defective transmission valve

(ECMV) function
6 Defective brake valve
Parking brake lever
Left brake pressure
Right brake pressure
Free
Min. 2.45 MPa

{Min. 25 kg/cm2}
Min. 2.45 MPa

{Min. 25 kg/cm2}
If the result of the troubleshooting in cause 6 is abnormal, the parkDefective parking brake lever
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

sion
check it.
D275AX-5E0
40 Troubleshooting
SEN01647-00
H-2 Machine does not move (At 2nd or 3rd speed)

Trouble
Related
information
Machine does not move. (At 2nd or 3rd speed)

Confirm that the transmission main relief pressure is normal before troubleshooting. (See H-1.)
Cause


converter
PCCS lever
torque converter
Torque converter
delivery pressure
Full neutral
0.49 1.0 MPa

{5 10 kg/cm2}
0.49 0.1 MPa

{5 1 kg/cm2}
Possible causes
and standard
value in normal
state
D275AX-5E0

(ECMV) function
Transmission clutch
Clutch pressure
2ND
3RD
Internally defective transmis- The transmission clutch (2nd or 3rd speed) is assumed to be
sion clutch
defective internally; directly check it.
Defective parking brake

function (Drag)
Defective brake function

(Drag)
Internally defective transmis- The transmission is assumed to be defective internally; directly

sion
check it.
The parking brake function is assumed to be defective (dragged);

check the linkage valves.
a Move to a flat place, and start the engine for troubleshooting.
If the machine does not run by low idle + F2 operation, brake drag
occurs. (Carry out troubleshooting "H-8 Brake does not work.")
SEN01647-00
40 Troubleshooting
H-3 Machine does not move in any speed range

Trouble
Related
information
Machine does not move in any speed range.

Cause

Defective and Internally

defective set pressure of
2
transmission main relief
valve
PCCS lever

pressure
Full neutral
Number of shims: 6
idle mode for troubleshooting. (Before this, confirm that the
transmission main relief pressure is normal.)
Possible causes
and standard
value in normal
state

3
(ECMV) function
Transmission clutch
Clutch pressure
FWD
Min. 2.65MPa {Min. 27kg/cm2}
REV
1ST
2ND
3RD
Internally defective transmis- The transmission clutch (2nd or 3rd speed) is assumed to be
sion clutch
a Move to a flat place, raise the parking lever and drive the
engine in high idle mode for troubleshooting. (Before this, confirm that the transmission main relief pressure is normal.)
5 Defective brake function
Brake pedal
Brake hydraulic pressure

(left/right)
Release
Pedal
0 {0}
If oil pressure is abnormal, carry out troubleshooting in "H-8 Brake

does not work".
6
Carry out troubleshooting for failure codes [DDQ2KA], [DDQ2KB]

and [DDQ2L4]. Even if these failure codes are not displayed,
switch
check that switch input changes normally.
D275AX-5E0
40 Troubleshooting
SEN01647-00
H-4 Machine travels only in one direction forward or in reverse

Trouble
Related
information
Machine travels only in one direction forward or in reverse.

Cause


valve or internal defect
PCCS lever

pressure
Full neutral
Number of shims: 6
Possible causes
and standard
value in normal
state
transmission main relief pressures is normal.)
3
(ECMV) function
Transmission clutch
Clutch pressure
FWD
REV
1ST
2ND
3RD
Defective transmission clutch When the troubleshooting in cause 3 is abnormal, the clutch seal is
seal
assume to be defective; directly check it.
Internally defective transmis- The transmission clutch (forward or reverse) is assumed to be

sion clutch

(Dragging)
a Stop machine on level ground, start engine, and carry out troubleshooting.
Set transmission in F2 at low idle. If machine does not move at
this time, brake is dragging (Carry out troubleshooting for H-8
"Brake does not work").
Defective function of direc7 tional potentiometer of travel Carry out troubleshooting related to directional potentiometer.
lever
D275AX-5E0
SEN01647-00
40 Troubleshooting
H-5 When gear is shifted or travel direction is changed, large time lag is
made
1
Trouble
Related
information
When gear is shifted or travel direction is changed, large time lag is made.
Cause


valve or internal defect

pressure
Full neutral
Number of shims: 6
Possible causes
and standard
value in normal
state
transmission main relief pressure is normal.)
PCCS lever

(ECMV) function
Transmission clutch
Clutch pressure
FWD
REV
1ST
2ND
3RD
Defective transmission clutch When the troubleshooting in cause 3 is abnormal, the clutch seal is
seal
assume to be defective; directly check it.
Internally defective transmis- The transmission clutch is assumed to be defective internally;

sion clutch
directly check it.

(Drag)
a Move to a flat place, then start the engine for troubleshooting.

If the machine does not run by low idle + F2 operation, brake drag
occurs. (Carry out troubleshooting "H-8 Brake does not work.")
D275AX-5E0
40 Troubleshooting
SEN01647-00
H-6 Machine does not turn (Not turned rightward or leftward)

Trouble
Related
information
Machine does not turn. (Not turned rightward or leftward)

Confirm that the oil quantity for function is normal before troubleshooting.
Cause
Defective set pressure or
1 defective function of HSS
main relief valve

defective function of self2
pressure reducing valve
(HSS servo charge pressure)
Possible causes
and standard
value in normal
state
D275AX-5E0

charge relief valve

a Start engine and prepare, then run engine at high idle and carry
PCCS lever
Left or right stroke end
38.2 41.7 MPa

{390 425 kg/cm2}
a Prepare with starting the engine, then drive the engine in high
PCCS lever
Original pressure of control

circuit
Neutral
3.43 +0.49
0.2 MPa
+5.0
{35 2.0 kg/cm2}
PCCS lever
Charge relief pressure
Neutral
2.6 3.4 MPa

{27 35 kg/cm2}
Defective function of HSS

pump solenoid valve
The HSS pump solenoid valve function is assumed to be defective;

directly check it.
Defective function of pivot

turn solenoid valve
The pivot turn solenoid valve is assumed to be defective; directly

check it.

turn valve
The function of the pivot turn valve is assumed to be defective;

directly check it.
Abnormal sound from HSS

peripheral equipment
If an abnormal sound occurs in the HSS peripheral equipment,

carry out troubleshooting "H-11 Abnormal sound around HSS
pump or HSS motor."
Defective function of steering

Carry out troubleshooting related to steering potentiometer.
potentiometer of travel lever
SEN01647-00
40 Troubleshooting
H-7 Steering speed or power is low

Trouble
Related
information
Steering speed or power is low.

Cause
main relief valve

Possible causes
and standard
value in normal
state
10

charge relief valve

PCCS lever
38.2 41.7 MPa

{390 425 kg/cm2}
PCCS lever

circuit
Neutral
3.43 +0.49
0.2 MPa
+5.0
{35 2.0 kg/cm2}
PCCS lever
Neutral
2.6 3.4 MPa

{27 35 kg/cm2}
Defective function of HSS

pump solenoid valve
The HSS pump solenoid valve function is assumed to be defective;

directly check it.


pump or HSS motor."

turn valve
The function of the pivot turn valve is assumed to be defective;

directly check it.


pump or HSS motor."
Defective function of steering

Carry out troubleshooting related to steering potentiometer.
potentiometer of travel lever
D275AX-5E0
40 Troubleshooting
SEN01647-00
H-8 Brake does not work

Trouble
Related
information
Brake does not work.

Confirm that the main relief pressure for transmission is normal before troubleshooting. (See H-1.)
Cause

Possible causes
and standard
value in normal
state
Defective brake valve function
Brake hydraulic pressure
At release
Min. 2.45 MPa

{Min. 25 kg/cm2}
At pedaling
0 {0}
Defective adjustment of
2
brake pedal linkage
If the troubleshooting in cause 1 is abnormal, the adjustment of the

brake pedal linkage is assumed to be abnormal; directly check it.
3 Defective brake seal
If the troubleshooting in cause 1 is abnormal, the brake seal is

assumed to be defective; directly check it.
Slipped or abrasive brake

disk plate
Lowering of brake perfor5

mance
D275AX-5E0
Brake pedal
The brake disk plate is assumed to be slipped or abrasive; directly

check it.
Press brake pedal, set transmission in F2, and run engine at
high idle. If machine starts moving at this time, brake performance has lowered.
11
SEN01647-00
40 Troubleshooting
H-9 Torque converter does not lock-up

Trouble
Related
information
Torque converter does not lock-up.

Confirm that the main relief pressure for transmission is normal before troubleshooting. (See H-1.)
Cause
Possible causes
and standard
value in normal
state

lock-up valve function
3 Defective lock-up clutch seal

4
Internally defective lock-up

clutch
Torque converter
At lock-up
1.27 0.2 MPa

{13 2 kg/cm2}
If the troubleshooting in cause 2 is abnormal, the lock-up clutch

seal is assumed to be defective; directly check it.
The lock-up clutch is assumed to be defective internally; directly
check it.
12

converter
Number of engine rotations
F3 stall
1,510 rpm
Stall in F3 + Relief of work equipment system (Pitch back)
1,450 rpm
D275AX-5E0
40 Troubleshooting
SEN01647-00
H-10 Overheat of power train oil temperature

Trouble
Related
information
Overheat of power train oil temperature.

Confirm that the value of the oil temperature of the power train matches the actual oil temperature
before troubleshooting. (If they do not match, carry out troubleshooting "Abnormal power train oil temperature.") Confirm that the main relief pressure for transmission is normal before troubleshooting.
(See H-1.)
Cause
1 Defective engine system
2
Defective power train pump

or air from suction circuit

The engine cooling system is assumed to be defective or the
engine output is assumed to be increased; see the Shop Manual:
Engine.
a The power train pump is assumed to be defective or aired from
the suction circuit; directly check it.
Possible causes
and standard
value in normal
state

converter
PCCS lever
torque converter
Torque converter
delivery pressure
Full neutral
0.49 1.0 MPa

{5 10 kg/cm2}
0.49 0.1 MPa

{5 1 kg/cm2}
Defective transmission clutch The transmission clutch is assumed to be defective internally

function (Slip)
(slipped); directly check it.
a Prepare with starting the engine for troubleshooting.
D275AX-5E0

(Drag)

(Slip)
1. Use the blades and ripper to float the machine from the ground.
2. Convert the drive position while low-idle.
3. If the track shoe does not rotate, brake drag occurs. (Carry out
troubleshooting "H-8 Brake does not work.")
a Prepare with starting the engine for troubleshooting.
Carry out F3 stall. If the machine does not stop completely, brake
slip occurs.
13
SEN01647-00
40 Troubleshooting
H-11 Abnormal sound around HSS pump or HSS motor

Trouble
Related
information
Abnormal sound around HSS pump or HSS motor.

Confirm that the oil quantity on the hydraulic oil tank is normal before troubleshooting.
Cause
main relief valve

Possible causes
and standard
value in normal
state

charge relief valve
4 Defective HSS charge pipe
14

PCCS lever
38.2 41.7 MPa

{390 425 kg/cm2}
PCCS lever

circuit
Neutral
3.43 +0.49
0.2 MPa
+5.0
{35 2.0 kg/cm2}
PCCS lever
Neutral
2.6 3.4 MPa

{27 35 kg/cm2}
The clamp of the HSS charge pipe is assumed to be loosened or

the O ring is assumed to be damaged; directly check it.
Internally defective HSS

pump
The HSS pump is assumed to be defective internally; directly

check it.
Internally defective HSS

motor
The HSS motor is assumed to be defective internally; directly

check it.
Internally defective work

equipment pump
The work equipment pump is assumed to be defective internally;

directly check it.
D275AX-5E0
40 Troubleshooting
SEN01647-00
H-12 All work equipment speeds are slow

Trouble
Related
information
All work equipment speeds are slow.

Confirm that the oil quantity of the hydraulic oil tank is normal before troubleshooting.
Cause
Defective PTO (pump drive

unit of work equipment)
The PTO pump drive unit of the work equipment is assumed to be

defective; directly check it.

pump
The pump of the work equipment is assumed to be defective;

directly check it.
Possible causes
and standard
value in normal
state
Defective unload valve function

4 defective function of main
relief valve
Work equipment lever
Unload pressure
Full neutral
2.45 +1.37
MPa
+0
2}
{25 +14
kg/cm
+0
Stroke end
27.44 1.37 MPa

{280 14 kg/cm2}
Defective function of self5 pressure reducing valve
(PPC original pressure)
D275AX-5E0
Internally defective PPC

valve

circuit
Full neutral
3.43 +0.49
0.2 MPa
+5.0
{35 2.0 kg/cm2}
When the troubleshooting in cause 5 is abnormal, the PPC valve is

assumed to be defective internally; directly check it.
15
SEN01647-00
40 Troubleshooting
H-13 Work equipment does not move

Trouble
Related
information
Work equipment does not move.

Cause
Defective PTO (Pump drive

unit of work equipment)
The PTO pump drive unit of the work equipment is assumed to be


pump
The work equipment pump is assumed to be defective; directly

check it.
Possible causes
and standard
value in normal
state
Defective unload valve function

4 defective function of main
relief valve
Unload pressure
Full neutral
2.45 +1.37
MPa
+0
2}
{25 +14
kg/cm
+0
Stroke end
27.44 1.37 MPa

{280 14 kg/cm2}
Defective function of self5 pressure reducing valve
(PPC original pressure)
Defective function of work

6 equipment lock lever and
PPC lock valve
16

circuit
Full neutral
3.43 +0.49
0.2 MPa
+5.0
{35 2.0 kg/cm2}
Check if PPC lock valve is operating normally by turning work

equipment lock lever ON and OFF.
D275AX-5E0
40 Troubleshooting
SEN01647-00
H-14 Blade lift speed is slow or lacks power

Trouble
Related
information
Blade lift speed is slow or lacks power.

Confirm whether the blade is remodeled.
When the hydraulic drift rate of the blade lift is also high, carry out troubleshooting "H-18 Excessive
hydraulic drift of blade lift."
Cause

Possible causes
and standard
value in normal
state
1 Defective PPC valve function
Lift stroke end

2
Defective function of blade

lift operation valve (Spool)
3 Aired blade lift cylinder
D275AX-5E0
Blade lever
PPC valve output pressure

3.14 3.92 MPa
{32 40 kg/cm2}
The spool function of the blade lift operation valve is assumed to

be defective; directly check it.
The blade lift cylinder is assumed to be aired; carry out the air
bleed and observe how the phenomenon changes.
17
SEN01647-00
40 Troubleshooting
H-15 Blade tilt speed is slow or lacks power

Trouble
Related
information
Blade tilt speed is slow or lacks power.

When the hydraulic drift rate of the blade tilt is also high, carry out troubleshooting "H-19 Excessive
hydraulic drift of blade tilt."
Cause

Possible causes
and standard
value in normal
state
Lift stroke end

3

tilt operation valve (Spool)
4 Aired blade tilt cylinder
18
Blade lever

3.14 3.92 MPa
{32 40 kg/cm2}
The spool function of the blade tilt operation valve is assumed to

The blade tilt cylinder is assumed to be aired; carry out the air
D275AX-5E0
40 Troubleshooting
SEN01647-00
H-16 Ripper lift speed is slow or lacks power

Trouble
Related
information
Ripper lift speed is slow or lacks power.

Confirm whether the ripper is remodeled.
When the hydraulic drift rate of the ripper lift is also high, carry out troubleshooting "H-20 Excessive
hydraulic drift of ripper lift."
Cause


Possible causes
and standard
value in normal
state
D275AX-5E0
Ripper lever
Lift stroke end
Defective function of ripper

lift operation valve (Spool)

3.14 3.92 MPa
{32 40 kg/cm2}
The spool function of the ripper lift operation valve is assumed to


3 lift operation valve (suction
valve)
The suction valve of the ripper lift operation valve is assumed to be

a Replace the suction valve in the head with one at the bottom,
and observe how the phenomenon changes.
4 Aired ripper lift cylinder
The ripper lift cylinder is assumed to be aired; carry out the air
19
SEN01647-00
40 Troubleshooting
H-17 Ripper tilt speed is slow or lacks power

Trouble
Related
information
Ripper tilt speed is slow or lacks power.

Cause


Possible causes
and standard
value in normal
state
20
Ripper lever
Tilt stroke end

tilt operation valve (Spool)

3.14 3.92 MPa
{32 40 kg/cm2}
The spool function of the ripper tilt operation valve is assumed to


3 tilt operation valve (Suction
valve)
The suction valve of the ripper tilt operation valve is assumed to be

a Replace the suction valve in the head with one at the bottom,
and observe how the phenomenon changes.
4 Aired ripper tilt cylinder
The ripper tilt cylinder is assumed to be aired; carry out the air
D275AX-5E0
40 Troubleshooting
SEN01647-00
H-18 Excessive hydraulic drift of blade lift

Trouble
Related
information
Excessive hydraulic drift of blade lift.

Confirm that no oil leaks the circuits in the work equipment before troubleshooting.
Cause

a Prepare with starting the engine, then stop the engine for troubleshooting.
Possible causes
and standard
value in normal
state
D275AX-5E0
Follow the procedure below for troubleshooting. If the hydraulic

drift speed becomes high, the spool seal of the blade lift operation
valve is assumed to be defective.
1. Prop up the machine using the blade lift, and lift the front of the
machine.
2. Stop the engine, and release the lock lever.
3. Set the blade lever to the lift lowering side, and confirm how the
phenomenon changes.
Defective seal of blade lift

operation valve (Spool)
Defective seal of blade lift

cylinder
Raise blade about 1,000 mm and check hydraulic drift of cutting

Defective fitting of quick drop
edge.
valve
300 mm/15 min
The seal of the blade lift cylinder is assumed to be defective;

directly check it.
21
SEN01647-00
40 Troubleshooting
H-19 Excessive hydraulic drift of blade tilt

Trouble
Related
information
Excessive hydraulic drift of blade tilt.

Cause

Possible causes
and standard
value in normal
state
22
Defective seal of blade tilt

Defective seal of blade tilt

cylinder

drift speed becomes high, the spool seal of the blade tilt operation
valve is assumed to be defective.
1. Prop up the machine using the blade tilt, and lift the right of the
machine.
3. Set the blade lever to the right tilt side, and confirm how the
phenomenon changes.
Blade tilt cylinder
Cylinder leak quantity
Right tilt stroke end
16 cc/min
D275AX-5E0
40 Troubleshooting
SEN01647-00
H-20 Excessive hydraulic drift of ripper lift

Trouble
Related
information
Excessive hydraulic drift of ripper lift.

Cause

Possible causes
and standard
value in normal
state
D275AX-5E0
Defective seal of ripper lift

Defective seal of ripper lift

cylinder

drift speed becomes high, the spool seal of the ripper lift operation
valve (Hi) is assumed to be defective.
1. Prop up the machine using the blade tilt, and lift the rear of the
machine.
3. Set the blade lever to the lift lowering side, and confirm how the
phenomenon changes.
Cylinder leak quantity
Lowering stroke end
16 cc/min
23
SEN01647-00
40 Troubleshooting
H-21 Ripper pin puller cylinder does not work (Giant ripper attachment
machine)
1
Trouble
Related
information
Ripper pin puller cylinder does not work.

Confirm that the main relief pressure for transmission is normal before troubleshooting.
Cause

Possible causes
and standard
value in normal
state
24
Defective function of pin

puller solenoid
Pin puller switch
Measurement
position
Pin puller working

pressure
Push-in
Cylinder bottom side
Pull-in
Cylinder head side
Min. 2.45 MPa

{Min. 25 kg/cm2}
Internally defective pin puller The pin puller cylinder is assumed to be defective internally;
cylinder
directly check it.
Defective fuse FS2-2 (20 A)

for pin puller
Check fuse for breakage. If it is broken, circuit probably has short

circuit. Check wiring harness of related circuit.
D275AX-5E0
40 Troubleshooting
SEN01647-00
H-22 Blade pitch does not work (Dual tilt attachment machine)
Trouble
Blade pitch does not work.
Related
information
Cause
Possible causes
and standard
value in normal
state
D275AX-5E0

The spool of the blade pitch operation valve is assumed to be
pitch selection solenoid valve defective; directly check it.

The function of the blade pitch cylinder is assumed to be defective;
pitch operation valve (Spool) directly check it.

pitch cylinder
The function of the blade pitch selection solenoid valve is assumed

to be defective; directly check it.

pitch switch
Carry out troubleshooting related to blade pitch switch.

Even if no failure codes are displayed, check that switch input
changes normally.
25
SEN01647-00
40 Troubleshooting
H-23 Abnormal sound comes out from around work equipment pump 1
Trouble
Related
information
Abnormal sound comes out from around work equipment pump.

Cause
1 Inappropriate oil
Possible causes
and standard
value in normal
state
3 Air inhaled in suction circuit

4
26
Clogged hydraulic oil tank

strainer
Internally defective work

equipment pump

The oil used is assumed to be inappropriate; directly check it.
The strainer of the hydraulic oil tank is assumed to be clogged;
directly check it.
Air is assumed to be inhaled in the suction circuit of the work
machine pump; directly check the pipes.
The work equipment pump is assumed to be defective internally;
directly check it.
D275AX-5E0
40 Troubleshooting
SEN01647-00
H-24 Fan speed is abnormal (Sound and/or vibration of fan are/is

abnormally large or engine overheats).
Trouble
Related
information
Fan rotation is abnormal (Sound/Vibration of fan is abnormally large or engine overheats).

Before carrying out troubleshooting, check that oil level in hydraulic tank is normal.
Cause

1 Defective engine rotation
Engine speed
Engine low idling
700 rpm
Engine high idling
2,150 rpm
If engine speed is low, carry out troubleshooting for the engine

troubleshooting "S-5 Rotation is irregular".
2
Defective PTO (fan pump

drive)
Fan pump drive of PTO may be defective. Check it directly.

a Prepare with starting switch OFF, then run engine at high idle
Possible causes
and standard
value in normal
state
Fan pump EPC circuit basic

pressure
+0.49-
Defect in fan pump or fan

motor
3.43 - 0.20 MPa

{25
+5
-2
kg/cm2}
Fan drive circuit pressure
Fan 100% mode
16.17 19.11 MPa

{165 195 kg/cm2}
4 Defective fan
D275AX-5E0
Defective fan
Fan 100% mode
1400 - 1500 rpm
Fan may be broken or installed defectively. Check it directly.
27
SEN01647-00
40 Troubleshooting
28
D275AX-5E0
SEN01648-00
BULLDOZER
1SHOP MANUAL
D275AX-5E0
Machine model
Serial number
D275AX-5E0
30001 and up
40 Troubleshooting

Method of using troubleshooting chart............................................................................................................ 3
S-1 Starting performance of engine is poor .................................................................................................... 6
S-2 Engine does not start ............................................................................................................................... 8
S-3 Engine does not pick up smoothly.......................................................................................................... 12
S-4 Engine stops during operation................................................................................................................ 13
S-5 Engine does not rotate smoothly ............................................................................................................ 14
S-6 Engine lack output (or lacks power) ....................................................................................................... 15
S-7 Exhaust gas is black (incomplete combustion) ...................................................................................... 16
S-8 Oil consumption is excessive (or exhaust gas is blue)........................................................................... 18
S-9 Oil becomes dirty quickly........................................................................................................................ 19
S-10 Fuel consumption is excessive............................................................................................................. 20
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................................... 21
S-12 Oil pressure drops ................................................................................................................................ 22
S-13 Oil level rises (Entry of coolant or fuel)................................................................................................. 24
S-14 Coolant temperature becomes too high (Overheating) ........................................................................ 26
S-15 Abnormal noise is made....................................................................................................................... 27
S-16 Vibration is excessive ........................................................................................................................... 28
D275AX-5E0
40 Troubleshooting
SEN01648-00
Method of using troubleshooting chart

Causes
Questions
1
2
3
4
5
6
Check items
Troubleshooting
The troubleshooting chart consists of the "questions", "check items", "causes", and "troubleshooting" blocks.
The questions and check items are used to pinpoint
high probability causes by simple inspection or
from phenomena without using troubleshooting
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]
Items to be drawn from the user or operator.
They correspond to A and B in the chart on the
right. The items in A are basic ones. The
items in B can be drawn from the user or operator, depending on their level.
[Check items]
Simple check items used by the serviceman to
narrow the causes. They correspond to C in
the chart on the right.
[Causes]
Items to be narrowed from the questions and
check items. The serviceman narrows down
the probable causes from A, B, and C.
[Troubleshooting]
Items used to find out the true cause by verifying the narrowed causes finally in order from
the most probable one by applying troubleshooting tools or direct inspection.
8
9
10
11
a
b
c
d
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.)
D275AX-5E0
SEN01648-00
40 Troubleshooting
<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".
S-7 Exhaust gas is black

(Incomplete combustion)
Clogged fuel spill piping (on cylinder head side)
Improper fuel injection timing
Improper fuel injection pressure
Defective coolant temperature sensor or wiring harness
Correct
Adjust
Adjust
Replace
Clogged or seized injector
Abnormally worn injector

Replace
Stuck or seized supply pump plunger

Replace
Replace
Crushed or clogged muffler
Worn piston ring or cylinder liner

Replace
Leakage of air between turbocharger and cylinder head

Correct
Replace
Defective contact of valve and valve seat
Improper valve clearance

Adjust
Replace
Replace
Stuck EGR valve
Clogged EGR gas pressure piping
Replace
Clogged air cleaner element
Seized turbocharger or interference of turbocharger

Replace
General causes why exhaust gas is black

Insufficient intake of air
Excessive injection of fuel
Defective condition of fuel injection
Improper selection of fuel
Overheating
See "S-14 Coolant temperature becomes too high
(Overheating)"
Control by controller in derate mode (limiting injection
rate (output) because of an error in electrical system)
EGR valve stuck open (There is much EGR gas and
intake of air is insufficient)
Clogged EGR gas pressure piping (Exhaust gas is
mixed in intake air during acceleration and deceleration)
Clean
Cause
Confirm recent repair history

Degree of use of machine
Operated for long period
Questions
Suddenly became black

Exhaust gas color
Gradually became blackB

Blue under light load
Non-specified fuel is used

Oil must be added more frequently
Power was lost
Suddenly
Gradually
Dust indicator is red (if it is installed)

Muffler is crushed
Air leaks between turbocharger and cylinder head or clamp is loosened
Engine is operated in low-temperature mode at normal temperature
Check items
Immediately after engine is started, temperature of exhaust manifold

of a cylinder is low
When engine is rotated, interference sound comes out from around
turbocharger
When engine is rotated, abnormal sound comes out from around
cylinder head
Torque converter stall speed or pump relief speed is high
(Fuel is injected excessively)
Exhaust noise is abnormal
Engine does not pick up smoothly and combustion is irregular
Blow-by gas is excessive
When spill hose from injector is disconnected, abnormally much fuel spills
Inspect air cleaner directly
Troubleshooting
Turbocharger is heavy to rotate with hand

Carry out troubleshooting according to "EGR Valve Servo Error 1 (*1)"
in E mode
Check EGR gas pressure piping directly (*2)
Compression pressure is low
Inspect valve clearance directly
When muffler is removed, exhaust gas color improves
Carry out troubleshooting according to "Rail Press Low Error (*3)" in E mode
When a cylinder is cut out for reduced cylinder mode operation, engine
speed does not change
Inspect fuel spill piping (on cylinder head side) directly
Carry out troubleshooting according to "Coolant Temp Sens
(High/Low) Error (*4) in E mode
Remedy
D275AX-5E0
40 Troubleshooting
SEN01648-00
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.
[Causes]: 6 items
Step 1
Clarify the relationship between the 3 items in the
[Questions] and [Check items] sections and the 6 items
in the [Causes] section.
[Questions] [Check items]: 3 items
Step 2
Count the and marks on the 3 items in the
[Questions] and [Check items] sections and the 6 items
in the [Causes] section.
(1) Clogged air cleaner element
:
(2) Clogged EGR gas pressure piping
:
(3) Defective contact of valve and valve seat :
(4) Leakage of air between turbocharger and
cylinder head
:
(5) Worn piston ring and cylinder liner
:
(6) Clogged or seized injector
:
Step 3
The result of Step 2 shows that the item having the
closest relationship with the trouble is "Clogged air
cleaner". If the "troubleshooting" items connected to it
and marked with are carried out, remedy of cleaning is
indicated. Accordingly, the exhaust gas color can be
changed to normal by cleaning.
D275AX-5E0
SEN01648-00
40 Troubleshooting
S-1 Starting performance of engine is poor

General causes why starting performance is poor
q
Defective electrical system
q
Insufficient supply of fuel
q
q
q
Coolant in exhaust pipe
a The common rail fuel injection system (CRI) recognizes the fuel injection timing electrically. Accordingly, even if the starting operation is carried out, the
engine may not start until the crankshaft revolves 2
turns at maximum. This phenomenon does not indicate a trouble, however
Defective or deteriorated battery
Defective alternator (generator section)
Defective alternator (regulator section)
Defective intake air heater system
Defective injector
Clogged feed pump gauze filter
Clogged fuel filter element
Leaking or clogged fuel piping or entry of air
Clogged air breather hole of fuel tank cap
Worn piston ring, cylinder
Defective contact of valve and vale seat
Cracked EGR cooler (Coolant in exhaust pipe)
Causes
Questions
Starting performance
E E
E E
Became worse gradually
Q Q w w
Q Q
E
w
Engine starts easily when warm
Filters have not been replaced according to Operation and Maintenance Manual
w w Q Q
w
Engine oil must be added more frequently

When engine is preheated or when temperature is low, preheating monitor does not
indicate normally (if monitor is installed)
During operation, charge level monitor indicates abnormal charge

(if monitor is installed)
w w
w
Air breather hole of fuel tank cap is clogged

Fuel is leaking from fuel piping
Priming pump is too light or too heavy to operate
w Q Q
Check items
When air bleeding plug of fuel filter is removed, fuel does not
flow out
w w
w
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
Q Q
w
Q w Q Q
Engine hunts (rotation is irregular)

When EGR cooler outlet gas piping is removed, coolant containing antifreeze flows
out (*1)
q
q q
When air is bled from fuel system, air comes out

Troubleshooting
Starting motor cranks engine slowly

While engine is
rotated with starting
motor
Inspect fuel filter and strainer directly
Inspect feed pump gauze filter directly

Carry out troubleshooting according to "Rail Press (Very) Low Error (*2)" indicated by
code
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
not change
When starting switch is turned to HEAT, intake air heater mount does not become
warm
Is voltage of 25 30 V generated between alternator terminals R and E
while engine is running at low idle?
Q Q Q Q
q
q
Yes
No
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Correct
Clean
Replace
Correct
Replace
Remedy
Clean
Specific gravity of electrolyte and battery voltage are low
Replace
Degree of use of
machine
D275AX-5E0
40 Troubleshooting
SEN01648-00
*1: EGR cooler outlet gas piping

Loosen 4 mounting bolts (1) of the EGR cooler outlet gas piping and see if the coolant flows out.
A little condensate produced from cooled exhaust gas may flow out. If it is colorless and transparent,
however, it is not a problem.
*2: Displayed failure codes: [CA559] and [CA2249]
D275AX-5E0
SEN01648-00
40 Troubleshooting
S-2 Engine does not start
a) Engine does not rotate

General causes why engine does not rotate
q
Seized internal parts of engine
o See "S-4 Engine stops during operation"
q
Water hammer caused by coolant which entered cylinder
q
Defective electrical system
q
Trouble in power train
Defective power train
Defective starting circuit wiring
Defective starting motor (motor section)
Defective starting motor (safety relay section)
Defective battery relay
Defective connection of battery terminal
Broken flywheel ring gear
Cracked EGR cooler (Coolant in exhaust pipe)
Causes
E E E
When starting switch is Horn does not sound

turned ON
Horn volume is low
Battery electrolyte level is low
Battery terminal is loose

When starting switch is turned ON, no operating sound comes out from battery relay
When starting switch is turned to START, starting pinion does not move out
Q
Q
Speed of rotation is low
When starting switch is

turned to START, start- Makes grating noise
ing pinion moves out,
Soon disengages again
but
Makes rattling noise and does not turn
w
w
w
w
Q
Q w
When EGR cooler outlet gas piping is removed, coolant containing antifreeze flows out
q
(*1).
q
q

There is not voltage (20 30 V) between battery relay terminals B and E
Turn starting switch
OFF, connect cables,
turn starting switch ON,
and carry out troubleshooting
When terminals B and C of starting switch are connected,

engine starts
When terminals B and C at safety relay outlet are connected,

engine starts
Even if terminals B and C at safety relay outlet are connected,

engine does not start
Replace
Replace
Replace
Correct
Replace
Replace
Replace
Remedy
q
Replace
Troubleshooting
Inspect flywheel ring gear directly
Carry out troubleshooting on

H-mode
Check items

E-mode
Degree of use of
machine
Questions
D275AX-5E0
40 Troubleshooting
SEN01648-00

D275AX-5E0
SEN01648-00
40 Troubleshooting
b) Engine rotates but no exhaust gas comes out

General causes why engine rotates but no exhaust gas
comes out
q
Fuel is not supplied
q
Supply of fuel is extremely small
q
Improper selection of fuel (particularly in winter)
Defective fuel injector
Malfunction flow damper
Malfunction of overflow valve (Does not close)
Wrong connection of supply pump PCV
Defective supply pump PCV
Broken supply pump shaft or key

Seized or abnormally worn feed pump
Clogged fuel filter element
Insufficient fuel in tank
Use of improper fuel
Causes
E E E
w Q w w w
Exhaust gas suddenly stopped coming out (when starting again)

Fuel tank is empty
Q w
There are rust and water in fuel drained from fuel tank
w
Check items
There is not fuel in removed fuel filter
Q Q Q
Q Q
w Q Q
When air bleeding plug of fuel filter is removed, fuel does

not flow out
While engine is
rotated with starting
When spill hose from injector is disconnected, little fuel
motor
spills
E E
Q
w Q
w w w w
q q
Inspect fuel filter directly

Troubleshooting
w w
Inspect feed pump directly

Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indicated by code
Carry out troubleshooting according to "PCV1 Short/Open Error (*2) or PCV2
Short/Open Error (*3)" indicated by code
q
q
q
Inspect overflow valve directly
q q
Replace
Correct
Replace
Replace
Replace
Clean
Replace
Replace
Correct
Correct
Add
Remedy
Replace
Engine can be started in reduced cylinder mode
Replace
Degree of use of
machine
Replace
Questions
*1: Displayed failure codes [CA559] and [CA2249]

10
D275AX-5E0
40 Troubleshooting
SEN01648-00
c) Exhaust gas comes but engine does not start

(fuel is injected)
General causes why exhaust smoke comes out but engine
does not start
q
Lack of rotating force due to defective electrical system
q
q
q
Defective intake air heater system
Clogged injector or defective spray
Clogged fuel filter or strainer
Leaking or clogged fuel system or entry of air
Worn dynamic valve system (Valve, rocker lever, etc.)
Causes
E E
Suddenly failed to start
E
w
Q Q

w w
w

When engine is preheated or when temperature is low, preheating monitor does not indicate normally (if monitor is installed)
w
w
w w
There is not fuel in removed fuel filter

w Q Q
w
Check items
Starting motor rotates engine slowly
When engine is rotated, abnormal sound comes out from around cylinder head
While engine is rotated
with starting motor,
When air bleeding plug of fuel filter is removed, fuel does not
flow out
When spill hose from injector is disconnected, little fuel spills
Immediately after engine is started, temperature of exhaust manifold of a cylinder is low
Inspect dynamic valve system directly

Troubleshooting
w w

code
q
q
When injector unit is tested, spray condition is bad
Coolant temperature gauge does not indicate normally (if it is installed)
q
Replace
Replace
Clean
Replace
Clean
Clean
Correct
Clean
Replace
Replace
Replace
Remedy
Clean
When starting switch is turned to HEAT, intake air heater mount does not become warm
Replace
Questions
Degree of use of machine Operated for long period
D275AX-5E0
11
SEN01648-00
40 Troubleshooting
S-3 Engine does not pick up smoothly
General causes why engine does not pick up smoothly

q
q
q
Defective condition of fuel spray
q
q
Control by controller in derate mode
(limiting injection rate (output) because of an error in
electrical system)
q
EGR valve stuck open
(There is much EGR gas and intake of air is insufficient)
Clogged injector or defective spray
Malfunction of flow damper (Large leakage from injector)
Stuck EGR valve
Causes
E E E
Engine pick-up suddenly became worse
E E
Q Q
Q
w w w

w
w
Dust indicator is red (if indicator is installed)
w w
w Q Q
Q
Check items
Exhaust gas color
Black
When engine is rotated, interference sound comes out from around turbocharger
High idle speed under no load is normal, but speed suddenly drops when load is applied
w w
Q w
Carry out troubleshooting according to "EGR Valve Servo Error (*1)" indicated by code

Troubleshooting
w w
q
q

code
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
change
Replace
Clean
Clean
Correct
Clean
Replace
Replace
Adjust
Replace
Replace
Clean
Remedy
q q
Correct
Degree of use of
machine
Replace
Questions

12
D275AX-5E0
40 Troubleshooting
SEN01648-00
S-4 Engine stops during operation
General causes why engine stops during operation

q
Seized parts inside engine
q
q
Overheating
q
Broken auxiliary equipment (pump, compressor, etc.)
Broken supply pump shaft or key
Q w Q w
Broken or seized feed pump
Leaking or clogged fuel piping
Broken or seized gear train
Broken or seized crankshaft bearing
Broken or seized piston or connecting rod
Broken dynamic valve system (valve, rocker arm, etc.)
Causes

E E

w w w w
Questions
Made abnormal noise stopped suddenly

Engine
w Q
Overheated and stopped
Stopped slowly
Q Q
Hunted and stopped
w Q
Q Q 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)
Fuel tank is empty
w
w

w Q Q
w w
Check items
w w
There are metal particles in oil drained from oil pan
Q Q
w w
Engine does not rotate at all

When engine is
rotated with hand
Engine rotates in opposite direction
Engine moves by gear backlash
w
w
Supply pump shaft does not turn
Engine rotates, but stops when load is applied to machine
Inspect piston and connecting rod directly
Inspect crankshaft bearing directly
Inspect gear train directly
Inspect feed pump directly

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
Replace
Replace
Replace
Clean
Clean
Correct
Clean
Add
Replace
Replace
Replace
Replace
Remedy
q
Replace
Troubleshooting
Carry out troubleshooting

on H-mode
Degree of use of
machine
D275AX-5E0
13
SEN01648-00
40 Troubleshooting
S-5 Engine does not rotate smoothly
General causes why engine does not rotate smoothly

q
Air in fuel system
q
Defective speed sensor
(Error at degree that it is not indicated)
q
Defective EGR valve
q
Defective bypass valve
Defective Bkup speed sensor or wiring harness
Defective Ne speed sensor or wiring harness
Clogged injector or defective spray (dirt in injector)
Malfunction of flow damper (Large leakage from injector)
Malfunction of bypass valve
Malfunction of EGR valve
Low setting of low idle speed
Causes
E E
At a certain speed range
Q Q Q
At low idle
Engine hunts
E E
Q Q
Q Q Q Q Q Q Q
Q Q
Even when speed is raised
Q Q
On slopes
Q Q
w w
w
Check items
Fuel tank is empty
Q Q
w Q Q
q
Carry out troubleshooting according to "EGR Valve Servo Error (*1)" indicated by code
Troubleshooting
Carry out troubleshooting according to "Bypass Valve Servo Error (*2)" indicated by
code
q
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 (*3)" indicated by
code
Carry out troubleshooting according to "Eng Bkup Speed Sensor Error (*4)" indicated
by code
Correct
Correct
Replace
Replace
Replace
Correct
Clean
Add
Replace
Replace
Correct
Remedy
q
Correct
Questions

*2: Displayed failure code [CA1628] and [CA1629]
*3: Displayed failure code [CA689]
*4: Displayed failure code [CA778]
14
D275AX-5E0
40 Troubleshooting
SEN01648-00
S-6 Engine lack output (or lacks power)
D275AX-5E0
E E
Q Q
Q Q
Q Q Q
Q
Defective fuel temperature sensor or wiring harness
Defective charge pressure sensor or wiring harness
Defective installation of charge pressure sensor (air leakage)
Defective drive of injector (signal or solenoid)
Clogged injector or defective spray (dirt in injector)
Q
w
Q Q Q
w
w
w
w
w w
w
w
w
w
Q
w w Q
w
Q Q
Q Q Q Q
q
q
q
q q
q
q
Replace
Replace
Correct
Replace
Replace
Replace
Clean
Correct
q
Clean
Replace
Adjust
Replace
Replace
Correct
Remedy
E
Q

q
Inspect air intake piping directly
q
Boost pressure is low
q q q
q
q
q
indicated by code
When a cylinder is cut out for reduced cylinder mode operation, engine speed
does not change
Inspect charge pressure sensor mount directly
Carry out troubleshooting according to "Chg Air Press Sensor High (Low)
Error (*2)" indicated by code
Carry out troubleshooting according to "Fuel Temp Sensor High (Low) Error
(*3)" indicated by code

Leaking or clogged fuel piping
Replace

Suddenly
Power was lost
Gradually
Filters have not been replaced according to Operation and Maintenance
Manual
Output becomes insufficient after short stop of operation
Black
Exhaust gas is
Immediately after engine is started, temperature of exhaust manifold of a
cylinder is low
turbocharger
High idle speed is too high
High idle speed under no load is normal, but speed suddenly drops when load
is applied
Air leakage from air intake piping or from aftercooler
Causes
Clean
Troubleshooting
Check items
Questions
General causes why engine lacks output

q
q
q
Defective spray condition of fuel
q
q
Overheating
o See "S-14 Coolant temperature becomes too
high (Overheating)"
q
(limiting injection rate (output) because of an
error in electrical system)
15
SEN01648-00
40 Troubleshooting
S-7 Exhaust gas is black (incomplete combustion)

General causes why exhaust gas is black
q
q
q
Defective condition of fuel injection
q
q
Overheating
o See "S-14 Coolant temperature becomes too
high (Overheating)"
q
(limiting injection rate (output) because of an
error in electrical system)
q
EGR valve stuck open
(There is much EGR gas and intake of air is
insufficient)
q
(Exhaust gas is mixed in intake air during acceleration and deceleration)
1
Improper fuel injection pressure
Clogged fuel spill piping (on cylinder head side)
Abnormally worn injector
Crushed or clogged muffler
Stuck EGR valve
Causes
E
E
w Q Q
w
w
Questions
Suddenly became black

Exhaust gas color
Gradually became black
E
Q
w
Q Q

Power was lost
E
Q Q
Q Q
Suddenly
Q
w
Gradually
Q Q
Q
Muffler is crushed
Air leaks between turbocharger and cylinder head or clamp is loosened
Q Q Q
Check items
Engine is operated in low-temperature mode at normal temperature

cylinder is low
turbocharger
Q w
w
When engine is rotated, abnormal sound comes out from around cylinder
head
Torque converter stall speed or pump relief speed is high (Fuel is injected
excessively)
w
Q Q
Q
Q Q
Exhaust noise is abnormal

w
Q Q Q
Q
Q w
w
When spill hose from injector is disconnected, abnormally much fuel spills

Carry out troubleshooting according to "EGR Valve Servo Error (*1)" indicated
by code
q
q
Troubleshooting
Inspect EGR gas pressure piping directly (*2)
q
q
When muffler is removed, exhaust gas color improves

indicated by code
does not change
q
q
q
Inspect fuel spill piping (on cylinder head side) directly

Carry out troubleshooting according to "Coolant Temp Sens High (Low) Error
(*4)" indicated by code
16
Adjust
Adjust
Correct
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Replace
Replace
Replace
Replace
Clean
Remedy
q
Replace
D275AX-5E0
40 Troubleshooting
SEN01648-00

*2: EGR gas pressure piping
Remove 2 EGR gas pressure pipes (2) and check their inside for clogging.

D275AX-5E0
17
SEN01648-00
40 Troubleshooting
S-8 Oil consumption is excessive (or exhaust gas is blue)

General causes why oil consumption is excessive
q
Abnormal consumption of oil
q
Long-time operation of engine at low idle or high
idle (Do not run engine at idle for more than 20
minutes continuously)
q
External leakage of oil
q
Wear of parts in lubrication system
1
Oil leakage from oil pan, cylinder head, etc.
Oil leakage from oil drain plug
Oil leakage from oil piping
Oil leakage from oil filter
Oil leakage from oil cooler
Broken oil cooler
Worn or damaged rear oil seal
Broken piston ring
Clogged breather or breather hose
Oil leakage from EGR valve stem
Turbocharger
Worn seal at blower end
Worn seal at turbocharger end
Worn or damaged valve (stem, guide, or seal)
Dust sucked in from intake system
Causes
E E E E
E
w
Oil consumption suddenly increased

Q
Q
w
Q Q w
Oil becomes dirty quickly
w w w w w
Outside of engine is dirty with oil

w
There are loose piping clamps in intake system
w
Q w
Inside of turbocharger exhaust outlet pipe is dirty with oil
There is oil in coolant

w
Oil level in damper chamber is high

Q
Exhaust gas is blue under light load

Q
Excessive
w w
w
There is dust in intake manifold
Inside of intake manifold is abnormally dirty
q q
Play of turbocharger shaft is excessive
Exhaust port of EGR valve is dirty with oil
Check breather and breather hose directly
q q
Inspect rear oil seal directly
q q
Leakage from oil cooler is detected by pressure test
q q q q
18
Replace
Replace
Correct
Replace
Replace
Clean
Replace
Replace
Replace
Correct
Remedy
Correct
Oil leaks out of engine
Correct
Troubleshooting
None
Correct
Amount of blow-by gas
w w
Correct
Check items
Inside of turbocharger intake outlet pipe is dirty with oil
Correct
Questions
D275AX-5E0
40 Troubleshooting
SEN01648-00
S-9 Oil becomes dirty quickly
Exhaust gas color is bad
Clogged turbocharger lubrication drain tube
E E E E

Q
w
w Q
Q Q
Inside of exhaust pipe is dirty with oil
w
w
Engine oil temperature rises quickly
Blow-by gas
Black
Q
Comes out excessively
Q w
Q
w
Does not come out at all

q
Play of turbocharger shaft is excessive
Exhaust port of EGR valve is dirty with oil
q q
See S-7
Exhaust gas is
Check breather and breather hose directly
Inspect oil cooler directly
Inspect oil filter directly
Spring of oil filter safety valve is hitched or broken
D275AX-5E0
Replace
Replace
Clean
Clean
Replace
Replace
Replace
Remedy
Replace
Inspect turbocharger lubrication drain tube directly
Check items
Defective oil filter safety valve
Even when engine oil temperature rises, oil filter clogging monitor indicates clogging
(if monitor is installed)
Troubleshooting
Clogged oil filter
Clogged oil cooler
Clogged breather or breather hose
Worn valve or valve guide
Worn EGR valve guide
Defective seal at turbocharger turbine end
Causes
Clean
Questions
General causes why oil becomes dirty quickly

q
Entry of exhaust gas into oil due to internal wear
q
Clogging of lubrication passage
q
q
Use of improper oil
q
Overload operation
19
SEN01648-00
40 Troubleshooting
S-10 Fuel consumption is excessive
General causes why fuel consumption is excessive

q
Leakage of fuel
q
Defective condition of fuel injection (fuel pressure or injection timing)
q
Malfunction of injector
Defective spray by injector
Defective common rail pressure
Defective supply pump plunger
Defective feed pump oil seal
Fuel leakage from fuel filter, piping, etc.
Fuel leakage inside head cover
Causes
E E
Gradually increased
Q Q
Suddenly increased
There is external leakage of fuel from engine
Combustion is irregular
w
w
w
Low idle speed is high
Torque converter stall speed or pump relief speed is high

Exhaust gas is
Q Q
Black
Q Q
White
Remove head cover and inspect inside directly
Inspect feed pump oil seal directly
Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indicated by code
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change
When spill hose from injector is disconnected, much fuel spills

Carry out troubleshooting according to "Coolant Temp Sens High (Low) Error (*2)" indicated by
code
Correct
Replace
Replace
Correct
Correct
Remedy
q
Replace
Confirm with real-time monitoring mode
Correct
Check items
Engine oil level rises and oil smells of diesel fuel
Troubleshooting
Q Q Q
Q
Correct
Fuel consumption
E
Q
Is large compared to other machines of same model
Replace
Questions

20
D275AX-5E0
40 Troubleshooting
SEN01648-00
S-11 Oil is in coolant

(or coolant spurts back or coolant level goes down)
General causes why oil is in coolant

q
Leakage in lubrication system
q
Leakage in cooling system
q
Internal leakage in hydraulic oil cooler or power train oil cooler
Broken hydraulic oil cooler or power train oil cooler
Broken oil cooler core or O-ring
Insufficient protrusion of cylinder liner
Damaged cylinder liner O-ring or holes caused by pitting
Crack in cylinder block
Broken cylinder head or head gasket
Causes

Oil level
Oil level has risen and oil is milky
Q Q
There are excessive air bubbles in radiator and coolant spurts back
w
w
When hydraulic oil or power train oil is drained, water flows out
Leakage from cylinder head is detected by pressure test
q q
Inspect cylinder block and liner directly
Inspect cylinder liner directly
D275AX-5E0
Replace
Replace
Replace
Remedy
Replace

H-mode
Hydraulic oil or power train oil is milky
Check items
Q Q
Gradually increased
Hard water is used as coolant
Troubleshooting
Suddenly increased
Replace
Questions
21
SEN01648-00
40 Troubleshooting
S-12 Oil pressure drops
General causes why oil pressure drops

q
Leakage from, clogging, or wear of lubrication system
q
Defective oil pressure control
q
Improper selection of fuel (improper viscosity)
q
Deterioration of oil due to overheating
Defective oil pressure sensor or wiring harness
Leaking EGR hydraulic piping
Defective EGR oil pump
Leaking, crushed, or clogged hydraulic piping
Clogged oil filter
Defective oil pump relief valve
Defective oil pump
Clogged or broken pipe in oil pan
Clogged strainer in oil pan
Coolant or fuel in oil
Lack of oil in oil pan
Worn journal of bearing
Causes
E
Q w
Oil pressure monitor indicates low oil pressure (if monitor is installed)
Q
Non-specified oil is used
Q
w
w
Indicates pressure drop at low idle

Oil pressure monitor
(if installed)
Indicates pressure drop at low, high idle
Indicates pressure drop on slopes
Check items
w w w Q
Q Q
Sometimes indicates pressure drop

Oil level monitor indicates oil lever drop (if monitor is installed)
Oil level in oil pan is low
External hydraulic piping is leaking or crushed
Oil is milky or smells of diesel oil

There are metal particles in oil drained from oil filter
There are metal particles in oil filter
q q
Inspect oil pan strainer and pipe directly
Oil pump is heavy to rotate or it has play

See S-13
Troubleshooting
Valve spring of oil pump relief valve is fatigued or damaged

Inspect oil filter directly
Relief valve of EGR oil pump is damaged or oil leaks through it
q
q
q
q
Inspect EGR hydraulic piping directly

Carry out troubleshooting according to "Eng Oil Press Sensor High (Low) Error (*1)"
indicated by code
Replace
Replace
Correct
Replace
Adjust
Replace
Clean
Clean
Add
Replace
Remedy
q
Replace
Questions
*1: Displayed codes [CA135] and [CA141]
22
D275AX-5E0
SEN01648-00
40 Troubleshooting
S-13 Oil level rises (Entry of coolant or fuel)
General causes why oil level rises

q
Coolant in oil (milky)
q
Fuel in oil (smells diluted diesel fuel)
a If oil is in coolant, carry out troubleshooting for "S-11 Oil is in
coolant"
Fuel consumption has increased
Q Q
Coolant must be added more frequently
Q Q
Oil smells of diesel fuel

Oil is milky
Q Q
When engine is started, water drops from muffler
Q Q
When radiator cap is removed and engine is run at low idle, abnormally many bubbles
come out or coolant spurts back
w
w
Q
Q
Exhaust gas is white
Q
w
Water pump drain hole (breather hole) is clogged
When water pump drain hole (breather hole) is cleaned, coolant flows out
w
Oil level in damper chamber is low
Oil level in hydraulic tank is low

When EGR cooler outlet gas piping is removed, coolant containing antifreeze flows out
(*1).
q
q
Troubleshooting
Remove and inspect head cover directly
q q
Inspect cylinder block and liner directly
Inspect rear oil seal directly
Remove and inspect water pump directly
Remove and inspect thermostat cover directly
Remove and inspect supply pump directly
q
Replace
Correct
Replace
Replace
Correct
Replace
Replace
Correct
Replace
Remedy
Replace
Inspect seal of auxiliary equipment directly
24
Defective seal of auxiliary equipment (pump and compressor)
Defects in supply pump
Defective thermostat seat
Clogged water pump drain hole (breather hole) or defective seal
Broken oil cooler core or O-ring
Worn or damaged rear oil seal
Cracks inside cylinder block
E E
There is oil in coolant
Check items
Fuel leakage inside cylinder block
Replace
Questions
Cracked EGR cooler (Entry of coolant)
Causes
D275AX-5E0
40 Troubleshooting
SEN01648-00

D275AX-5E0
25
SEN01648-00
40 Troubleshooting
S-14 Coolant temperature becomes too high (Overheating)

General causes why coolant temperature becomes
too 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
Rise of power train oil temperature
Defective fan drive pump or fan motor

on H-mode

on H-mode
Defective coolant temperature gauge
Deformed or damaged fan
Defective radiator cap (pressure valve)
Clogged radiator core
Clogged or crushed radiator fins
Malfunction of thermostat
Broken water pump
Low coolant level
Clogged or broken oil cooler
External leakage of coolant from EGR cooler
Causes
E E E

Overheating
Coolant temperature
gauge (if installed)
E E
Occurred suddenly
Q w
Q
Q w w
Has continued at low level

Q
Rises quickly
w
w
Does not go down from red range
Radiator coolant level monitor indicates low (if monitor is installed)
w
w Q
Engine oil level has risen and oil is milky
Milky oil is floating on coolant

w
There are many bubbles in radiator and coolant spurts back
w
w
Dirt and mud are accumulated in radiator shroud and undercover
Coolant is leaking because of cracks in hose or loose clamps
Coolant flows out from radiator overflow hose

Power train oil temperature enters red range faster than engine coolant
temperature (if oil temperature gauge and coolant temperature gauge are
installed)
q
Inspect EGR cooler for coolant leakage
Inspect cylinder liner directly
Inspect oil cooler directly

Temperature difference between upper and lower tanks of radiator is
large
q
q
Thermostat does not open at cracking temperature

Temperature difference between upper and lower tanks of radiator is
slight
q
q
Inspect radiator core directly
Cracking pressure of radiator cap is low
Inspect fan directly
26
Replace
Correct
Correct
Replace
Replace
Add
Replace
Remedy
Replace
q
Replace
Measured fan speed is low

Replace
Coolant temperature is normal
Replace
Check items
When light applied to radiator core, no light passes through
Troubleshooting
Correct
Questions
D275AX-5E0
40 Troubleshooting
SEN01648-00
S-15 Abnormal noise is made
General causes why abnormal noise is made

q
Abnormality due to defective parts
q
Abnormal combustion
q
Air sucked in from intake system
a Judge if the noise is an internal noise or an external
noise before starting troubleshooting.
a The engine is operated in the low-temperature mode
while it is not warmed up sufficiently. Accordingly, the
engine sound becomes a little larger. This does not
indicate abnormality, however
a When the engine is accelerated, it is operated in the
acceleration mode and its sound becomes a little
larger for up to about 5 seconds. This does not indicate abnormality, however

(Defective coolant temperature sensor)
Dirt caught in injector
Deformed cooling fan
Removed or seized gear train bushing
Improper gear train backlash
Excessive wear of piston ring or cylinder liner
Defective inside of muffler (Removal of bulkhead)
Broken dynamic valve system (valve, rocker lever, etc.)
Cracked or leaking EGR gas piping
Interference of turbocharger or seized turbocharger
Causes

Abnormal noise
Gradually increased
Q
Q

w
Air leaks between turbocharger and cylinder head
When engine is rotated, interference sound comes out from around turbocharger
When engine is rotated, abnormal sound comes out from around EGR gas
piping
w
w
Check items
Q Q Q
Suddenly increased
w
w
When engine is rotated, beat noise comes out from around muffler
cylinder is low
Exhaust gas is
w Q
w

Q w
Black
Q
w

Q
Abnormal noise is loud when engine is accelerated
Q Q
Inspect EGR gas piping directly

Troubleshooting
Q
w
When muffler is removed, abnormal noise disappears
q q
Inspect fan directly

does not change
q q
q
Abnormal noise comes out only at start of engine
D275AX-5E0
Correct
Replace
Correct
Replace
Replace
Replace
Adjust
Replace
Correct
Replace
Replace
Remedy
Replace
Correct
Questions
27
SEN01648-00
40 Troubleshooting
S-16 Vibration is excessive
General causes why vibration is excessive

q
Defective parts (abnormal wear, breakage, etc.)
q
Misalignment between engine and applicable machine
q
Abnormal combustion
a If abnormal noise is made and vibration is excessive, carry out troubleshooting for "S-15 Abnormal noise is made", too
Broken parts in damper
Worn front support spigot joint
Misalignment of engine and power train
Loose engine mounting bolts or broken cushions
Improper injection timing
Worn camshaft bushing
Improper gear train backlash
Worn main bearing or connecting rod bearing
Stuck dynamic valve system (valve, rocker lever, etc.)
Causes
Oil pressure is low at low idle

Vibration
Suddenly increased
Gradually increased
Vibration occurs at medium speed

Q
Vibration follows engine speed

Exhaust gas is black
Q Q Q Q
Inspect main bearing and connecting rod bearing directly

Troubleshooting
Inspect camshaft bushing directly
Inspect engine mounting bolts and cushions directly
Radial runout or facial runout is detected
Inspect front support spigot joint directly
28
Replace
Adjust
Replace
Adjust
Replace
Replace
Replace
Remedy
Replace
Inspect inside of damper directly
Replace
Check items
Questions
D275AX-5E0
SEN01648-00
40 Troubleshooting
30
D275AX-5E0
SEN02340-00
BULLDOZER
1SHOP MANUAL
D275AX-5E0
Machine model
Serial number
D275AX-5E0
30001 and up
50 Disassembly and assembly1

General information on disassembly and
assembly
How to read this manual ................................................................................................................................. 2
List of adhesives ............................................................................................................................................. 4
Special tool list ................................................................................................................................................ 7
Sketchs of special tools ................................................................................................................................ 15
D275AX-5E0
SEN02340-00
How to read this manual
1. Removal and installation of assemblies

Special tools
q
Special tools which are deemed necessary for removal or installation of parts are
described as A1,X1 etc. and their part
names, part numbers and quantities are
described in the special tool list.
q
Also the following information is described
in the special tool list.
1) Necessity
t : Special tools that cannot be substituted and should always be used
(installed).
q : Special tools that will be useful if available and are substitutable with commercially available tools.
2) Distinction of new and existing special
tools
N:
Tools newly developed for this
model. They respectively have a
new part number.
R:
Tools with upgraded part numbers.
They are remodeled from already
available tools for other models.
Blank: Tools already available for other
models. They can be used without
any modification.
3) Circle mark Q in sketch column:
q
The sketch of the special tool is presented in the section of "Sketches of
special tools".
q
Part No. of special tools starting with
79 T:
means that they can not be supplied
from Komatsu in Japan (i.e. locally
made parts ).
* *** ****
General tools that are necessary for

removal or installation are described as
[1], [2]etc. and their part names, part
numbers and quantities are not described.
Removal
q
The "Removal" section contains procedures
and precautions for implementing the work,
know how and the amount of oil or coolant to
be drained.
q
Various symbols used in the "Removal" section
are explained and listed below.
k : Precautions related to safety in execution
of work.
a: This mark gives guidance or precautions when
doing the procedure.
[*1] : This mark shows that there are instructions or
precautions for installing parts.
6 : This mark shows the amount of oil or coolant
to be drained.
4 : Weight of part or component
Installation
q
Except where otherwise instructed, installation
of parts is done in the reverse order of removal.
q
Instructions and precautions for installing parts
are shown with [*1] mark in the "Removal" section, identifying which step the instructions are
intended for.
q
Marks shown in the "Installation" section stand
for the following.
of work.
2 : Type of coating material
3 : Tightening torque
5
: Quantity of oil or coolant to be added
Sketches of special tools

Various special tools are illustrated for the convenience of local manufacture.
D275AX-5E0
SEN02340-00
2. Disassembly and assembly of assemblies

Special tools
q
Special tools which are deemed necessary for disassembly and assembly of
parts are described as A1,X1 etc. and
their part names, part numbers and quantities are described in the special tool list.
q
Also the following information is described
in the special tool list.
1) Necessity
t : Special tools that cannot be substituted
and should always be used (installed).
q : Special tools that will be useful if available and are substitutable with commercially available tools.
2) Distinction of new and existing special
tools
N
: Tools newly developed for this
model. They respectively have a
new part number.
R
: Tools with upgraded part numbers.
They are remodeled from already
available tools for other models.
Blank : Tools already available for other
models. They can be used without
any modification.
3) Circle mark Q in sketch column:
q
The sketch of the special tool is presented in the section of "Sketches of
special tools".
q
Part No. of special tools starting with
79 T:
means that they can not be supplied
from Komatsu in Japan (i.e. locally
made parts ).
* *** ****
D275AX-5E0
Disassembly
q
In "Disassembly" section, the work procedures,
precautions and know-how for carrying out
those procedures, and quantity of the oil and
coolant drained are described.
q
The meanings of the symbols used in "Disassembly" section are as follows.
of work.
6: Quantity of oil or coolant drained
Assembly
q
In "Assembly" section, the work procedures,
precautions and know-how for carrying out
those procedures, and quantity of the oil and
coolant added are described.
q
The meanings of the symbols used in "Assembly" section are as follows.
of work
2 : Type of coating material
3 : Tightening torque
5
: Quantity of oil or coolant to be added
Sketches of special tools

Various special tools are illustrated for the convenience of local manufacture.
General tools that are necessary for disassembly and assembly are described
as [1], [2]etc. and their part names,
part numbers and quantities are not
described.
SEN02340-00
List of adhesives
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disassembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this list.
Adhesive
Category
Komatsu
code
Part No.
Q'ty
Container
Main features and applications
LT-1A
790-129-9030
150 g
Tube
Used to prevent rubber gaskets, rubber cushions, and

cork plugs from coming out.
LT-1B
790-129-9050
20 g
(2 pcs.)
Polyethylene
container
Used for plastic (except polyethylene, polypropylene,

tetrafluoroethylene and vinyl chloride), rubber, metal,
and non-metal parts which require immediate and
strong adhesion.
LT-2
09940-00030
50 g
LT-3
790-129-9060 Adhesive:
(Set of
1 kg
adhesive and Hardener:
hardener)
500 g
LT-4
790-129-9040
250 g
Holtz MH
705
790-129-9120
75 g
ThreeBond
790-129-9140
1735
Aron-alpha
790-129-9130
201
Gasket sealant
Used to stick and seal metal, glass, and plastics.
Polyethylene
Used to seal plugs.
container
Tube
Heat-resistant seal used to repair engines.
50 g
2g
Quick-setting adhesive.
Polyethylene Quick-setting type.
container
(max. strength is obtained after 30 minutes)
Used mainly to stick rubbers, plastics, and metals.
Polyethylene Features: Resistance to heat and chemicals.
container
Used for fitted portions used at high temperatures.
79A-129-9110
50 cc
LG-1
790-129-9010
200 g
790-129-9080
Can
Quick-setting adhesive.
Polyethylene Setting time: Within 5 sec. to 3 min.
container
Used mainly to stick metals, rubbers, plastics, and
woods.
Loctite
648-50
LG-5
Polyethylene Features: Resistance to heat and chemicals.

container
Used to fix and seal bolts and plugs.
1 kg
Tube
Used to stick or seal gaskets and packings of power

train case, etc.
Used to seal various threaded portions, pipe joints,

Polyethylene
and flanges.
container
Used to seal tapered plugs, elbows, and nipples of
hydraulic piping.
LG-6
790-129-9020
200 g
Tube
Features: Silicon-based heat and cold-resistant sealant.

Used to seal flange surfaces and threaded portions.
Used to seal oil pan, final drive case, etc.
LG-7
790-129-9070
1 kg
Tube
Features: Silicon-based quick-setting sealant.

Used to seal flywheel housing, intake manifold, oil
pan, thermostat housing, etc.
ThreeBond
790-129-9090
1211
100 g
Tube
Gasket sealant used to repair engine.
ThreeBond
419-15-18131
1207B
100 g
Tube
Features: Silicon-based, heat and cold-resistant,

vibration-resistant, impact-resistant sealant.
Used to seal transfer case, etc.
D275AX-5E0
Komatsu
code
Part No.
Q'ty
Container
LM-G
09940-00051
60 g
Can
To be sed as lubricant (anti squeaking) for sliding part.
Tube
To be used for press fit, shrink fit and preventing scratching or seizure of thread.
To be used as lubricant for linkage and bearing
etc..
LM-P
G2-LI
G0-LI(*)
* For cold
region
Grease
G2-CA
200 g
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
SYG2-160LI
SYGA-160CNLI
SYG0-400LI-A
(*)
SYG0-16CNLI
(*)
Various
kinds
Various kinds Versatile type
SYG2-400CA
SYG2-350CA
SYG2-400CA-A
SYG2-160CA
SYGA-160CNCA
Various
kinds
Various kinds
To be used for the place where the bearing

designed for normal temperature and low load
condition is used and contacts water and
steam.
400 g x 10 Bellows type

400 g x 20
16 kg
Can
Used for parts under heavy load.

Caution: Do not use this grease for ball bearings such as swing circle bearing.
Apply this grease to work equipment pins only when installing but
do not use it after then.
Grease with
molybdenum
disulphide
LM-G(G2-M)
SYG2-400M
SYG2-400M-A
SYGA-16CNM
Hyper white
grease
G2-T G0-T(*)
*: For cold
region
SYG2-400T-A
SYG2-16CNT
SYG0-400T-A
(*)
SYG0-16CNT
(*)
400 g
16 kg
Bellows type
Can
Higher anti seizure and heat resistance than

grease with molybdenum disulphide
Body dirt is not distinctive due to white color.
Biological
grease G2-B
G2-BT(*)
*: For heat
resistance
and heavy
load
SYG2-400B
SYGA-16CNB
SYG2-400BT
(*)
SYGA-16CNBT
(*)
400 g
16 kg
Bellows type
Can
To be shortly dissolved by a bacteria in nature

so that the influence to microorganism and animals and plants is suppressed to the minimum.
20 ml
Glass
container
To be used as primer for cab side.

(Term of validity: 4 months after manufacturing)
20 ml
Glass
container
To be used as primer for glass side.

20 ml
Glass
container
Sunstar
primer for
painting plane
580 super
Sunstar
primer for
glass 580
super
Primer
09940-00040
Sunstar
primer for
painting plane
435-95
Sunstar
primer for
glass
435-41
Sunstar
primer for
sash
GP-402
D275AX-5E0
417-926-3910
22M-54-27230
22M-54-27240
22M-54-27250
150 ml
Steel can
20 ml
Glass
container
For adhesion of cab glass
Lubricant with
molybdenum disulfide
Category
SEN02340-00
To be used as primer for painting plane of

cab side.
To be used as primer for black ceramic
coated plane of glass side and polycarbonate hard coat plane.
To be used as primer for sash (Alumite
surface treatment)
SEN02340-00
Komatsu
code
Part No.
Q'ty
Container
Sunstar penguin seal 580

super "S" or
"W"
417-926-3910
320 ml
Polyethylene
container
"S" and "W" are used as glass adhesive

compound in high temperature (April October) and in low temperature (October
-April ) respectively.
Sika Ltd,
Japan Sika
Flex 256HV
20Y-54-39850
310 ml
Polyethylene
container
To be used as glass adhesive compound.

Sunstar
pengiun
super 560
22M-54-27210
320 ml
ECOCART
(special container)
Sunstar
pengiun seal
No. 2505
417-926-3920
320 ml
Polyethylene
container
Sekisui silicone sealant
20Y-54-55130
333 ml
Polyethylene
container
GE Toshiba
Silicones
Tosseal 381
22M-54-27220
333 ml
Cartridge
For adhesion of cab glass
Coaking compound
Adhesive compound
Category
To be used as glass adhesive compound.

To be used as seal for joints of glass.
To be used for seal of front window.
To be used as seal for joints of glass.
semi-transparent white seal
D275AX-5E0
SEN02340-00
Special tool list
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.
bolt
01643-31032
washer
795-521-1110
Push tool
t 1
790-101-5221
Grip
t 1
01010-51225
Bolt
t 1
01010-31640
Bolt
t 3
Seal puller
t 1
3 795-931-1100
795T-421-1210 Push tool

Engine assembly
Bolt
t 4
01050-31625
Bolt
t 4
795T-421-1220 Push tool

Bolt
t 4
01050-31645
Bolt
t 4
Wrench
q 1
Remover
t 1
Puller
(294kN {30ton})
t 1
790-101-1102
Pump
t 1
791-612-1100
Installer
t 1
790-101-4200
Puller (294kN {30ton})
t 1
790-101-1102
Hydraulic pump
t 1
799-301-1600
Oil leak tester
t 1
791-622-1110
Bracket
t 1
1 01010-62095
Bolt
t 1
01016-61690
Bolt
t 1
Wrench
t 1
791-451-1000
7 790-101-2102
Damper assembly
TORQFLOW transmission assembly
2 796-550-1301
D275AX-5E0
Sketch
t 1 N Q
5 01050-31625
6 790-331-1110
HSS case assembly
t 1 N Q
A 4 01050-31645
Removal of fuel supply

pump assembly
Removal, installation
t 1
Installation of Engine front

seal
Installation of Engine rear

seal
Tighten of cylinder head bolt

Installation of radiator
guard
1 01010-81080
Remover
Nature of work, remarks
Press fitting of bearing
Disassembly, assembly
795-630-5500
Part Name
Checking actuation of piston
Part No.
Qty
Symbol
New/remodel
Component
Necessity
: 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)
Removal, Installation of
Brake-carrier assembly
Removal, Installation of lock nut
Lifting tool
t 1
791-627-1320
Shackle
t 2
791T-627-1810 Plate
t 1
01010-82090
Bolt
t 2
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
790-101-1102
Pump
t 1
791-627-1200
Remover
t 1
4 790-101-2102
Puller
t 1
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
Installer
t 1
7 791-627-1280
Sketch
Pulling out sprocket bearing
Removal of planetary gear

shaft
Removal of hub assembly
Press fitting of hub bearing
Press fitting of cover bearing

Installation of floating seal
791-630-1220
Rod
t 4
790-101-2510
Block
t 2
790-101-2570
Plate
t 4
01643-31445
Washer
t 4
01580-01411
Nut
t 4
790-101-2102
t 1
790-101-1102
Pump
t 1
2 791-515-1520
Installer
t 1
3 791-630-1240
Push tool
t 1
Press fitting of seal guide

Filling with oil
t 1
Lifting tool
t 1
790-401-1761
Adapter
t 1
790-401-1540
Shackle
t 2
790-401-1770
T-bolt
t 2
6 791T-630-1320 Plate
t 1 N Q
7 791T-630-1330 Push tool
t 1 N Q
8 791-651-1510
Installer
t 1
9 791-601-1000
Oil pump
t 1
14 791T-630-1380 Bracket
t 4
Oil pump
790-401-1700
4 791-601-1000
L
t 1 N Q
Idler assembly
Removal, Installation of final drive assembly
791T-630-1310 Plate
Track roller assembly
790-337-1032
Press fitting of bushing
Installation of No.1track
roller assembly
Filling with oil
Final drive assembly
Part Name
Part No.
New/remodel
Symbol
Qty
Component
Necessity
SEN02340-00
Secure bogie assembly
D275AX-5E0
Nut wrench
t 1
11 791-675-1510
Installer
t 1
t 1 N Q
13 791-601-1000
t 1
791T-630-1380 Bracket
t 2
791-630-1360
Spacer
t 1 N
790-101-2310
Block
t 1
790-101-2360
Plate
t 2
Screw
t 2
791-112-1180
Nut
t 2
790-101-4000
t 1
790-101-1102
Pump
t 1
790-201-2760
Spacer
t 1 N
791-630-1370
Adapter
t 1
790-434-1060
Screw
t 2
Nut
t 2
01643-33080
Washer
t 1
790-101-4000
t 1
790-101-1102
Pump
t 1
17 796-230-1120
t 1
18 790-701-3000
Seal checker
t 1
Check the airtight of the

floating seal
t 1 N Q
Adjustment procedure for

cartridge pin hole
19 791T-630-1390 Guide
790-101-2310
Block
t 1
790-445-4130
Screw
t 2
796T-470-1130 Plate
t 1
Plate
t 2
791-112-1180
Nut
t 2
790-101-4000
t 1
790-101-1102
Pump
t 1
20 790-101-2360
Oil pump
t 1
790-101-2310
Block
t 1
790-445-4130
Screw
t 2
21 791-601-1000
796T-470-1130 Plate
t 1
Plate
t 2
791-112-1180
Nut
t 2
790-101-4000
t 1
790-101-1102
Pump
t 1
Oil pump
t 1
20 790-101-2360
21 791-601-1000
D275AX-5E0

Filling with oil
16 01580-13024
Bogie assembly
t 6
15 790-445-4130
Oil pump
Removal, Installation of nut
791T-630-1380 Bracket
14
No. 2, 3, 4 Bogie
assembly
Sketch
12 791T-630-2410 Push tool
10 790-102-1891
Removal of shaft, ring
Track frame assembly
Part Name
Removal of shaft, ring
Press fitting of cartridge

pin assembly
Filling with oil
Carrier roller assembly
Part No.
Qty
Symbol
New/remodel
Component
SEN02340-00
Necessity
Press fitting of cartridge

pin assembly
Filling with oil
t 1
t 1
791-630-1870
Bracket
t 1
791-730-1110
Bolt
t 6
1 01580-12722
Nut
t 6
Washer
t 6
Installer
t 1
Cylinder (686kN {70ton})
t 1
790-101-1102
Pump
t 1
791-685-8502
Compressor
t 1
790-201-2780
Spacer
t 1
Extension
t 1
790-101-1600
Cylinder (686kN {70ton})
t 1
790-101-1102
Pump
t 1
791-630-1100
2 790-101-1600
M
3 791-635-3160
Equalizer bar bushing
N1
N2
791T-650-1930 Spacer
t 1 N Q
792-900-1520
Plate
t 1
791-520-4140
Screw
t 1
790-101-2470
Adapter
t 1
790-101-2540
Washer
t 1
791-112-1180
Nut
t 1
790-101-2102
t 1
790-101-1102
Hydraulic pump
t 1
791-650-1800
Remover
t 1
790-101-2102
t 1
790-101-1102
Hydraulic pump
t 1
Lifting tool
t 1
1 790-401-1700
791-650-1700
2 790-101-4200
790-101-1102
10
Installer
t 1
t 1
Hydraulic pump
t 1
Adapter
Bracket
790-401-1761
01643-32780
Equalizer bar assembly
t 1
791-630-1860
L
23
Lifting tool

track roller assembly
Pull up of No.1Bogie assembly
Disassembly of Idler yoke,
recoil cylinder
No.1 Bogie assembly
790-401-1700
Disassembly, assembly of
22
t 2
Removal of center pin
14 791T-630-1380 Bracket
spherical bushing
Part Name
Sketch
Part No.
New/remodel
Symbol
Qty
Component
Necessity
SEN02340-00
pivot shaft assembly
Press fitting of seal
D275AX-5E0
Sketch
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
791-601-1000
Pump
t 1
Installer
t 1 N
Remover & installer
t 1
Guide
t 1
t 1
791-680-1520
7 790-101-4200
790-101-4300
Cylinder (1470kN {150ton}) t 1
790-101-1102
Pump
t 1
791-632-1500
Push tool assembly
t 1 N
791-632-1420
Adapter
1 N
791-632-1430
Ring
1 N
791-632-1440
Plate
1 N
791-632-1450
Ring
1 N
Push tool
1 N
Adapter
1 N
791-632-1480
Spring
1 N
791-685-5730
Bar
01252-30650
Bolt
01580-01210
Nut
791-632-1400
Push tool assembly
791-632-1410
Adapter
1 N
791-632-1430
Ring
1 N
791-632-1440
Plate
1 N
791-632-1450
Ring
1 N
R 8 791-632-1460
791-632-1470
Track shoe assembly
9 791-632-1460
10
t 1 N
Push tool
1 N
791-632-1470
Adapter
1 N
791-632-1480
Spring
1 N
791-685-5730
Bar
01252-30650
Bolt
01580-01210
Nut
791-632-1490
Push tool
t 1 N
791-685-5740
Push tool
t 1
Supply oil
Installation of seal assembly
Disassembly of a link
6 791-632-1070
Plug remover
791-680-9802
D275AX-5E0
Part Name
1 791-646-7531
5
Track shoe assembly
Part No.
Qty
Symbol
New/remodel
Component
SEN02340-00
Necessity
Assembly of a link
11
12
Track shoe assembly

13
14
15
Track shoe assembly
790-434-1110
Adapter
t 1
790-434-1610
Guide
t 1
195-32-61210
Bolt
t 1
01010-51440
Bolt
t 2
790-101-4300
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
790-434-1110
Adapter
t 1
01010-51030
Bolt
t 1
04530-12030
Eyebolt
t 1
790-101-4300
790-101-1102
Pump
t 1
791-685-9540
Rod
t 1
791-685-9550
Nut
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 2
791-685-9560
Bolt
t 4
791-126-0150
Adapter
t 1
791-680-5520
Guide
t 1
791-126-0140
Pusher
t 1
790-434-1110
Adapter
t 1
01010-51030
Bolt
t 1
04530-12030
Eyebolt
t 1
791-685-9620
Extension
t 1
790-101-4300
790101-1102
Pump
t 1
791-680-1630
Spacer
t 1
t 1
Pump
t 1
16 790-101-4200
790-101-1102
12
Sketch
Part Name
11
Part No.
New/remodel
Symbol
Qty
Component
Necessity
SEN02340-00
Disassembly of a single
link
D275AX-5E0
791-680-5543
Adapter (for pin)
t 1
791-680-9630
Adapter (for bush)
t 1
790-101-4300
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
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
790-101-1102
Pump
t 1
791-685-9510
Frame
t 1
791-685-9520
Frame
t 1
791-685-9530
Rod
t 1
791-685-9540
Rod
t 1
791-685-9550
Nut
t 3
791-685-9560
Bolt
t 4
791-126-0150
Adapter
t 1
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
19 791-126-0150
Track shoe assembly
20
790-101-4300
790-101-1102
Pump
t 1
790-101-4200
t 1
790-101-1102
Pump
t 1
22 790-434-1160
Guide
t 1
21
D275AX-5E0
Sketch
Part Name
17
Part No.
Qty
Symbol
New/remodel
Component
SEN02340-00
Necessity
Assembly of a single link
13
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
Adapter
t 1
790-434-1150
Guide
t 1
790-434-1110
Adapter
t 1
01010-51030
Bolt
t 1
790-434-1160
Guide
t 1
790-101-4300
790-101-1102
Pump
t 1
790-502-1003
Cylinder repair stand
t 1
2
3
Hydraulic cylinder asU

sembly
5
790-101-1102
Pump
t 1
790-102-2303
Wrench
t 1
790-102-3802
Wrench
t 1
790-102-4300
Wrench
t 1
790-102-4310
Pin
t 2
790-201-1702
Push tool kit
t 1
790-101-5021
Clip
01010-50816
Bolt
790-201-1831
Push tool
790-201-1851
Push tool
790-201-1841
Push tool
790-201-1500
Push tool kit
Related to air conditioner
14
Assembly of a single link
Sketch
Disassembly, assembly of
hydraulic cylinder
Removal and assembly of
round head
Removal and assembly of
round head
For press fitting coil bushing
(Blade lift)
(Blade tilt, ripper lift)
(Ripper tilt)
790-101-5021
Clip
01010-50816
Bolt
790-201-1640
Plate
790-201-1650
Plate
(Blade tilt)
790-201-1660
Plate
For press fitting dust seal
(Ripper lift, ripper tilt)
(Blade lift)
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
07281-01919
Clamp
t 1
796-720-1680
Ring
t 1
(Blade tilt)
07281-01589
Clamp
t 1
(Blade tilt)
799-703-1200
Service tool kit
t 1
6 790-720-1000
t 1
Frame
791-685-9510
R 23 791-126-0150
Part Name
New/remodel
Part No.
799-703-1100
Vacuum pump (100W)
t 1
799-703-1110
Vacuum pump (220W)
t 1
799-703-1120
Vacuum pump (240W)
t 1
799-703-1401
Gas leak detector
t 1
Track shoe assembly
Symbol
Qty
Component
Necessity
SEN02340-00
Filling with air conditioner

refrigerant (gas)
D275AX-5E0
Sketchs of special tools
SEN02340-00
Note: We will not be liable for any result caused by a special tool made according to this drawing.
J1 Plate
L1 Plate
D275AX-5E0
15
SEN02340-00
L6 Plate
L7 Push tool
16
D275AX-5E0
SEN02340-00
L12 Push tool
L14 Bracket
D275AX-5E0
17
SEN02340-00
L19 Guide
L20 Plate
18
D275AX-5E0
SEN02340-00
N1 Spacer
D275AX-5E0
19
SEN02340-00
20
D275AX-5E0
SEN02341-00
BULLDOZER
1SHOP MANUAL
D275AX-5E0
Machine model
Serial number
D275AX-5E0
30001 and up

Removal and installation of engine assembly ................................................................................................. 2
Removal and installation of radiator assembly (including hydraulic oil cooler assembly and aftercooler
assembly) ................................................................................................................................................ 7
Removal and installation of hydraulic oil cooler assembly ............................................................................ 10
Removal and installation of aftercooler assembly......................................................................................... 12
Removal and installation of radiator guard assembly ................................................................................... 14
Removal and installation of fuel tank assembly ............................................................................................ 19
Removal and installation of engine hood assembly ...................................................................................... 20
Removal and installation of fan drive assembly ............................................................................................ 22
Removal and installation of fan motor assembly .......................................................................................... 24
D275AX-5E0
SEN02341-00
Removal and installation of

engine assembly
6. Disconnect sub-tank hose (6), aeration hose

(7), radiator inlet hose (8) and aftercooler inlet
hose (9).
[*1]
799-703-1200
Service tool kit
t 1
799-703-1100
Vacuum pump
(100 V)
t 1
799-703-1110
Vacuum pump
(220 V)
t 1
799-703-1120
Vacuum pump
(240 V)
t 1
799-703-1401
Gas leak detector t 1
Sketch
New/Remodel
Part name
Q'ty
Part No.
Necessity
Special tools
Sym
bol
Removal
k
k
k
5. Disconnect wiring connector (CN-RDG) (4) and

clamp (5).
Lower the work equipment to the ground and

stop the engine.
Set the parking brake lever and work equipment lock lever in the lock position.
Disconnect the cable from the negative ()
terminal of the battery.
7. Open undercover (10).

4
Undercover: 250 kg
1. Drain the coolant.

6
Coolant: 110 l
2. Remove the engine hood assembly. For details,

see "Removal and installation of engine hood
assembly".
3. Remove the right and left covers (1) and right
and left step covers (2).
8. Disconnect radiator lower tank inlet hose (11)

and radiator outlet hose (12) from the engine.
4. Remove right and left lower side covers (3).
D275AX-5E0
9. Disconnect ground cable (13).
SEN02341-00
12. Disconnect the wiring clamp.

13. Disconnect wiring intermediate connectors 101
(17), E21 (18) and E22 (19).
10. Disconnect air conditioner hoses (14) and (15).

[*2]
a Recover all the refrigerant (R134a) from the
air conditioner circuit.
a Plug the hoses so that dirt and water will
not enter them.
a Disconnect all the hose clamps.
14. Remove the hose clamp and disconnect heater

hoses (20) and (21) and disconnect air conditioner hoses (22) and (23).
[*3]
a Close the heater hose valve on the engine
side.
11. Disconnect starting motor wiring (16).

15. Disconnect wiring connectors PT1 (24) and
SS3 (25).
a You may remove the mounting bolts and
remove the wiring connectors and brackets
together without disconnecting the wiring
connectors.
D275AX-5E0
SEN02341-00
16. Disconnect heater switch wiring (26) (connected to aftercooler outlet).
21. Lift off bracket (32) (including the bulkhead and

sub-tank assembly) and lower plate together.
4
Bracket assembly: 180 kg
17. Close the fuel valve.

18. Disconnect fuel supply hose (27).
19. Disconnect fuel return hoses (28) and (29).
22. Sling universal joint assembly (33).

23. Remove the mounting bolts and lift off the universal joint assembly.
[*4]
4
20. Remove plate (30) and 2 bracket mounting

bolts (31).
a Similarly remove the plate and bolts on the
right side.
Universal joint assembly: 30 kg
24. Loosen clamps (34) and (35) and remove outlet

tube (36).
[*1]
D275AX-5E0
25. Remove 4 engine mounting bolts (37) and (38)

on the front and rear sides.
[*5]
SEN02341-00
Installation
Carry out installation in the reverse order to removal.
[*1]
a Set insertion length (c) of hose (a) and tube (b)
to the following value.
Hose (7): Min. 25 mm
Hose (8): 60 mm
26. Lift off engine assembly (39).

a Before lifting off, check that all the wirings
and pipings are disconnected.
4
Engine assembly: 2,050 kg
Air hose
a Use brand new article for MIKALOR clamp.
1) Align the hose to the original position
(marked position). (Air hose insertion depth:
80 mm)
a Clamp (35): Clamping position
2) Place the bridge (BR) under the clamping

bolt and adjust the overlapping (b) between
the bridge (BR) and band to MIN. 5 mm.
(b) dimension: Min. 5 mm
3
Threaded portion (BC) of clamping

blot: Lubricant (PANDO 18B from
Threebond)
a Impact wrench is not applicable to use.
D275AX-5E0
SEN02341-00
When the current hose is reused

3) Align the clamp position to the trace of the
clamp left on the hose.
3
Universal joint mounting bolt:

98.10 123 Nm {10 12.5 kgm}
Clamp tightening bolt:

Min. 6 Nm {0.6 kgm}
[*4]
When a new hose is used

4) Tighten the bolt until (a) dimension is:
17 20 mm
[*5]
Engine mounting bolt:

824 1,030 Nm {84 105 kgm}
Refilling with water

Add coolant through the coolant filler to the
specified level. Run the engine to circulate the
water through the system. Then, check the
water level again.
Cooling water: Approx. 110 l
Charging air conditioner with refrigerant gas

Using tool X, charge the air conditioner circuit
with refrigerant (R134a).
[*2] [*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 Before tightening each air conditioner hose
connector, check that the O-ring is fitted to it.
a Apply compressor oil (Showa-Shell, Sniso 4G
or 5G) sufficiently to the O-rings.
Tightening torque for refrigerant gas pipes

Thread size
Tightening torque
16 x 1.5
11.8-14.7Nm {1.2-1.5kgm}
22 x 1.5
19.6-24.5Nm {2-2.5kgm}
24 x 1.5
29.4-34.3Nm {3-3.5kgm}
D275AX-5E0
Removal and installation of radiator assembly (including hydraulic

oil cooler assembly and aftercooler assembly)
1
SEN02341-00

4
Undercover: 250 kg
Removal
k

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 outlet hose (6).
a Disconnect the hose and tubes together.
3. Move the radiator top inspection cover and disconnect headlamp wiring connector 209 (2).
7. Disconnect oil cooler hose (7) and radiator
lower tank inlet hose (8).
a Disconnect the hoses and tubes together.
4. Lift off radiator top cover (3).
D275AX-5E0
SEN02341-00
8. Disconnect wiring connector (CN-RDG) (9) and

clamp (10).
9. Disconnect sub-tank hose (11).
[*1]
10. Remove the right and left wind breaking panels.
17. Remove mounting bolts (19) (4 pieces on each

of the right and left sides).
11. Remove the engine hood. For details, see

"Removal and installation of engine hood
assembly".
12. Disconnect aeration hose (12), radiator inlet
hose (13) and aftercooler inlet hose (14).
13. Remove air conditioner condenser assembly
(15) and move it toward the engine.
14. Remove right and left brackets (16) and radiator right and left mounting bolts (17).
18. Lift off radiator assembly (20).

4
Radiator assembly: 500 kg
15. Disconnect the aftercooler outlet hose. For

details, see "Removal and installation of aftercooler assembly".
16. Remove the guard and fan net. Remove the
mounting bolts of lowest shroud (18) to make a
space for removing the mounting bolts on the
front side of the radiator.
D275AX-5E0
SEN02341-00
Installation
[*1]
Reservoir hose clamp:
34 5 Nm {3.4 0.5 kgm}

a Set insertion length (c) of hose (a) and tube
(b) to the following values.
Hoses (11) and (12): Min. 25 mm
Hose (13): 60 mm

Add coolant through the coolant fillers of the
main radiator and sub-radiator to the specified
level. Run the engine to circulate the water
through the system. Then, check the water
level again.
Cooling water: 110 l
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
D275AX-5E0
SEN02341-00

hydraulic oil cooler assembly
5. Open the undercover.
6. Remove hydraulic oil cooler lower cover (6).
Removal
k
Disconnect the cable from the negative (-)

1. Drain the hydraulic oil.

6
2. Remove the radiator top cover. For details, see

"Removal and installation of radiator assembly
(including hydraulic oil cooler and aftercooler
assembly)".
3. Disconnect connector (1) and 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).
8. Remove the 4 upper and lower mounting bolts

and lift off hydraulic oil cooler assembly (9).
4
10
Hydraulic oil cooler assembly: 35 kg
D275AX-5E0
SEN02341-00
Installation

again.
5
D275AX-5E0
11
SEN02341-00
Removal and installation of aftercooler assembly

1
5. Loosen the clamp of stay (7) and disconnect

aftercooler outlet hose (8) from the aftercooler.
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 inlet hose (3).
a Drain the coolant in advance to a degree
that the coolant will not leak when the radiator 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).
12
D275AX-5E0
9. Open the undercover.

10. Remove aftercooler lower mounting bolt (13)
and lift off aftercooler assembly (14).
SEN02341-00
Installation

Add coolant through the coolant fillers of the
main radiator and sub-radiator to the specified
level. Run the engine to circulate the water
through the system. Then, check the water
level again.
5
D275AX-5E0
Cooling water: 110 l
13
SEN02341-00
Removal and installation of radiator guard assembly

1
791-451-1000
A 7 790-101-2102
790-101-1102
Remover
t 1
Puller
(294kN {30ton})
t 1
Pump
t 1
Sketch
Part name
New/Remodel
Part No.
Q'ty
Sym
bol
Necessity
Special tools
2. Disconnect hose (3).

k Release the residual pressure in the hydraulic circuit. For details, see Testing
and adjusting, "Releasing residual pressure in hydraulic circuit".
a Plug the piping to prevent dirt from entering
it.
Removal
k

1. Remove blade lift cylinder cap (1).

a Check the thickness and quantity and of
shim (3).
[*1]
k Run the engine, retract the piston rod to
the stroke end, and bind it with wires so
that it will not come off down.
3. Sling blade lift cylinder assembly (4), install the

cylinder fitting to it, and fix it to the radiator
guard.

5
Coolant: 110 l
5. Remove the engine hood assembly. For details,

see "Removal and installation of engine hood
assembly".
6. Disconnect wiring connector (5).
7. Disconnect aeration hose (6), sub-tank hose
(7), radiator inlet hose (8) and aftercooler inlet
hose (9).
[*2]
14
D275AX-5E0
SEN02341-00

lower tank inlet hose (13).
[*2]
a Disconnect the hose and tube together.

6 Hydraulic tank: 130 l
9. Remove right and left side covers (10).

outlet hose (15).
a Disconnect the hoses and tubes together.

4
Undercover: 250 kg
D275AX-5E0
13. Disconnect fan motor hoses (16), (17) and (18)

and blade lift cylinder hose (19).
15
SEN02341-00
14. Remove hydraulic oil cooler lower cover (20).
15. Remove lower hydraulic oil cooler hoses (21)

and (22).
16. Remove air conditioner condenser mounting

bolts (23) and put down condenser (24) toward
the engine.
a Do not disconnect the condenser hoses but
remove only the mounting bolts and put the
hoses aside.
18. Loosen the clamp of stay (26) and disconnect

aftercooler outlet hose (27) from the aftercooler.
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.
[*3]
20. Remove lock plate (30). Using tool A7, pull out
front pin (31) toward outside of the radiator
guard to remove.
17. Remove condenser mounting bracket (25).
16
D275AX-5E0
21. Lift off radiator guard assembly (32).

a Take care extremely not to damage the wiring and piping.
4
Radiator guard assembly: 2,450 kg
SEN02341-00
Installation
[*1]
Install the blade lift cylinder according to the following 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.
Standard clearance (a): 0.2 0.5 mm
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
D275AX-5E0
17
SEN02341-00
[*3]
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

Add coolant through the coolant filler to the
specified level. Run the engine to circulate the
water through the system. Then, check the
water level again.
5

again.
18
Coolant: 110 l
D275AX-5E0
SEN02341-00
Removal and installation of fuel

tank assembly
1
7. Disconnect fuel level sensor wiring connector

423 (7).
Removal
8. Disconnect 3 fuel hoses (8).

1. Remove step (1).

2. Remove cover (2).
9. Remove 4 mounting bolts (9).
4. Close the fuel supply valve.

5. Remove drain hose clamp (4) and drain block
(5).
10. Lift off fuel tank assembly (10).
4
Fuel tank assembly:

390 kg (When empty)
1,100 kg (When full)
6. Remove plate (6).
Installation
D275AX-5E0
19
SEN02341-00

engine hood assembly
Removal
6. Remove the clamp and disconnect sub-tank

hose (5).
7. Remove left rear mounting bolt (6).

"Removal and installation of radiator assembly".
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).
4. Disconnect sub-tank hose (3).
5. Remove front right and left mounting bolts (4).
20
11. Disconnect muffler tube (11).

12. Remove right rear mounting bolt (12).
D275AX-5E0
13. Lift off engine hood assembly (13).

4
Engine hood assembly: 210 kg
D275AX-5E0
SEN02341-00
Installation
21
SEN02341-00
Removal and installation of fan

drive assembly
1
4. Remove the hose clamp and disconnect fan

motor hoses (3), (4) and (5).
Removal
5. Disconnect fan motor wiring connector (6).

5
6. Remove lowest shroud (7).

a Put an oil stopper to the piping so that dirt
will not enter the piping.
2. Remove the mounting bolts and radiator mask

(1).
4
Radiator mask: 92 kg
7. Sling fan drive assembly (8) and remove the

mounting bolts.
3. Remove fan net (2).
22
8. Lift off fan drive assembly (8).

4
Fan drive assembly: 135 kg
D275AX-5E0
SEN02341-00
Installation

again.
5
D275AX-5E0
23
SEN02341-00

motor assembly
1
5. Remove the 4 mounting bolts and fan motor

assembly (4).
[*3]
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).
24
D275AX-5E0
SEN02341-00
Installation
[*1]
Be sure to align the hole of lock plate (1) by rotating
nut (2) in the tightening direction.
[*2]
Mounting nut (2):
441 539 Nm {45 55 kgm}

a After tightening the nut, check dimension (d)
shown in the figure below.
MIN: 1.2 mm
MAX: 3.0 mm
[*3]
a Wipe off dirt from the engaging portions of the
fan motor and fan, and then degrease those
parts.
D275AX-5E0
25
SEN02341-00
26
D275AX-5E0
SEN02342-00
BULLDOZER
1SHOP MANUAL
D275AX-5E0
Machine model
Serial number
D275AX-5E0
30001 and up

Engine
Removal and installation of fuel supply pump assembly ................................................................................ 2
Removal and installation of common rail ........................................................................................................ 6
Removal and installation of cylinder head assembly ...................................................................................... 9
Removal and installation of fuel injector assembly ....................................................................................... 20
Removal and installation of engine front seal ............................................................................................... 24
Removal and installation of engine rear seal ................................................................................................ 26
D275AX-5E0
SEN02342-00

supply pump assembly
1
Special tools
795-630-550
A1 01010-81080
01643-31032
Standard puller
5. Remove left lower side cover (2).

Sketch
Part name
New/Remodel
Part No.
Q'ty
4. Open the left side cover.

Necessity
Sym
bol
3. Release the residual pressure in the fuel system. For details, see Testing and adjusting,
"Releasing residual pressure in fuel system".
t 1
Bolt
Washer
Removal
k
k
k

stop the engine.
6. Remove fuel main filter (3) and disconnect fuel

supply hose (fuel prefilter) (4).
[*1]
1. Close the fuel valve.

2. Remove undercover (1).
7. Remove clamp (6) of high-pressure pipe (5)

between the common rail and supply pump.
8. Remove clamp (7) and joint bolt (8) and then
remove tube (9) between the fuel main filter
head and supply pump.
[*2]
9. Disconnect fuel return hose (10).
[*3]
D275AX-5E0
10. Remove bolts (11) of the 3 clips and joint bolt

(12) and disconnect tube (13).
[*4]
11. Remove filler gauge (14).
12. Remove high-pressure pipe (5).
SEN02342-00
16. Rotate the crankshaft forward to set intermediate point "a" between the stamps of 2/5 TOP
and 3/4 TOP on damper (22) to pointer (23).
a At this time, check that the forcing tap of the
drive gear is set to the bolt hole at the top of
cover (21). (If not, rotate the crankshaft 1
more turn.)
a At this point, the key of the pump shaft is
rotated 15 degrees clockwise from the top.
13. Remove coolant pipe bracket (15) and oil

cooler cover (16).
14. Remove fuel tube and lubrication tube (17).
[*5]
Disconnect wiring connectors PCV1 (18), PCV2
(19) and G (20).
15. Remove engine front cover (21).
D275AX-5E0
17. Remove mounting nut (24).

[*6]
a Take care not to drop the mounting nut into
the gear case.
18. Remove mounting bolts (26) of fuel supply

pump assembly (25) and bracket (27).
a Keep bolts (26) tightened by 2 3 turns to
prevent the pump from falling.
SEN02342-00
19. Set tool A1 and tighten bolt (B) to remove gear

(25) from the shaft.
20. Remove remaining mounting bolts (26) and fuel
supply pump assembly (25).
a If tool A1 is removed, the gear falls.
Accordingly, keep tool A1 installed until the
pump is installed.
Installation
1. Set fuel supply pump assembly (25).
a Before setting, check that key (d) of shaft
aligns to the key slot (e) of drive gear.
2. Temporarily tighten four mounting bolts (26),
bracket (27) and high-pressure (5) with fingers.
2
Mounting bolt: Liquid adhesive (LT-2)
High-pressure piping
When handing the high-pressure piping and

clamp, pay attention to the following.
It is strictly prohibited to bend the high-pressure piping to use it again or using it in other
locations.
Install the specified clamp securely in the
specified position with the specified torque.
Don't apply lubricant and the like to the highpressure 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.
Before installing the high-pressure piping,
check it for the following defects. If there is
any of these defects, it can cause fuel leakage. Accordingly, replace the high-pressure
piping.
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).
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.
D275AX-5E0
SEN02342-00
[*4]
Joint bolt of fuel tube (13):

14.8 19.6 Nm {1.5 2.0 kgm}
(Supply pump side)
17.7 22.6 Nm {1.8 3.0 kgm}
(Common rail side)
[*5]
7.9 12.7 Nm {0.8 1.3 kgm}

(Supply pump side)
9.8 12.7 Nm {1.0 1.3 kgm}
(Block side)
3. Tighten high-pressure pipe (5) permanently.

3
Sleeve nut:
39.2 44.1 Nm {4 4.5 kgm}
(Both on common rail side and supply
pump side)
4. Tighten fuel supply pump (25) permanently

3
3
5. Finger tighten upper and lower high-pressure

pipe clamps (6) and then tighten them permanently in order.
Mounting nut of fuel supply pump drive gear:

176 196 Nm {18 20 kgm}
59 74 Nm {6.0 7.5 kgm}

19.6 29.4 Nm {2.0 3.0 kgm}
[*6]
Fuel supply pump mounting bolt:

Bracket (27) mounting bolt:
Joint bolt of lubrication tube (17):
Check that the fuel injector wiring harness is

at least 10 mm apart from the high-pressure
pipe.
Bleed air from the fuel system, referring to
Bleeding air from fuel system in Testing and
adjusting.
Clamp bolt: 9.8 1 Nm {1.0 0.1 kgm}
Carry out the following installation in the reverse

order of removal.
[*1]
Fuel supply hose:

128 186 Nm {13 19 kgm}
[*2]
Joint bolt of fuel tube (9):

14.8 19.6 Nm {1.5 2.0 kgm}
(Supply pump side)
24.5 34.3 Nm {2.5 3.5 kgm}
(Fuel filler side)
[*3]
Joint bolt of fuel hose (10):

14.8 19.6 Nm {1.5 2.0 kgm}
D275AX-5E0
SEN02342-00
Removal and installation of common rail

1
5. Remove common rail cover (7).
Removal
1. Remove left side cover (1).
6. Remove high-pressure pipe (5).

7. Remove bolts (8) of the 3 clips, joint bolt (9) and
tube (10).
2. Remove fuel filter (2).
8. Remove clamp (12) of high-pressure pipe (11).
3. Disconnect fuel supply hose (3) and remove

fuel prefilter (4).
9. Disconnect fuel level gauge sensor wiring (13).

between the common rail and supply pump.

on the injector side and clamp (15) on the common rail side.
D275AX-5E0
11. Loosen sleeve nut (16) and disconnect highpressure pipe (11).
12. Remove the mounting bolts of common rail (17)
to remove the common rail.
SEN02342-00
Installation
High-pressure piping
k
D275AX-5E0
When handing the high-pressure piping and

clamp, pay attention to the following.
It is strictly prohibited to bend the high-pressure piping to use it again or using it in other
locations.
Install the specified clamp securely in the
specified position with the specified torque.
Don't apply lubricant and the like to the highpressure 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.
Before installing the high-pressure piping,
check it for the following defects. If there is
any of these defects, it can cause fuel leakage. Accordingly, replace the high-pressure
piping.
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).
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.
SEN02342-00
1. Set common rail (17) to the installation position

and fix it temporarily with the mounting bolts
and then tighten all of 6 sleeve nuts (16) of the
high-pressure pipe (11) on the common rail
side.
2. Tighten the sleeve nuts of the high-pressure
pipe (Both on common rail side and injector
side) permanently and then tighten the common rail mounting bolts permanently.
3
8. Tighten clamp (6) temporarily and then tighten

them permanently.
3
High-pressure pipe sleeve nut (Both on

injector side and common rail side):
39.2 44.1 Nm {4 4.5 kgm}
Common rail mounting bolt:
59.0 74.0 Nm {6.0 7.5 kgm}
Clamp bolt: 9.8 1 Nm {1 0.1 kgm}
Carry out the following installation in the reverse

order to removal.
Check that each high-pressure pipe is at
least 10 mm apart from the wiring harness
around it. If not, adjust the wiring harness to
secure a clearance of 10 mm.
Bleeding air
Bleed air from the fuel system. For details, see
Testing and adjusting, "Bleeding air from fuel
system".
3. Tighten high-pressure pipe clamp (14), (15)

permanently.
3
Clamp bolt: 9.8 1 Nm {1 0.1 kgm}
4. Install each cover (18) with clip (19) so that its

slit portion will be as shown in the figure.
5. Connect the fuel pressure sensor wiring.

6. Install tube (10) with joint bolt (9) and fix it with
the clip.
3
3
Joint bolt (Sapply pump):

14.8 19.6 Nm {1.5 2.0 kgm}
Joint bolt (Common rail pressure limiter
area): 17.7 22.6 Nm {1.8 2.3 kgm}
7. Install high-pressure pipes (5) temporarily to

the common rail side and supply pump side and
then tighten them permanently.
3
High-pressure pipe sleeve nut (Both on

common rail side and supply pump side):
39.2 44.1 Nm {4 4.5 kgm}
D275AX-5E0
SEN02342-00
Removal and installation of cylinder head assembly

1
A 6 790-331-1110
Wrench
Sketch
Part name
New/Remodel
Part No.
Q'ty
Sym
bol
Necessity
Special tools
q 1
Removal
k
k
k

stop the engine.
1. Remove the engine hood referring to the section "Removal and installation of engine hood
assembly".
8. Remove two joint bolts (8), and remove fuel

main filter head assembly (9).
[*1]
9. Remove two joint bolts (10), and remove corrosion resistor head assembly (11).
[*2]
10. Remove fuel tube (12), and remove priming
pump bracket assembly (13).
[*3]

6
Coolant: 110 l
3. Remove stay (1).
12. Disconnect connecters, BP, SBP, EGR and

SEGR.
4. Remove filter head side mounting bolt of tube

(2), and remove oil filter head assembly (3).
5. Disconnect fuel hose (4).
6. Remove fuel tube (5), and remove fuel pre filter
head assembly (6).
D275AX-5E0
SEN02342-00
13. Disconnect connector PEVA (19).
19. Remove air intake housing.

1) Remove tube (25) and block (26).
14. Disconnect terminal RHT (20).

15. Remove breather tube (21).
16. Remove wiring harness bracket (22).
17. Remove air intake connector (23).
[*4]
2) To secure the room for operation, loosen

the tension of belt and move air conditioner
compressor downward, referring the section of Testing and adjusting, "Testing and
adjusting air conditioner compressor belt
tension".
[*5]
3) Remove air intake housing (27).
18. Remove air intake connector (24).

20. Remove oil tube bracket (28) and oil filler tube
bracket (29).
21. Disconnect fuel hose (30).
10
D275AX-5E0
SEN02342-00
22. Remove clamp (31).

23. Remove mounting bolts of bracket (32), and
move bracket (32) with hose (33).
24. Disconnect connectors, TFUEL (34), TIM (35)

and PIM (36).
25. Remove spill tube (37).
26. Remove two, upper and lower side, wiring harness clamps (38) at the rear side of intake manifold.
27. Remove charge pressure sensor (39) with plate

(40) and bracket (41).
a This is to secure the room for operation to
loosen turbocharger lubrication tube clamp.
[*6]
28. Remove five stays (42) for high pressure pipe
clamp.
[*7]
D275AX-5E0
11
SEN02342-00
29. Remove stays (43), (44), (45) and (45a), for

high pressure pipe clamp.
[*8]
32. Remove heat insulation covers, (48), (49) and

(50).
30. Remove water tube (46) in front of intake manifold.
33. Remove muffler (51).
31. Remove intake manifold (47).
34. Remove tube (52).
12
[*9]
Muffler: 62 kg
[*10]
Intake manifold: 50 kg
D275AX-5E0
SEN02342-00
35. Remove heat insulation covers (53) and (54),

and bracket (56).
40. Remove heat insulation cover (62).

41. Remove brackets (63), (64), (64a) and (64b)
and remove bypass tube (65).
[*12]
36. Remove EGR tube (57).
[*11]
37. Remove water tube (58).
42. Remove oil tube (66) and water tube (67). [*13]
38. Remove turbocharger side mounting bolt for oil

tube (59).
39. Remove heat insulation cover (60) and bracket
(61).
43. Remove turbocharger and exhaust manifold

assembly (68).
[*14]
4
D275AX-5E0
Turbocharger and exhaust manifold

assembly: 80 kg
13
SEN02342-00
44. Disconnect connectors CN1 (69), CN2 (70),

CN3 (71), CN4 (72), CN5 (73) and CN6 (74),
and move wiring harnesses (75) and (76).
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).
48. Remove water tube (82).
[*19]
49. Remove cylinder head cover (83).
[*20]
50. Rotate crankshaft forward, align damper

"1.6TOP" stamp line (c) to pointer (91), and
then set the No.1 cylinder to the compression
top dead center.
a Crank the crankshaft at hexagonal part (d)
of water pump drive shaft tip.
45. Remove common rail cover (77) and clamp

(78).
[*15]
46. Remove spill tube (79).
[*16]
47. Remove cover (80) and high pressure pipe (81)

depending on the cylinder head assembly to be
removed.
[*17] [*18]
14
51. Remove three mounting bolts (84) through (86),

and remove rocker arm and rocker shaft
assembly (87).
a Loosen lock nut (89), and loosen adjustment screw (90) two or three turns to prevent excessive force applied to push rod
(88), when installing rocker arm and rocker
shaft assembly.
[*21]
D275AX-5E0
52. Remove fuel injector assembly.

1) Remove wiring harness clamping bolt (92)
and clip (93).
[*22]
2) Remove two wiring harness capture nuts
(94) from fuel injector assembly.
[*23]
a Loosen nuts alternately.
3) Unscrew bolt (95) to remove holder (96).
4) Push connecter (97) into rocker housing,
and remove injector wiring harness (98).
[*24]
a O-ring is installed in connector (97).
SEN02342-00
53. Remove two push rods (102).
54. Remove crosshead (103).

55. Remove three mounting bolts (104), three bolts
(105) and auxiliary bolt (106), and remove cylinder head assembly (107).
5) Remove mounting bolt (100) of holder (99).

[*25]
6) Set L type bar [1] under fuel injector assembly inlet connector (e), and remove slowly
fuel injector assembly (101) with holder
using leverage action.
[*26]
a Do not grip the solenoid valve at the top
of the injector to pull off the injector.
D275AX-5E0
15
SEN02342-00
Installation
a When tool A6 is not available, put marks (a)

and (b) to bolt and cylinder head, and
retighten bolt 90 (+30/0).
2) Tighten auxiliary bolt (tightening order: 7th)
with the following torque.
1. Install cylinder head assembly.

1) Install cylinder head gasket (115).
a Check that the mounting surface of cylinder head and the inside of cylinders
are free from foreign material.
a Check that the gasket is free from peeling or coming off of grommet.
Auxiliary bolt:
66.6 7.4 Nm {6.8 0.8 kgm}
2) Check cylinder head mounting bolts for the

following items, and if out of standard,
replace mounting bolt without reusing it.
Bolt tightening should be 5 times or less.
(The number of punch mark at the head
of bolt should be 5 or less.)
Bolt under head length service limit (a)
Short bolt:Less than 170.8 mm
Long bolt:Less than 205.8mm
3) Install cylinder head assembly.

4) Tighten mounting bolts in order of 1 through
6 as shown in the figure.
2
Mounting bolt:
Lubricant with molybdenum disulfide (LM-P)
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 A6.
16
D275AX-5E0
2. After installing cross head (103), make adjustment as follows.

1) Loosen lock nut (111), and loosen adjustment screw (112).
2) Lightly push cross head (103) contact surface (h) with rocker arm, and hold cross
head to contact with push rod (102) side
valve stem (113).
3) Screw slowly adjustment screw (112), and
check the position where adjustment screw
touches valve stem (114).
4) From the above condition, screw adjustment screw (112) 20.
5) While holding adjustment screw (112) with
a flat-head screwdriver, tighten locknut
(111).
3
Locknut:
58.7 5.9 Nm {6.0 0.6 kgm}
SEN02342-00
4. Carry out the rest of installation in the reverse

order of removal.
[*1] [*2]
3
Joint bolt: 24.5 34.3 Nm {2.5 3.5 kgm}
[*3]
Fuel tube sleeve nut:

43 47 Nm {4.4 4.8 kgm}
[*4] [*10]
a When loosened hose clamp, replace clamp
with new one.
a Tighten the hose clamp according to the following procedure.
1) Locate the punch mark (f) of bridge (108)
as shown in the figure, and adjust the position of bridge to be under band (109).
2) Tighten bolt (110) so that the dimension (g)
is between 8 and 10 mm.
2
Threaded portion of bolts:
PANDO 18B from Three Bond

3) Tighten bolt (110) with the following torque.
3Bolt:
25 5 Nm {2.55 0.5 kgm}
3. Install push rod (102).

a Raise push rod slightly, and check that
push rod is securely inserted in cam follower.
[*5]
a Adjust the tension of air compressor belt, referring Testing and adjusting section "Testing and
adjusting of air conditioner compressor belt tension".
D275AX-5E0
17
SEN02342-00
[*12]
[*6]
3
3
Joint bolt (37a):
9.8 12.7 Nm {1.0 1.3 kgm}

Joint bolt (37b):
19.6 29.4 Nm {2.0 3.0 kgm}
Threads and seat surface of bypass tube

mounting bolt: Lubricant with molybdenum
disulfide (LM-P)
Bypass tube mounting bolt:
44.1 53.9 Nm {4.5 5.5 kgm}
[*13]
Oil tube cylinder block side joint bolt:

24.5 34.3 Nm {2.5 3.5 kgm}
[*14]
a Tighten exhaust manifold mounting bolts in the
numerical order shown below.
Threads of mounting bolt:

Lubricant with molybdenum disulfide
(LM-P)
Mounting bolt: 58.8 73.5 Nm {6 7.5 kgm}
[*7] [*8] [*15] [*18]

a Install high pressure pipe, clamp, stay and
common rail cover referring to the section,
"Removal and installation of fuel injector
assembly".
[*9]
a Tighten intake manifold mounting bolts in the
numerical order shown below.
Mounting bolt: 58.8 73.5 Nm {6 7.5 kgm}
[*16]
Spill tube joint bolt:

9.8 12.7 Nm {1.0 1.3 kgm}
[*17]
a Install cover with the notch downward.
[*19]
9.8 12.7 Nm {1.0 1.3 kgm}
[*11]
Water tube joint bolt:
EGR tube mounting bolt threaded portion:

Lubricant with molybdenum disulfide
(LM-P)
EGR tube mounting bolt, EGR tube and
bracket mounting bolt:
[*20]
Cylinder head cover mounting bolt:

29.4 34.3 Nm {3.0 3.5 kgm}
44.1 53.9 Nm {4.5 5.5 kgm}
18
D275AX-5E0
[*21]
a When installing rocker arm and rocker shaft
assembly (87), check the ball portion of adjustment screw (90) to be inserted securely into
socket of push rod (88), and tighten mounting
bolts.
a As three mounting bolts are different each
other, install them referring the followings.
Mounting bolt (84): Stem length 120mm
Mounting bolt (86): Stem length 75.2 mm
3
SEN02342-00
[*25] [*26]
a Install the fuel injector assembly referring to the
section, "Removal and installation of fuel injector assembly".
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 (98).
2) Install injector wiring harness (98) in rocker
housing, install holder (96) and tighten bolt
(95).
3) Install clip (93).
4) Tighten two capture nuts (94).
a Tighten capture nuts alternately.
3
Capture nut: 2 0.2 Nm {0.2 0.02 kgm}
5) Install wiring harness clamping bolt (92).
D275AX-5E0
19
SEN02342-00

injector assembly
1
5. Remove clamp (7) and stay (8), and remove

common rail cover (9).
[*2]
Removal
a This section explains the procedure for removing No.1 fuel injector assembly.
k
k
k

stop the engine.
1. Remove the engine hood referring to the section "Removal and installation of engine hood
assembly".
6. Remove clamp (10), and remove cover (11).
2. Remove tube (1) filter head side mounting bolt,

and remove oil filter head assembly (2).
8. Remove stays (13) through (16).
7. Loosen sleeve nut (12).
3. Remove two joint bolts (3), and remove fuel

main filter head assembly (3a).
[*1]
4. Remove tube (5) and block (6).
20
D275AX-5E0
SEN02342-00
9. Remove cylinder head cover (17).
[*3]
[*4]
11. Remove mounting bolts (19) through (21), and

remove rocker arm and rocker shaft assembly
(22).
[*5]
a Loosen lock nut (24), and loosen adjustment screw (25) two or three turns to prevent excessive force applied to push rod
(23), when installing rocker arm and rocker
shaft assembly.
16. Set L type bar [1] under fuel injector assembly

inlet connector (a), and remove slowly fuel
injector assembly (32) with holder (33) using
leverage action.
a Do not pull out solenoid valve portion at the
top of injector by pinching with pliers, etc.
12. Loosen sleeve nut (26), and remove high pressure pipe (27) from injector.
13. Remove wiring harness clamping bolt (28) and
clip (29).
[*6]
14. Remove two wiring harness capture nuts (30)
from fuel injector assembly.
[*7]
a Tighten nuts alternately.
15. Remove holder mounting bolt (31).
D275AX-5E0
21
SEN02342-00
Installation
1. Install fuel injector assembly.
1) Check that no foreign material stays inside
injector sleeve.
2) Install O-rings (34) and (35), and gasket
(36) to injector.
a Take care not to install O-ring to groove
(b).
6) Tighten bolts (31) to the specified torque.

3
Bolt (31):
58.8 73.5 Nm {6 7.5 kgm}

7) Tighten sleeve nuts (26) and (12).
3
Sleeve nuts (26) and (12):

39.2 49 Nm {4 5 kgm}
3) Set fuel injector assembly (32) with holder

(33) to cylinder head.
4) Attach spherical washer (37) to bolt (31),
and tighten temporarily bolt (31).
3
Spherical washer: Engine oil
5) Tighten temporarily high pressure pipe

sleeve nuts (26) and (12).
k
Install high pressure pipe after

checking the followings. If an abnormality takes place, it may cause fuel
leakage, and replace high pressure
pipe.
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).
Check the difference at (d) portion (tip of
taper seal portion: within 2 mm from the
tip) for any catches on a finger nail (no
fatigue).
2. Install high pressure pipe clamp and stay.

1) Temporarily tighten high pressure pipe
clamp, stay (16), clamping bolts (38)
through (42), and stay mounting bolt, with
fingers.
2) Tighten permanently high pressure pipe
clamping bolt.
3
Clamping bolt:
9.8 1 Nm {1 0.1 kgm}

3) Tighten permanently stay mounting bolt.
4) Temporarily tighten high pressure pipe
clamp, stay (15), clamping bolts (44)
through (48), and stay mounting bolt, with
fingers.
5) Install cover (11).
a Install with the notch toward cylinder
block side.
6) Install high pressure pipe clamp (10) and
common rail cover (9) temporarily.
7) Tighten clamping bolt for high pressure pipe
clamp (10) permanently.
3
Clamping bolt:
9.8 1 Nm {1 0.1 kgm}
22
D275AX-5E0
8) Tighten common rail cover (9) permanently.

9) Tighten high pressure pipe clamp, stay (15)
and clamping bolts (44) through (48), permanently.
3
Clamping bolt:
9.8 1 Nm {1 0.1 kgm}

10) Tighten permanently stay mounting bolt.
SEN02342-00
a As 3 mounting bolts are different each other,
install them referring to the followings.
Mounting bolt (20): Stem length 90 mm
Mounting bolt (21): Stem length 75.2 mm
Mounting bolts (19), (20) and (21):
93 103 Nm {9.5 10.5 kgm}

a Adjust valve clearance referring to the section
of Testing and adjusting, "Adjusting valve clearance".
[*6] [*7]
a Install wiring harness according to the following
procedure.
1) Install clip (29).
2) Tighten two capture nuts (30).
a Tighten capture nuts alternately.
3
Capture nut:
2 0.2 Nm {0.2 0.02 kgm}

3) Tighten wiring harness clamping bolt (28).
3. Install the subsequent procedure in the reverse
order of removal.
[*1]
3
Joint bolt: 24.5 34.3 Nm {2.5 3.5 kgm}
[*2]
Clamping bolt (7): 9.8 1 Nm {1 0.1 kgm}
[*3]
Cylinder head cover mounting bolt:

29.4 34.3 Nm {3.0 3.5 kgm}
[*4]
a Install with the notch downward.
[*5]
a When installing rocker arm and rocker shaft
assembly (22), check the ball portion of adjustment screw (25) to be inserted securely into
socket of push rod (23), and tighten mounting
bolts.
D275AX-5E0
23
SEN02342-00

engine front seal
Installation
A2
795-521-1110
Push tool
t 1
790-101-5221
Grip
t 1
01010-51225
Bolt
t 1
01050-31640
Bolt
t 3
Sketch
Part name
New/Remodel
Part No.
Q'ty
Sym
bol
Necessity
Special tools
Removal
1. Remove the radiator guard assembly. For
details, see Removal of radiator guard assembly.
2. Sling damper pulley (1) temporarily and remove
the mounting bolts.
[*1]
3. Lift off damper pulley (1).
4. Remove front seal (2).
24
[*2]
[*1]
a Match the taper pin of the damper pulley and
tighten the 6 mounting bolts.
3
Mounting bolt:
245 309 Nm {25 31.5 kgm}
[*2]
Installation procedure for front seal (2)
a Before installing the seal, make sure that
the end corners and lip sliding surfaces of
the crankshaft and housing are free from
flaw, burr, fin, and rust.
a When installing the seal, do not apply oil or
grease to the shaft and seal lip. Wipe off
the oil from the shaft.
a Never remove the inside plastic cylinder of
the replacement seal before installing the
seal.
1) Bring the large inside diameter side of plastic inside cylinder (3) to the end of crankshaft (4).
a Take care not to mistake the installing direction.
D275AX-5E0
SEN02342-00
2) Hold the metal ring of seal (2) with both

hands and push it in firmly as if you are
passing over the large inside diameter side
of the plastic inside cylinder.
3) After pushing in seal (2), remove plastic
inside cylinder (3).
a When removing the inside cylinder, take
care not to damage the seal lip.
4) Tighten the bolts of tool A2 evenly to press

fit seal (2) until the end of tool A2 reaches
the end of crankshaft (4).
a When press fitting the seal, take care
not to damage the lip on the PTO side
with the tool set, etc.
a After press fitting the seal, remove the
red sealant layer from its periphery.
D275AX-5E0
25
SEN02342-00

engine rear seal
3 795-931-1100
Seal puller
t 1
Sketch
Push tool
t 1 N Q
4 01050-31645
Bolt
t 4
01050-31625
Bolt
t 4
795T-421-1220
Push tool
t 1 N Q
5 01050-31625
Bolt
t 4
01050-31645
Bolt
t 4
795T-421-1210
A
Part name
New/Remodel
Part No.
Q'ty
Sym
bol
Necessity
Special tools
5. Remove rear seal (2) according to the following

procedure.
a Measure the distance from the end of the
housing.
1) Before pulling out rear seal (2), drive in it a
little to separate it from the housing.
Removal
1. Remove the damper assembly and hub assembly. For details, see "Removal of damper
assembly".
2. Remove 1 mounting bolt of flywheel (1) and
install guide bolt [1].
3. Using eyebolt [1] (12 mm, P = 1.75), sling flywheel (1) temporarily and remove the 8 mounting bolts.
2) If the seal is sleeved, cut and remove

sleeve (5) with a chisel and a hammer.
a When cutting, take care extremely not
to damage crankshaft (4).
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).
a Do not use a drill etc. since chips may
enter the engine.
a If chips were made, remove all of them.
Tool A3
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
26
D275AX-5E0
Installation
a Check the Teflon seal (Laydown lip seal) by
checking the wear of the shaft and replace it
with the "standard seal" or "sleeved seal".
If the shaft is worn to the degree of luster (If
wear which you feel with your finger is less than
10 m) and does not have any flaw, install standard seal (A). In other cases, install sleeved
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
SEN02342-00
1. Procedure for installing standard seal

a When installing rear seal (2), do not apply
oil or grease to the shaft and seal lip.
1) Set large inside diameter side (b) of plastic
inside cylinder (3) of rear seal (2) to the end
of crankshaft (4).
a Take care not to mistake the direction of
the plastic inside cylinder.
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 plastic
inside cylinder (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 surface (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.
D275AX-5E0
27
SEN02342-00
4) Tighten the 3 bolts evenly to press fit rear

seal (2) until the end of tool A4 (for press fitting the seal) reaches the end of crankshaft
(4).
a Tighten tool A4 (for press fitting the
seal) first until it reaches the bolt (45
mm) and then tighten the bolt (25 mm).
a When press fitting the seal, take care
not to damage the lip on the PTO side
with the tool set etc.
2. Procedure for installing sleeved seal

a When installing the rear seal, do not apply
oil or grease to the shaft and sleeve inside
cylinder surface (C).
1) Set sleeve and rear seal assembly (6) to
tool A5 (for fitting the sleeved seal).
2
Sleeve inside cylinder surface (C):

28
2) Set sleeve of the rear seal to the end of

crankshaft (4) and tighten the 3 bolts evenly
to press fit sleeve and rear seal assembly
(6) until the end of tool A5 reaches the end
of crankshaft (4).
sleeved seal) first until it reaches the
bolt (45 mm) and then tighten the bolt
(25 mm).
3) Remove tool A5 (for press fitting the

sleeved seal) and install tool A4 (for press
fitting the seal).
4) Tighten the 3 bolts evenly to press fit sleeve
and rear seal assembly (6) until the end of
tool A4 (for press fitting the seal) reaches
the end of crankshaft (4).
seal) first until it reaches the bolt (45
mm) and then tighten the bolt (25 mm).
a Rear seal driving depth:
13.2 0.2 mm from end of crankshaft
a When installing, set the dowel pin of the
crankshaft to the dowel hole of the flywheel.
D275AX-5E0
3. Flywheel
Using eyebolt [1] (12 mm, P = 1.75), sling flywheel (1), install it to the crankshaft, and tighten
the bolts.
a If there are 5 punch marks on a bolt, do not
use that bolt but replace it.
2
SEN02342-00
a After tightening, make 1 punch mark (9) on
each bolt head to indicate the number of tightening time.
Threads and seat of bolt:

Engine oil SAE No. 30
Flywheel: 65 kg
a After installing the flywheel, measure the facial

runout and radial runout with tool [1].
a Radial runout: Max. 0.30 mm
a Facial runout: Max. 0.30 mm
a Tighten the mounting bolts according to the following 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
in
+0
the order of [1] [8].
2) When not using tool A2
Make marks on each bolt and flywheel with paint, then retighten
each bolt by 90 +30
in the order of
+0
[1] [8].
D275AX-5E0
Carry out the following installation in the reverse order to removal.
29
SEN02342-00
30
D275AX-5E0
SEN02343-00
BULLDOZER
1SHOP MANUAL
D275AX-5E0
Machine model
Serial number
D275AX-5E0
30001 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 ........................................................................ 15
Disassembly and assembly of PTO assembly .............................................................................................. 26
Disassembly and assembly of torque converter assembly ........................................................................... 33
Disassembly and assembly of torqflow transmission assembly ................................................................... 43
D275AX-5E0
SEN02343-00

damper assembly
6. Disconnect ground wire (25).
799-703-1200
Service tool kit
t 1
799-703-1100
Vacuum pump
(100 V)
t 1
799-703-1110
Vacuum pump
(220 V)
t 1
799-703-1120
Vacuum pump
(240 V)
t 1
799-703-1401
7. Remove the mounting bolts of damper cover assembly (24).

[*2]
Sketch
New/Remodel
Part name
Q'ty
Part No.
Necessity
Special tools
Sym
bol
5. Using hanging bolt [1], sling damper cover assembly (24) temporarily.
Removal
1. Remove the bracket (bulkhead). For details,
see "Removal and installation of engine assembly".
8. Using 2 forcing screws [2], lift off damper cover

assembly.
[*3]
4
Damper cover assembly: 55 kg
2. Sling universal joint assembly (21).

3. Remove the mounting bolts and lift off universal
joint assembly.
[*1]
4
9. Using hanging bolt [3], sling damper assembly

(26) and remove the mounting bolts.
[*4]
4. Disconnect breather hose (22) and remove it

and oil level detection pipe (23) together.
D275AX-5E0
SEN02343-00
10. Using 2 forcing screws [4], lift off the damper assembly.
4
Damper assembly: 75 kg
D275AX-5E0
SEN02343-00
Installation
Air conditioner hose

them.
a Before tightening each air conditioner hose connector, check that the O-ring is fitted to it.
a Apply compressor oil (Showa-Shell, Sniso 4G or
5G) sufficiently to the O-rings.
[*5]
Damper assembly mounting bolt:

98.10 123 Nm {10 12.5 kgm}
Refilling with oil.

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
Damper chamber oil: 1.5 l (SAE30CD)
3
3
3

Thread size :
16 x 1.5
22 x 1.5
24 x 1.5
Tightening torque
11.8 14.7 Nm {1.2 1.5 kgm}
Drain plug: 58.8 78.5 Nm {6 8 kgm}

Level plug: 127 177 Nm {13 18 kgm}

19.6 24.5 Nm {2 2.5 kgm}

29.4 34.3 Nm {3 3.5 kgm}
[*1]

98.10 123 Nm {10 12.5 kgm}
[*2]
Damper cover assembly mounting bolt:

98.10 123 Nm {10 12.5 kgm}
[*3]
a When installing the damper cover assembly, degrease the shaft spline and apply dry lubricant A
and leave it as it is for 2 - 3 minutes. Then, apply
extreme pressure lithium grease containing molybdenum B to the shaft spline.
A
Molybdenum disulfide
Sumiko, lubricant
dry lubricant
Extreme pressure lith- Kyodo Yushi, Molylex No. 2

B ium grease containing Showa-Shell, Letinax AM
molybdenum
Nihon Sekiyu Molytex
D275AX-5E0
SEN02343-00
Disassembly and assembly of damper assembly
791-612-1100
Installer
t 1
790-101-4200
Puller
(294kN {30ton})
t 1
790-101-1102
Hydraulic pump
t 1
D275AX-5E0
Sketch
Part name
New/Remodel
Part No.
Q'ty
Sym
bol
Necessity
Special tools
SEN02343-00
Disassembly
1. Disassembly of damper cover assembly (1).
1) Coupling
Remove bolt (3) from cover (2), then remove
holder (4) and coupling (5).
3) Bearing and oil seal

i) Remove oil seal (9) from cover (2), then
remove inner race (7-3) of bearing (7).
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).
D275AX-5E0
SEN02343-00
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.
D275AX-5E0
SEN02343-00
Assembly
1. Assembly of damper assembly (10)
1) Set flange (16) and outer body (13) to cylinder [1], matching their bolt holes, and install
inner body (14).
2
2
2
Mating faces of flange and outer body:

Inside of outer body: Grease (G2-LI)
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
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 (74) 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}
D275AX-5E0
2) Press fit inner race (7-1) of bearing (7) to

shaft (6) with tool B.
SEN02343-00
5) Fit oil seals (8) and (9) to cover assembly

(2).
2
2
Press fitting face of oil seal:

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 secure them with bolts (3).
3
Coupling mounting bolt:

245 309 Nm {25 31.5 kgm}
4) Set cover (2) to shaft (6). Using tool B,

press fit bearing inner race (7-3).
D275AX-5E0
SEN02343-00
Removal and installation of power

train unit assembly
1
Removal
k

1. Drain the oil.

6
6
Hydraulic tank: Approx. 130 l

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
Undercover: 320 kg
5. Disconnect intermediate wiring connector FE2

(1) from bracket (2).
10. Disconnect the following 4 oil filter hoses.
(7): Power train oil filter inlet hose
(8): Power train oil filter outlet hose
(9): Steering lubricating oil filter inlet hose
(10): Steering lubricating oil filter outlet hose
7. Disconnect wire clamp (3).

8. Disconnect fan pump discharge hose (4) and
drain hose (5).
10
D275AX-5E0
11. Disconnect 4 hose clamps (11) and (12).

12. Disconnect the following 4 ripper hoses.
(13): Ripper tilt hose (port A5)
(14): Ripper tilt hose (port B5)
(15): Ripper lift hose (port A4)
(16): Ripper lift hose (port B4)
13. Disconnect intermediate wiring connector 241

(17).
SEN02343-00
16. Disconnect the following 4 self-pressure reducing valve hoses.

(22): hose (Port P1)
(23): hose (Port PC)
(24): hose (Port PR)
(25): hose (Port LS)
17. Remove oil level detection pipe for the power

train (26).
18. Remove power train oil supply pipe (27).
14. Disconnect work equipment pump tube coupling

(18).
15. Disconnect charge pump hose (19), HSS pump
hose (20) and HSS motor hose (21).
D275AX-5E0
11
SEN02343-00
19. Remove pin puller block (28).

a Un disconnect hose.
24. Disconnect torque converter outlet hose (34)

and transmission inlet hose (35).
20. Disconnect oil cooler hoses (29) and (30).
25. Loosen the hose clamp and disconnect tube

(36).
21. Disconnect cooler hose (31) and drain hose

(32).
22. Sling universal joint assembly (33) temporarily.
26. Remove the mounting bolts and final drive shaft

cover (37).
a Remove the final drive shaft cover on the
opposite side similarly.
23. Remove the mounting bolts and lift off universal

joint assembly (33).
[*1]
4
12
D275AX-5E0
27. Pull out drive shaft (38) according to the following procedure.
Using forcing screw [1], pull out the drive shaft
until the spline on the steering case side comes
off.
a If the shaft is difficult to pull out, raise the
shoe grouser with a jack and find out a position where the shaft is pulled out easily.
a Pull out the drive shaft on the opposite side
similarly.
SEN02343-00
30. Remove left (42) and right (43) mounting bolts

on the front side.
31. Lift off the power train unit assembly (44).

4
[*3]
Power train unit assembly: 2,650 kg
28. Remove 2 covers (39) on both sides.
29. Loosen coupling clamp (40) and move seal (41)

outward.
[*2]
D275AX-5E0
13
SEN02343-00
Installation
[*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 (41).
Refilling with oil

5
5
14

Bleeding air
Bleed air from the fan pump. For details, see
Testing and adjusting, "Bleeding air from fan
pump".
D275AX-5E0
Disconnection and connection of

power train unit assembly
1
Disconnection
SEN02343-00
5. Disconnect left brake oil pressure pick-up hose.

[*1]
(5): Left brake oil pressure pick-up hose
(Color band: White)
1. Draining oil
Before setting the power train unit assembly to
the block, drain the oil from the PTO case and
steering case.
2. Sling and set power train unit assembly (1) to
block [1].
4
Power train unit assembly: 2,650 kg
6. Disconnect the following 2 torque converter outlet oil pressure pick-up hoses.
[*1]
(6): Torque converter outlet oil pressure
pick-up hose (Color band: White/Red)
(7): Torque converter inlet oil pressure pickup hose (Color band: Blue)
4. Disconnect steering oil filter hose (3) and pwer

train oil filter hose (4).
D275AX-5E0
15
SEN02343-00
7. Disconnect right brake oil pressure pick-up hose

(8).
[*1]
(8): Right brake oil pressure pick-up hose
(Color band: Yellow)
10. Disconnect EPC valve main pressure hoses

(18) and (19).
8. Disconnect the following 6 HSS motor hoses.

(9): Drain hose (Port T1)
(10): (Pilot hose (Port P)
(11): From charge filter hose (Port C)
(12): To cooler hose (Port CD)
(13): HSS pump hose (Port PA)
(14): HSS pump hose (Port PB)
12. Disconnect hose (21) between the HSS motors

and hose (22) between the drain collecting
block.
a Disconnect the hoses from the HSS motor
end and drain collecting block end.
11. Disconnect charge pump hose (20).
13. Remove pivot turn solenoid (23).

a Remove the solenoid and bracket together.
9. Disconnect pin puller solenoid valve hoses (15)

and (16) and steering lubrication oil supply hose
(17).
16
D275AX-5E0
14. Disconnect the following 5 transmission oil pressure pick-up hoses.

[*1]
(24): Transmission forward oil pressure
pick-up hose (Color band: Blue/White)
(25): Transmission 2nd gear speed oil pressure pick-up hose (Color band: Yellow/
White)
(26): Transmission reverse oil pressure
pick-up hose (Color band: Blue/Red)
(27):Transmission 3rd gear speed oil pressure pick-up hose (Color band: Black/Yellow)
(28): Transmission 1st gear speed oil pressure pick-up hose (Red)
15. Disconnect the following 3 torque converter oil

pressure pick-up hoses.
[*1]
(29): Torque converter T/M pressure pick-up
hose (Color band: Transparent)
(30): Torque converter S/C pressure pick-up
hose (Color band: Yellow/Blue)
(31): Torque converter L/U pressure pick-up
hose (Color band: Red/Yellow)
SEN02343-00
17. Disconnect the following 4 hoses.

(39), (40): HSS pump hose (Port Pd2 )
(41): Work equipment pump hose (Port PA2)
(42): Work equipment pump hose (Port
PLS1)
18. Remove 4 hose clamps (43) and oil pressure

pick-up bracket assembly (44).
[*2]
a After removing the hose clamps, remove the
disconnected hoses, too.
a Remove the oil pressure pick-up bracket assembly and oil pressure pick-up hose together.

(32): Charge pump hose (Port PA2)
(33): Work equipment pump hose (Port PA1)
(36): HSS pump hose (Port Pd1)
(37): HSS pump hose (Port PCD)
(38): HSS pump hose (Port PC)
D275AX-5E0
17
SEN02343-00
19. Disconnect hydraulic oil temperature sensor

wiring connector 452 (45) and sudden stop prevention solenoid wiring connector STB (46).
20. Disconnect pivot turn changeover solenoid wiring connector MFR (47).
21. Remove cooler bypass valve and drain collecting block (48).
a Remove the block without disconnecting the
hoses.
22. Disconnect HSS pump solenoid valve wiring

connectors PUPA (49) and PUPB (50).
23. Disconnect fan pump solenoid valve wiring connector FAC (51), torque converter lockup solenoid valve wiring connector 653 (52), and torque
converter oil temperature sensor wiring connector 453 (53).
24. Disconnect the following 8 wiring connectors.

(55): TM1 bevel gear speed sensor
(56): ST1 (HSS oil pressure sensor)
(57): ST2 (HSS oil pressure sensor)
(58): FRB (Right brake ECMV fill switch)
(59): SRB (Right brake ECMV solenoid)
(60): FLB (Left brake ECMV fill switch)
(61): SLB (Left brake ECMV solenoid)
25. Disconnect the wire clamp and wires (62) and
(63).
18
D275AX-5E0
26. Remove plate (64) and disconnect road (65).

[*3]
SEN02343-00
32. Disconnect suction tube (75) and remove block

(76).
27. Remove brackets (66) and (67) and hose bracket (68).
33. Remove the 2 mounting bolts and lift off work

equipment and HSS charge pump assembly
(77).
28. Disconnect HSS motor gear lubrication tube
(69).
Work equipment and HSS charge pump

assembly: 75 kg
29. Disconnect suction tubes (70) and (71).

30. Disconnect scavenging pump suction tube (72).
31. Disconnect pump drive gear lubrication tube

(73) and remove transmission lubrication tube
(74).
[*4]
D275AX-5E0
19
SEN02343-00
34. Remove the 2 mounting bolts and lift off HSS

pump assembly (78).
4
HSS pump assembly: 110 kg
35. Remove hose bracket (79).

36. Remove the 4 mounting bolts and scavenging
pump (80).

motor assembly (84).
4
HSS motor assembly: 65 kg
37. Remove the 2 mounting bolts and lift off power

train and lubricating oil pump assembly (81).
4
Power train and lubricating oil pump assembly: 30 kg
41. Remove torque converter oil temperature sensor block (85) and pull out 2 sleeves (86).
38. Remove pump drive gear lubrication tube (73)

and tube (82).
39. Remove the 4 mounting bolts and fan pump assembly (83).
4
20
Fan pump assembly: 30 kg
D275AX-5E0
42. Remove torque converter valve assembly (87)

and pull out the sleeve.
[*5]
SEN02343-00
45. Loosen the 6 mounting bolts and remove retainer (90) by using 2 forcing screws [2].
[*6]
a Check the quantity and thickness of inserted
shims (91).

case assembly (88).
4
HSS case assembly: 1,000 kg
44. Remove coupling (89).
D275AX-5E0
46. Remove snap ring (92).
47. Set PTO, torque converter, and transmission assembly (93) with the PTO side up.
21
SEN02343-00
48. Remove the 19 mounting bolts and lift off PTO

assembly (94).
4
Connection
PTO assembly: 400 kg
Carry out connection in the reverse order to disconnection.
[*1]
a The adapters of the oil pressure hoses have respective collar codes. (For details, see "Connection diagram of centralized oil pressure pick-up
hose")
[*2]
a Layout of oil pressure pick-up hose block.
1) Upper line: (7) (R), (6) (FWD), (30) (TM), (31)
(SC), (29) (LU), (24) (OUT), (26) (IN)
2) Lower line: (27) (3RD), (25) (2ND), (28) (F1), (8)
(RB), () (RC), (5) (LB), () (LC)
49. Sling the torque converter assembly temporarily
and remove 11 mounting bolts (95).
[*11]
50. Lift off torque converter assembly (96).

4
Torque converter assembly: 160 kg
[*3]
a Adjust the brake pedal. For details, see Testing
and adjusting, "Adjusting brake pedal and parking brake lever".
[*4]
Eye-joint bolt:
34.3 44.2 Nm {3.5 4.5 kgm}
[*5]
Mounting bolt:
44.1 54 Nm {4.5 5.5 kgm}
[*6]
a Adjust the shims for the retainer according to the
1) Install retainer (90) and secure the 6 mounting
bolts to the following torque without inserting
any shim.
2
3
22
Oil seal: Grease (G2-LI)

Mounting bolt: 9.8 Nm {1 kgm}
D275AX-5E0
SEN02343-00
2) Using a thickness gauge, measure clearance

(a) between retainer (90) and PTO housing (97).
a Measure clearance (a) at 5 places on the periphery (A, B, C, and D) and obtain the average.
a Apply lubricant containing molybdenum disulfide (LM-P) to part (P) of the PTO input shaft
and grease (G2-LI) to spline (b).
[*7]
3)
4)
Select shim thickness.

0
Shim thickness = a 0.05
mm
Types of shims: 0.15 mm, 0.2 mm, 0.5 mm
Standard shim thickness: 0.5 mm
Insert a shim of the selected thickness and tighten the mounting bolts of retainer (90) to the
specified torque.
2
3
2
3
Mounting bolt: Thread tightener (LT-2)

Mounting bolt:
98.10 123 Nm {10 12.5 kgm}
Mounting bolt:
58.8 73.6 Nm {6.0 7.5 kgm}
a Select the shims so that their thickness and
quantity on both sides will be the same.
a Insert the shims so that they will not block the
forcing tap hole of the retainer as shown below.
D275AX-5E0
23
SEN02343-00
Connection diagram of centralized oil pressure pick-up hoses
24
D275AX-5E0
(5):
Left brake oil pressure pick-up hose

(Color band: White)
(6):
Torque converter outlet oil pressure pickup hose

(Color band: White/Red)
(7):
Torque converter inlet oil pressure pick-up

hose
(Color band: (Blue)
(8):
Right brake oil pressure pick-up hose

(Color band: Yellow)
(24): Transmission FORWARD oil pressure

pick-up hose
(Color band: Blue/White)
(25): Transmission 2ND oil pressure pick-up

hose
(Color band: Yellow/White)
(26): Transmission REVERSE oil pressure

pick-up hose
(Color band: Blue/Red)
(27): Transmission 3RD oil pressure pick-up

hose
(Color band: Black/Yellow)
(28): Transmission 1ST oil pressure pick-up

hose
(Color band: Red)
(29): Torque converter TM oil pressure pick-up

hose
(Color band: Not attached)
(30): Torque converter SC oil pressure pick-up

hose
(Color band: Yellow/Blue)
(31): Torque converter LU oil pressure pick-up

hose
(Color band: Red/Yellow)
D275AX-5E0
SEN02343-00
25
SEN02343-00
Disassembly and assembly of

PTO assembly
ii) Remove bearing inner race (3B) and

bearing (6) from gear (7).
Disassembly
1. Lubrication tube
Remove shaft lubrication tube (1).
2. HSS pump/fan pump drive gear, cover assembly

1) Remove mounting bolts, then using forcing
screws and guide bolts, remove pump drive
gear and cover assembly (2).
2) Remove bearing outer race and roller (3A)

from PTO case.
3) Disassemble pump drive gear and cover assembly as follows.
i) Remove cover (4) from gear and bearing (5).
26
3. Hydraulic/HSS charge pump and power

train/lubrication pump drive gear, cover assembly
screws and guide bolts, remove pump drive
gear and cover assembly (8).
2) Disassemble pump drive gear and cover assembly as follows.

i) Remove cover (9) from gear and bearing (10).
D275AX-5E0
ii) Remove 2 bearings (11) from gear (12).
4. Scavenging pump drive gear

1) Remove snap ring (13).
2) Knock drive gear (14) out from snap ring

end to remove.
D275AX-5E0
SEN02343-00
3) Remove snap ring (15), then remove bearing (16).
5. Idler gear assembly

1) Remove plate (17).

screws (1) and guide bolts (2), remove shaft
(18).
27
SEN02343-00
a Bearing (19) and spacer (20) separate
from shaft (18) and gear (21) comes off.
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).
7. Sleeve
Remove sleeve (29) from PTO case.
8. Magnet assembly
1) Remove mounting bolts, then remove cover
(30).
6. Input shaft bearing
1) Knock input shaft bearing and race assembly (24) out from inside PTO case to remove.
2) Remove spacer (25) and outer race (26).
2) Remove 2 springs (31) and 2 magnet assemblies (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.
28
D275AX-5E0
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 assembling.
a After press fitting the bearing, drop approx. 6 cc
of oil (EO30-CD or EO10-CD) 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-CD
or EO10-CD) on the bearing, and rotate it 10
times.
a Check that the snap ring is fitted securely in the
groove.
SEN02343-00
2. Sleeve
Install sleeve (29) to PTO case.
a Install the sleeve with the chamfered side
facing the inside of the PTO case.
a Expand fit the sleeve.
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).
D275AX-5E0
29
SEN02343-00
3) Assemble input shaft bearing and race assembly (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
3
Mounting bolt:
Thread tightener (LT-2)
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 become 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.
30
D275AX-5E0
5. Scavenging pump drive gear

1) Press fit bearing (16) to PTO case.
2) Install snap ring (15).
SEN02343-00
6. Hydraulic/HSS charge pump and power

train/lubrication pump drive gear, cover assembly
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 bearing (10) to cover (9).

3) Fit O-ring and install pump drive gear and
cover assembly (8) to PTO case.
2
2
3
D275AX-5E0

Mounting bolt:
Mounting bolt:
98.0 122.5 Nm {10.0 12.5 kgm}
31
SEN02343-00
7. HSS pump/fan pump drive gear, cover assembly

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).
8. Lubrication tube
Install shaft lubrication tube (1).
3) Using push tool [14], press fit gear and bearing (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
2
3
32

Mounting bolt:
Mounting bolt:
98.0 122.5 Nm {10.0 12.5 kgm}
D275AX-5E0

torque converter assembly
SEN02343-00
Disassembly
3. Disassembly of drive case, housing assembly

1) Remove snap ring (5), then remove spacer
(6).
1. Input shaft
1) Remove mounting bolts, then using eyebolts [1], remove input shaft (1).
2) Using 2 forcing screws [3], remove bearing

(7) from turbine end.
2) Remove 2 seal rings (2) from input shaft (1).
3) Remove mounting bolts, then using eyebolts [4], remove housing (8).
2. Drive case, housing assembly
1) Remove 36 mounting bolts (3) between
drive case and pump, then using eyebolts
[2], remove drive case and housing assembly (4).
D275AX-5E0
33
SEN02343-00
4) Remove 2 seal rings (9) from housing (8).
5) Remove lock-up clutch piston (10).

6) Remove 2 seal rings (11) from lock-up clutch
piston (10).
4. Stator
2) Remove stator and boss (17).

7) Remove 2 lock-up clutch discs (12) and
lock-up clutch plate (13).
3) Remove boss (18) from stator (19).

8) Using eyebolts [5], raise drive case (14) and
remove from turbine and gear (15).
34
D275AX-5E0
SEN02343-00
5. Pump
1) Remove pump assembly (21) from stator
clutch assembly (22).
2) Remove mounting bolts, then remove retainer (23) and outer race (24) from pump
(25).
2) Remove stator clutch piston (27).

3) Remove seal ring (28) from stator clutch piston (27).
4) Remove 5 pins (29) and 10 springs (30),
then remove 2 stator clutch discs (31) and
stator clutch plate (32) from housing (33).
5) Disassemble housing and shaft assembly

as follows.
i) Using forcing screws [6], remove shaft
and bearing assembly (34).
6. Stator clutch assembly

1) Loosen 3 mounting bolts slowly and disconnect housing and shaft assembly (26).
D275AX-5E0
35
SEN02343-00
ii) Remove snap ring (35), then remove

bearing (36) from shaft (37).
iii) Remove seal ring (38) from shaft (37).
iv) Remove bushing (39) from shaft (37).
v) Remove snap ring (40), then remove

gear (41).
vii) Remove snap ring (44), then remove

bearing (45) from shaft (46).
viii) Remove seal ring (47) from shaft (46).
ix) Remove seal ring (48) from housing

(43).
vi) Remove shaft and bearing assembly

(42) from housing (43).
36
D275AX-5E0
Assembly
SEN02343-00
4) Using push tool [7], press pit shaft and bear-

parts with engine oil before installing.
times.
groove.
ing assembly (42) to housing (43) with

press.
1. Assembly of stator clutch assembly

shaft (46) with press.
5) Using push tool (8), press fit bearing (36) to
shaft (37).
7) Install bushing (39) to shaft (37).
a Expand fit the bushing.
8) Install seal ring (38) to shaft (37).
a Fit the seal ring securely to the shaft with
grease.
Seal ring: Grease (G2-LI)
2) Install snap ring (44) to shaft (46).

3) Install seal ring (47) to shaft (46).
grease.
9) Install shaft and bearing assembly (34) to

housing (43).
D275AX-5E0
37
SEN02343-00
10) Turn over housing assembly, then fit gear

(41) and install snap ring (40).
11) Install seal ring (48) to housing (43).

a The seal ring must be installed facing in
the correct direction. Assemble as
shown in the diagram.
14) Install 5 pins (29).

15) Install 2 stator clutch discs (31) and stator
clutch plate (32).
Outside circumference of seal ring:

Grease (G2-LI)
12) Install seal ring (28) to stator clutch piston
(27).
2

Grease (G2-LI)
13) Install stator clutch piston (27) to housing.
2
38
Seal ring contact surface:

Grease (G2-LI)
16) Install 10 springs (30).
D275AX-5E0
17) Set housing (33) on top and install 3 mounting bolts (a).
a Tighten the 3 mounting bolts uniformly in
turn.
2
3
Mounting bolt:
Mounting bolt:
98.0 122.5 Nm {10.0 12.5 kgm}
18) Before installing pump, insert 11 mounting

bolts (b) of torque converter assembly and
transmission assembly in bolt holes.
SEN02343-00
2. Pump
1) Press fit outer race (24) to pump (25).
2) Install retainer (23) to pump.
2
3
Mounting bolt:
Mounting bolt:
58.8 73.6 Nm {6.0 7.5 kgm}
@@
3) Install pump assembly (21) to stator clutch

assembly (22).
3. Snap ring
Install snap ring (20) to shaft.
D275AX-5E0
39
SEN02343-00
4. Stator
1) Install boss (18) to stator (19).
2
3
5. Assembly of drive case and housing

1) Set turbine and gear (15) on block [9].
Mounting bolt:
Mounting bolt:
58.8 73.6 Nm {6.0 7.5 kgm}
2) Using eyebolts [5], set drive case (14) on top

of turbine and gear (15).
2) Install stator and boss (17).
3) Install 2 lock-up clutch discs (12) and lockup clutch plate (13) to case (14).
3) Install snap ring (16) to shaft.
40
D275AX-5E0
4) Install 2 seal rings (11) to lock-up clutch piston (10).

2

Grease (G2-LI)
SEN02343-00
7) Using eyebolts [4], raise housing (8) and install to drive case.
a Lower the housing gradually and align
the 3 holes in the top surface of the piston with the protruding pins on the inside
of the housing.
a Or, install the piston to the housing, then
support the piston so that it does not fall
out, and install the housing.
2
3
Mounting bolt:
Mounting bolt:
98.0 122.5 Nm {10.0 12.5 kgm}
5) Install lock-up clutch piston (10).
8) Using eyebolts [2], install drive case and

housing assembly (4).
a Align pump plug (48) with the oil groove
in the drive case when installing.
2
3
6) Install 2 seal rings (9) to housing (8).

2
D275AX-5E0
Mounting bolt:
Mounting bolt:
49.0 58.8 Nm {5.0 6.0 kgm}
Plug: 14.7 19.6 Nm {1.5 2.0 kgm}

Grease (G2-LI)
41
SEN02343-00
9) Using push tool [10], push bearing (7) with

press and press fit.
10) Fit spacer (6) and install snap ring (5).
6. Input shaft
1) Install 2 seal rings to shaft (1).
grease.
2
2) Using eyebolts [1], install input shaft (1).

2
3
42
Mounting bolt:
Mounting bolt:
98.0 122.5 Nm {10.0 12.5 kgm}
D275AX-5E0
SEN02343-00

torqflow transmission assembly 1
3. Transmission control valve assembly

1) Remove 5 pressure detection nipples (126).
799-301-1600
Oil leak testerll
Sketch
Part name
New/Remodel
Part No.
Q'ty
Sym
bol
Necessity
Special tools
t 1
Disassembly
a Store the discs and plates in a flat place to prevent them from becoming deformed.
1. Elbow
Remove elbow (1).
3) Remove wiring connector (136) from cover.

2. Main relief valve assembly

Remove main relief valve assembly (2).
5) Remove flanges (138) and (139) and

sleeves (140) and (141).
D275AX-5E0
43
SEN02343-00
6) Remove 4 mounting bolts (4), then remove

transmission control valve assembly (5).
a Do not remove 2 connecting bolts (6)
connecting the top and bottom control
valve.
4. Sleeve
Remove sleeve (7).
5. Transmission case
1) Set input shaft end at top and put on block [1].
44
2) Remove 13 tie bolts (8) used to tighten

transmission case.
a Do not remove 4 tie bolts (9) not used to
tighten transmission case.
3) Using eyebolts [2], remove transmission

case (10).
6. Tie bolts
Remove 4 remaining tie bolts (9).
D275AX-5E0
7. Input shaft, front cover, No. 1 carrier assembly

1) Using eyebolts [3], remove input shaft, front
cover, and No. 1 carrier assembly (11).
2) Disassemble input shaft, front cover, and

No. 1 carrier assembly as follows.
i) Remove snap ring (12), then remove
No. 2 sun gear (13).
ii) Remove snap ring (14).
iii) Remove snap ring (15), then remove
No. 1 sun gear (16) and spacer (17).
SEN02343-00
vi) Remove snap ring (142), then remove

bearing (143) from front cover (19).
vii) Remove seal ring (121).
viii) Remove spacer (144).

ix) Remove snap ring (20), then knock input shaft (21) out from torque converter
end, and remove from No. 1 carrier assembly (118).
x) Remove bearing (117) from input shaft
(21).
xi) Remove seal ring (158) from input shaft.
iv) Remove snap ring (18).

v) Using push tool [7], push input shaft and
No. 1 carrier assembly, and remove
from front cover (19).
D275AX-5E0
45
SEN02343-00
3) Disassemble No. 1 carrier assembly as follows.

i) Remove snap ring (22) from No. 1 carrier assembly, then remove No. 1 ring
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).
3) Remove seal ring (145) from No. 1 housing

(33).
4) Remove seal ring (146) from No. 1 piston
(34).
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 housing.
46
D275AX-5E0
11. Sleeves
Remove 17 sleeves (40).
12. Lubrication relief valve
Remove lubrication relief valve (41) and spring
(120).
13. No. 2 housing, No. 2 carrier assembly

and No. 2 carrier assembly (42).
2) Remove No. 2 piston (43).
SEN02343-00

6) Using push tool [8], push No. 2 carrier assembly (45), and remove from No. 2 housing (46).
7) Remove snap ring (58), then remove bearing (59) from No. 2 housing (46).
8) Remove seal ring (57).

(46).
(43).
D275AX-5E0
47
SEN02343-00
9) Disassemble No. 2 carrier assembly as follows.

i) Remove spacer (47) and No. 2 ring gear
(48) from No. 2 carrier assembly.
15. No. 3 ring gear

Remove No. 3 ring gear (64).
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).

48
D275AX-5E0
2) Disassemble No. 3 and No. 4 carrier assembly 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 bearing (71), and No. 4 planetary gear (70).
v) Remove No. 3 shaft (72) and ball (76).
vi) Remove 2 thrust washers (73), needle
bearing (75), and No. 3 planetary gear
(74).
vii) Remove snap ring (156), then remove
bearing (157).

1) Using eyebolts [10] remove No. 3 housing
(77).
SEN02343-00

1) Remove 6 guide pins (83).
19. No. 5 carrier, No. 4 ring gear assembly

1) Remove 8 mounting bolts (84).
2) Remove No. 5 carrier and No. 4 ring gear
assembly (85).

(77).
(78).
D275AX-5E0
49
SEN02343-00
3) Disassemble No. 5 carrier and No. 4 ring

gear as follows.
i) Remove shaft (86) and ball (90).
ii) Remove 2 thrust washers (87), needle
bearing (89), and planetary gear (88)
from No. 5 carrier (93).
iii) Remove snap ring (91), then remove

No. 4 ring gear (92) from No. 5 carrier
(93).

(94).
(95).


(94).
50
D275AX-5E0
SEN02343-00
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).
1) Remove snap ring (110), then remove bearing (111) from No. 5 housing.
2) Remove snap ring (112), then remove bearing (113) from No. 5 housing.
3) Remove cage (114).
4) Remove seal rings (115) and (116) from
cage (114).
26. Seal rings

(109).
2) Remove seal ring (154) from No.5 piston
(106).
Assembly
27. Output shaft, spacer

1) Remove spacer (108).
2) Remove snap ring (155), then remove output shaft (107) from No. 5 housing (109).
D275AX-5E0

times.
groove.
a Coat the blind plugs with thread tightener (LT-2),
then after assembling, caulk 2 places on diagonally opposite sides.
51
SEN02343-00

1) Install seal rings (116) and (115) to cage
(114).
2
3) Install spacer (108) to shaft (107).
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).
2

6) Using push tool [13], press fit bearing (111)
until it contacts snap ring (110).
2) Install seal ring (153) to No. 5 housing (109).

2
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).
52
D275AX-5E0
SEN02343-00
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
7. Bearing, No. 4 sun gear, spacer

to spacer (157).
2) Install bearing and spacer (104).
3) Install No. 4 sun gear (103) and spacer
(102).

1) Install guide pin (83).
2) Install 4 No. 5 plates (98), 3 No. 5 discs (97),
and 18 springs (99).
3) Install 12 springs (96).
a Free length of spring: 70 mm
D275AX-5E0

2
3) Install No. 4 piston (95) to No. 4 housing

(94).
4) Using eyebolts [11], install No. 4 housing
(94).
a Check that the spring is fitted securely in
the groove.
53
SEN02343-00
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 planetary 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
2) Using guide bolt [17], install No. 5 carrier

and No. 4 ring gear assembly (85).
2
3
54
Mounting bolt:

2
Mounting bolt:
58.8 73.5 Nm {6.0 7.5 kgm}
D275AX-5E0

(77).
4) Using eyebolts [10], install No. 3 housing
(77).
the groove.
SEN02343-00
2) ALign meshing of gears, then using eyebolts

[9], install No. 3 and No. 4 carrier assembly
(65).
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
(69) in contact on both sides, and set to
No. 4 carrier.
thrust washers.
iv) Install No. 4 shaft (68).
v) Check that the position of the pin holes
matches, then install pin (67) to No. 4
shaft (68).
D275AX-5E0

55
SEN02343-00
16. No. 2 housing, No. 2 carrier assembly

1) Assembly No. 2 carrier assembly as follows.
i) Set ring gear (56) to No. 2 carrier (45),
and install snap ring (55).
ii) Assemble needle bearing (53) to planetary gear (52), put 2 thrust washers (51)
2 carrier.
thrust washers.
iii) Install shaft (50) and ball (54).

No. 2 housing (46).
3) Using push tool [19], press fit No. 2 housing

(46) to No. 2 carrier assembly (45).
a Push the bearing inner race to press fit.
iv) Install No. 2 ring gear (48).

v) Install spacer (47).
a Install with the cut side facing the carrier.
56
D275AX-5E0
SEN02343-00

2

2

2

1) Install guide pins (35).

(46).
9) Using eyebolts [5], install No. 2 housing and
No. 2 carrier assembly (42).
2

2
17. Sleeves
Install 17 sleeves (40).
18. Lubrication relief valve
Install lubrication relief valve (41) and spring
(120).
D275AX-5E0
57
SEN02343-00

(33).
4) Using eyebolts [4], align No. 2 piston (34)
with guide pin position, then install No. 1
housing (33).
the groove.
4) Using push tool [21] press fit bearing outer

end of input shaft (21) to No. 1 carrier assembly (118).
21. Input shaft, No. 1 carrier assembly

1) Assemble No. 1 carrier assembly as follows.
i) Assemble needle bearing (27) to planetary gear (26), put 2 thrust washers (25)
2 carrier.
thrust washers.
ii) Install shaft (24) and ball (28).
iii) Set No. 1 ring gear (23) to No. 1 carrier,
and install snap ring (22).

6) Fit No. 1 sun gear and install snap ring (15)
to input shaft.
2) Install seal ring (158) to input shaft (21).

2

to input shaft (21) with press.
58
D275AX-5E0
8) Fit No. 2 sun gear (13) and install snap ring

(12) to input shaft.
9) Align meshing of No. 2 sun gear and No. 1

planetary gear, then using eyebolts [3], install input shaft and No. 1 carrier assembly
(119).
22. Spacer
Install spacer (144).
D275AX-5E0
SEN02343-00
24. Front cover

to front cover (19).

3) Install seal ring (121) to front cover (19).
2
4) Using eyebolts [6], install front cover (19).

the groove.
59
SEN02343-00
5) Using push tool [23], press fit inner side of

bearing (143) inside front cover (19).
25. Tie bolts

Install 4 tie bolts (9).
3
Tie bolt:
156.8 176.4 Nm {16.0 18.0 kgm}
26. Piston actuation check

Using tool D, check stroke and actuation condition of each clutch piston.
Piston
60
Standard stroke (mm)
No.1
No.2
8.8
No.3
6.4
No.4
6.4
No.5
27. Transmission case

1) Fit O-ring, then using eyebolts [2], install
transmission case (10).
2
2) Install remaining 13 tie bolts (8).

3
Tie bolt:
156.8 176.4 Nm {16.0 18.0 kgm}
28. Sleeve
Fit O-ring and install sleeve (7).
2
D275AX-5E0
29. Transmission control valve assembly

1) Fit O-ring and install transmission control
valve assembly (5).
3
SEN02343-00
5) Fit gasket and install cover (3).

6) Install 5 pressure detection nipples (126).
Mounting bolt:
44.1 53.9 Nm {4.5 5.5 kgm}
30. Main relief valve assembly

Install main relief valve assembly (2).
3
2) Fit O-ring and install sleeves (140) and

(141), and sleeves (138) and (139).
2
Mounting bolt:
44.1 53.9 Nm {4.5 5.5 kgm}
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
D275AX-5E0
Mounting bolt:
39.6 42.4 Nm {4.0 4.3 kgm}
61
SEN02343-00
62
D275AX-5E0
SEN02344-00
BULLDOZER
1SHOP MANUAL
D275AX-5E0
Machine model
Serial number
D275AX-5E0
30001 and up

Power train, Part 2
Removal and installation of scavenging pump................................................................................................ 2
Disassembly and assembly of HSS case assembly ....................................................................................... 3
Removal and installation of final drive assembly .......................................................................................... 23
Disassembly and assembly of final drive assembly...................................................................................... 26
D275AX-5E0
SEN02344-00

scavenging pump
Installation
Removal
1. Remove inspection cover (1).
Refilling with oil (Power train case)

2. Drain the power train oil.

6
3. Remove tube (2).

4. Remove the 5 mounting bolts and scavenging
pump assembly (3).
D275AX-5E0
SEN02344-00

HSS case assembly
Bracket
t 1
1 01010-62095
Bolt
t 1
01016-61690
Bolt
t 1
Wrench
t 1
791-622-1110
E
2 791-550-1301
Sketch
Part name
New/Remodel
Part No.
Q'ty
Sym
bol
Necessity
Special tools
3. Disassembly of brake, carrier assembly

1) Remove flange (5) and plate (6).
Disassembly
1. Drain hose, joint
1) Remove drain hose (1).
2) Remove joint (2).
2. Brake, carrier assembly

1) To install tool E1 perpendicularly, use block
[1] and jack [2], and set HSS case assembly
at an angle of 15.
2) Loosen 4 hexagonal socket head bolts (7)

uniformly, then using eyebolts [3], remove
brake case (8).
a The case is being pushed by the brake
spring, so loosen uniformly a little at a
time.
3) Remove bearing (9A) from brake case (8).
2) Remove 16 mounting bolts, then using tool

E1, remove brake and carrier assembly (4).
a Do not remove the 4 hexagon socket
head bolts.
a Remove the brake and carrier assembly
on the opposite side in the same way.
D275AX-5E0
SEN02344-00
4) Remove brake spring (10), piston (11), and

cylinder (12).
5) Remove brake drum, disc, and plate assembly (13).
6) Remove 7 discs (14), 6 plates (15), and 7

springs (86) from brake drum (16).
9) Remove ring (20), then remove ring gear

10) Disassemble carrier assembly as follows.
i) Remove snap ring (23).

7) Remove mounting bolts, then remove carrier assembly (18) from hub (17).
8) Remove gear assembly (19) from hub (17).
D275AX-5E0
11) Remove bearing (9B) from hub (17).

12) Remove snap ring (29), then remove stopper (30) from hub (17).
4. Bevel pinion assembly

1) Using guide bolt [4] and forcing screws [5],
remove bevel pinion assembly (31) and
shims (32).
a Check the number and thickness of the
shims, and keep in a safe place.
SEN02344-00
ii) Remove pin (35).
iii) Hold with press so that bevel pinion

does not move, and use tool E2 to remove locknut (36).
iv) Support cage (37), and use push tool [6]

to remove bevel pinion and bearing (38).
2) Disassemble bevel pinion as follows.

i) Remove plate (34).
D275AX-5E0
SEN02344-00
v) Remove bearing (39A).

vi) Remove outer races (39B) and (40B)
from cage (37).
6. HSS motor housing assembly

1) Using eyebolts [7], remove HSS motor
housing assembly (44).
vii) Remove spacer (41) and bearing (40A)
from bevel pinion (42).
5. Transmission output speed sensor

Remove transmission output speed sensor (43)
together with flange.
a When removing the transmission output

speed sensor from the flange and replacing
it, measure distance (L) between the flange
and the tip of the speed sensor. When replacing the speed sensor, install so that the
installation dimension of the speed sensor is
(L) 0.2 mm.
D275AX-5E0
2) Disassemble HSS motor assembly as follows.

i) Remove mounting bolts, then remove
holder (45).
ii) Using push tool [8], remove shaft (46)
and ball (47).
iii) Remove gear and bearing assembly
(48).
SEN02344-00
v) Remove snap ring (52).

vi) Using puller [9], remove gear and bearing assembly (53).
vii) Remove 2 bearings (54) from gear (55).
7. Steering control valve assembly

1) Remove 3 sleeves (56).
a Remove on the opposite side in the
same way.
iv) Remove 2 bearings (49) and collar (50)
from gear (51).
D275AX-5E0
SEN02344-00
2) Remove mounting bolts, then using eyebolts [10], remove steering control valve assembly (57).
2) Using puller [11], remove gear and bearing

assembly (61).
3) Remove 2 sleeves (58) from HSS case.
3) Remove snap ring (62) and spacer (83),

then remove bearing (63) from gear (64).
8. Sun gear
Remove sun gear (59).
4) Using puller [12], remove bearing (65).

9. Gear, bearing
D275AX-5E0
10. HSS motor output gear, shaft

1) Remove mounting bolts, then remove plate
(66) and gear (67).
a Remove on both the left and right sides.
2) Knock out shaft (68) with plastic hammer
and remove.
a Bearing inner race (69) at one end will
come off and the bearing inner race at
the other end will remain on the shaft.
SEN02344-00
3) Remove outer race (73) from right cage

(71).
4) Using forcing screws [14], disconnect retainer (74) from case.

5) Remove forcing screws [14], then using
eyebolts [15], remove retainer (74).
3) Remove bearing (70) from left side of case.
6) Remove bearing (70) from retainer (74).
11. Bevel gear shaft, bevel gear assembly

1) Set with right side of HSS case at top.
screws [13], remove right cage (71) and
shims (72).
D275AX-5E0
SEN02344-00
7) Hook wire to bevel gear and shaft assembly

(75) and remove.
iv) Using puller [17], remove bearing (80)

from shaft (77).
8) Disassemble bevel gear and shaft assembly

as follows.
i) Remove 2 seal rings (76) from shaft
(77).
12. Left cage

Remove mounting bolts, then using forcing
screws [18] and guide bolt [19], remove left cage
(81) and shims (82).
ii) Using puller [16], remove bearing (78)

from shaft (77).
iii) Remove bevel gear (79) from shaft (77).
10
13. Tube
Remove tube (84).
D275AX-5E0
Assembly
times.
groove.
a Coat the blind plugs with thread tightener (LT-2),
then after assembling, caulk 2 places on opposite sides.
SEN02344-00
3. Bevel gear shaft, bevel gear assembly

1) Set with right side of HSS case at top.
2) Assemble bevel gear and shaft assembly as
follows.
i) Using push tool [20], press fit bearing
(80) to shaft (77).
1. Tube
1) Install tube (84).
ii) Install bevel gear (79) to shaft (77).
3
Mounting nut:
215.6 274.4 Nm {22 28 kgm}
iii) Using push tool [21], press fit bearing
(78) to shaft (77).
2. Left cage
Using guide bolt [19], install shims (82) and left
cage (81).
a Assemble the same amount and thickness
of shims (82) that was removed.
Types of shim thickness:
0.1 mm, 0.2 mm, 0.5 mm
3
D275AX-5E0
iv) Install 2 seal rings (76) to shaft (77).
Mounting bolt:
98.1 122.6 Nm {10 12.5 kgm}
11
SEN02344-00
3) Hook wire to bevel gear and shaft assembly

(75) and install to HSS case.
a Be careful not to damage the seal rings
of the shaft.
4) Press fit bearing (70) to retainer (74).
6) Using push tool [23], press fit outer race (73)

to cage (71).
7) Using guide bolt [24], install right cage (71)

and shims (72).
a Assemble the same amount and thickness of shims (72) that was removed.
0.1 mm, 0.2 mm, 0.5 mm
3
Mounting bolt:
98.1 122.6 Nm {10 12.5 kgm}
5) Using eyebolts [15] and guide bolt [22], install retainer (74).
3
12
Mounting bolt:
98.1 122.6 Nm {10 12.5 kgm}
D275AX-5E0
8) Set HSS case assembly horizontally.

9) Adjust preload of cage bearing.
Push tip of tooth of bevel gear (79) with
push-pull scale [25] 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}
(At tip of bevel gear tooth:
21.6 27.4 N {2.2 2.4 kg})
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 thickness at the left and right cages as follows:
If value is LOW, ADD shims
If value is HIGH, REMOVE shims
4. Bevel pinion
1) Assemble bevel pinion as follows.
i) Using push tool [26], press fit bearing
(40A) to bevel pinion (42) with press.
ii) Install spacer (41).
SEN02344-00
iv) nstall cage (37) to bevel pinion (42).

v) Using push tool [28], press fit bearing
(39A) with press.
vi) Hold with press so that bevel pinion

does not move, and use tool E2 to tighten locknut (36).
a Rotate the cage while tightening.
a After tightening the locknut, check that
the bevel pinion rotates smoothly.
2
3
Locknut: Thread tightener (LT-2)

Locknut: 392 441 Nm {40 45 kgm}
iii) Using push tool [27], press fit outer race

(39B) to cage (37).
a Press fit outer race (40B) in the same
way.
D275AX-5E0
13
SEN02344-00
vii) After tightening locknut, turn locknut in

direction of loosening to a point where 1
of 5 pin insertion holes in pinion shaft
and 1 of 8 pin insertion holes in locknut
are aligned.
Angle to loosen: 0 9
viii) Install pin (35) in aligned hole.
ix) Fit plate (34).

2
3
Mounting bolt:
Mounting bolt:
11.8 14.7 Nm {1.2 1.5 kgm}
5. Adjusting backlash, tooth contact

1) Adjusting backlash
i) Put probe of dial gauge [29] in contact
with tooth face at tip of bevel gear.
ii) Fix bevel pinion in position, and read
scale when bevel gear is moved backward and forward (in direction of rotation).
Standard value of backlash:
0.25 0.33 mm
a Measure at 3 places on diametrically opposite sides.
2) Using guide bolt [4], install bevel pinion assembly (31) and shims (32).
a Assemble the same amount and thickness of shims (32) that was removed.
0.1 mm, 0.2 mm, 0.5 mm
3
14
Mounting bolt:
98.1 122.6 Nm {10 12.5 kgm}
D275AX-5E0
iii) If the result of the measurement shows

that the backlash is not correct, adjust
as follows.
a When adjusting the shim thickness, add
or remove shims on the left or right
sides. However, to prevent the preload
of the bearing from changing, always
keep the same total thickness of shims
on the left and right. (Adjust by moving
shims from one side to the opposite
side.)
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).)
SEN02344-00
2) Adjusting tooth contact

Testing
i) Coat the tooth face of the bevel pinion
lightly with red lead (minium), then rotate
the bevel gear forward and backward
and inspect the tooth contact pattern left
on the bevel gear teeth.
ii) The standard value for the tooth contact
is as follows
(from tip of bevel pinion tooth)
a. Center of tooth contact: 20 40 % of
tooth width (from small end)
b. Width of tooth contact: 30 50 % of
tooth width
c. Center of tooth contact: 35 65 % of
tooth height (from root of tooth)
d. Width of tooth contact: 60 80 % of
tooth height
In addition, check that there is no strong
contact at the tip or root of the teeth or at
the big and small ends.
a If the gears are adjusted to this pattern,
the tooth contact will be correct when
load is applied.
When backlash is too large:

Reduce the shim thickness on the left
side of the chassis and add the same
shim thickness to the right side. (Move
the bevel gear in direction (B).)
D275AX-5E0
15
SEN02344-00
Adjusting
If the result of the inspection shows that the
correct tooth contact is not being obtained,
adjust again as follows.
i) When bevel pinion is too far from center
line of bevel gear:
Contact is at the small end of the convex
tooth face of the bevel gear and at the
big end of the concave tooth face.
Adjust the shim thickness at the bevel
pinion end and move the bevel pinion in
direction (A).
Or, adjust the shim thickness and move
the bevel gear in direction (B).
After adjusting, check the tooth contact
pattern and backlash again.
ii) When bevel pinion is too close to center

line of bevel gear:
Contact is at the big end of the convex
tooth face of the bevel gear and the
small end of the concave tooth face.
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 contact pattern and backlash again.
16
6. HSS motor output gear, shaft

1) Press fit bearing (70) to left side of case.
2) Using push tool, press fit bearing inner race

(69) to shaft (68).
a Install only one end of the shaft.
a Press fit until distance (a) from the end
face of the shaft to the bearing is 26 mm.
3) Insert shaft (68) and fit bearing inner race

(69) from opposite side.
4) Using push tool [30], press fit bearing inner
race (69).
a Hold down the shaft from the opposite
end and press fit the bearing inner race.
D275AX-5E0
SEN02344-00
5) Install gear (67) and plate (66).

a Install on both the left and right sides.
2
3
Mounting bolt:
Mounting bolt:
98.1 122.6 Nm {10 12.5 kgm}
8. Sun gear
Fit spacer (93) and install sun gear (59).
7. Gear, bearing
1) Using push tool [31], press fit bearing (65).
9. Steering control valve assembly

1) Install 2 sleeves (58) to HSS case.
2

gear (64).
3) Install snap ring (62) and spacer (83).
4) Fit gear and bearing (61), then using push

tool [33], press fit bearing inner side.
D275AX-5E0
17
SEN02344-00
2) Fit O-ring to HSS case end, then using

guide bolt [34] and eyebolts [10], install
steering control valve assembly (57).
2) Using push tool [36], press fit gear and bearing assembly (53) to housing.

3) Install 3 sleeves (56).
2
a Install on the opposite side in the same

way.

gear (51).
5) Assemble collar (50), and press fit other
bearing (49) in same way as Item 4).
10. HSS motor housing assembly
1) Assemble HSS motor housing assembly as
follows.
i) Using push tool [35], press fit 2 bearings
(54) to gear (55) with press.
18
D275AX-5E0
SEN02344-00
6) Install gear and bearing assembly (48) to

housing, fit ball (47) to shaft (46), then using
push tool [38], press fit shaft (46).
7) Install holder (45).

2
3
Mounting bolt:
Mounting bolt:
98.1 122.6 Nm {10 12.5 kgm}
8) Using eyebolts [7], install HSS motor housing assembly (44).

a Check that there are no dents, rust, oil,
grease, or moisture on the mating surface of both the case and housing.
a Coat both the case and housing with
gasket sealant, and make sure that
there is no gap in the sealant film.
2
3
D275AX-5E0
11. Transmission speed sensor

Install transmission speed sensor (43).
a Install the stamped mark [HSS UP] at the rotation sensor flange portion so that it faces
the top of the HSS case.
a Adjust the transmission speed sensor. For
details, see Testing and adjusting, "Adjusting transmission speed sensor".
12. Assembly of brake, carrier assembly

a Use the same procedure to assemble on
both the left and right sides.
1) Fit stopper (30) to hub (17), and install snap
ring (29).
2) Using push tool [39], press fit bearing (9B).
Housing mounting surface:

Mounting bolt:
98.1 122.6 Nm {10 12.5 kgm}
19
SEN02344-00
3) Assemble carrier assembly as follows.

i) Assemble needle bearing (27) to planetary gear (28), put 2 thrust washers (26)
in contact on both sides, and set to carrier.
thrust washers.
ii) Install shaft (24) and ball (25).
iii) Install snap ring (23).
viii) Install brake drum (16) to hub (17).

ix) Install 7 springs (86), 6 plates (15), and
7 discs (14).
4) Install seal rings (87) and (88) to cylinder

(12).
iv) Install 2 bushings (85) to gear (22).
v) Set gear (22) to ring gear (21), and install ring (20).
5) Install cylinder (12), piston (11), and brake

spring (10).
a Install stamped mark (A) facing the position shown in the diagram.
vi) Install gear assembly (19) to hub (17).
vii) Install carrier assembly (18) to hub (17).
20
Mounting bolt:
98.1 122.6 Nm {10 12.5 kgm}
D275AX-5E0
SEN02344-00
6) Using push tool [40], press fit bearing (9A) to

brake case (8).
7) Install bushing (89) and collar (90).
11) Install plate (6).

3
8) Install guide bolt [41] to cylinder (12).
Mounting bolt:
58.8 73.5 Nm {6.0 7.5 kgm}
12) Fit O-ring and install flange (5).

3
Mounting bolt:
58.8 73.5 Nm {6.0 7.5 kgm}
9) Fit O-ring, then using eyebolts [3], install

brake case (8).
10) Using push tool [42], push inner side of bearing (9A) 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.
D275AX-5E0
21
SEN02344-00
13. Brake, carrier assembly

1) To install tool E1 perpendicularly, use block
[1] and jack [2], and set HSS case assembly
(3) at an angle of 15.
15. Cover
If cover (91) at rear of HSS case has been removed, install new gasket.
a Coat both surfaces of the gasket with gasket
sealant.
2
Gasket: Gasket sealant (LG-1)
a Tighten connector bracket (92) of the transmission output speed sensor with the cover
mounting bolts.
2) Fit O-ring, then using tool E1, install brake

and carrier assembly (4).
3
Mounting bolt:
98.1 122.6 Nm {10.0 12.5 kgm}
14. Drain hose, joint

1) Install joint (2).
2) Install drain hose (1).
22
D275AX-5E0
SEN02344-00
Removal and installation of final

drive assembly
1
J1
790-337-1032
Lifting tool
t 1
791-627-1320
Shackle
t 2
791T-627-1810
Plate
t 1
01010-82090
Bolt
t 2
Sketch
Part name
New/Remodel
Part No.
Q'ty
Sym
bol
Necessity
Special tools
Removal
1. Expand the track shoe assembly. For details,
see "Expanding track shoe assembly".
6. Remove the 3 final drive bolts and install tool J1.

[*1]
7. Using tool J1, sling final drive assembly (5) temporarily.
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
4
D275AX-5E0
Sprocket tooth: 25 kg
Final drive assembly: 1,700 kg
23
SEN02344-00
Installation
[*1]
Mounting bolt:
456 569 Nm {46.5 58 kgm}
[*2] [*3]
3
3
Mounting bolt:
1,160 1,440 Nm {118 147 kgm}
Sprocket tooth mounting bolt:
1,080 1,270 Nm {110 130 kgm}
Refilling with oil (Final drive case)

5
24
Final drive case: Approx. 40 l (E030-CD)
D275AX-5E0
SEN02344-00
Sketch of special tool

Plate J1
D275AX-5E0
25
SEN02344-00

final drive assembly
3. Cover
Using hanging bolt [1], remove cover (4).
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
790-101-1102
Pump
t 1
791-627-1200
Remover
t 1
4 790-101-2102
Puller
t 1
790-101-1102
Pump
t 1
791-627-1400
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
Installer
t 1
791-627-1300
7 791-628-1280
Sketch
Part name
New/Remodel
Part No.
Q'ty
Sym
bol
Necessity
Special tools
4. Hub
1) Remove plate (5).
2) Using hanging bolt [2], remove hub (6).
Disassembly
1. Draining oil
Remove the drain plug and drain the oil from the
final drive case.
6
5. Sprocket assembly
1) Remove holder (7).
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).
26
D275AX-5E0
SEN02344-00
2) Using tool J2, disconnect sprocket hub assembly (8) and bearing (9).
3) Using hanging bolt [3], remove sprocket hub
assembly (8).
6. Cover assembly
1) Using a hanging bolt, remove cover assembly (15).
4) Remove bearing (10) from the sprocket hub

assembly.
2) Disassemble the cover assembly according

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.
D275AX-5E0
27
SEN02344-00
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 assembly (22).
6) Remove collar (27) and bearing (28) from

the carrier.
2) Disassemble the carrier assembly according 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).
28
D275AX-5E0
SEN02344-00
8. Sun gear shaft assembly

1) Remove sun gear shaft assembly (29).
5) Remove 2 outer races (39) from hub (40).

2) Remove the mounting bolts and holders
(30) and (31) from the sun gear shaft assembly.
3) Remove inner race (32).
4) Using push tool [5], remove sun gear shaft
(34) from sun gear (33).
6) Remove the mounting bolts and shaft assembly (41) from the case.
7) Disassemble the shaft assembly according
i) Remove collar (42).
ii) Remove bearing (43) and collar (44).
9. Hub and shaft assembly
1) Remove gear (35).
2) Remove the mounting bolts and plate (36).
3) Using tool J4, remove hub assembly (37).

4) Remove bearing (38).
D275AX-5E0
29
SEN02344-00
10. Cage assembly

1) Using hanging bolt [6], remove cage assembly (45).
2) Remove shim (46).
a Check the thickness and quantity of the
inserted shims, then store them.
12. Outer race and oil seal

1) Using puller [9], remove outer race (54).
2) Remove oil seals (55) and (56).
3) Disassemble the cage assembly according

i) Using puller [7], remove outer race (47).
ii) Remove oil seals (48) and (49).
11. Gear assembly

1) Remove gear assembly (50).
2) Using puller [8], remove bearings (51) and
30
D275AX-5E0
Assembly
a Clean the all parts and check them for dirt or
damage before installing.
a Coat sliding surfaces of each part with engine oil
before installing.
a Check that each snap ring is fitted to the groove
securely.
1. Oil seal
1) Using push tools [10] and [11], install oil
seals (56) and (55).
a Install the lower oil seal with the pressure 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 projected part.
2
2
SEN02344-00
3. Gear assembly
1) Using push tool [13], press fit bearings (52)
and (51) to gear (53).
Press fitting force for bearing:
0.9 2.6 kN {9 25 tons}
2) Install gear assembly (50).
a Lower and install the gear assembly
slowly so that the oil seal lip will not be
damaged.

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 pressure 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 projected part.
2. Outer race
Using push tool [12], press fit outer race (54).
Press fitting force for outer race:
1 13 kN {0.1 1.3 tons}
D275AX-5E0
2
2

Oil seal fitting surface:
31
SEN02344-00
2) Using push tool [16], press fit outer race

(47).

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 clearances (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
32
Mounting bolt:
98 123 Nm {10 12.5 kgm}
D275AX-5E0
SEN02344-00
Table 1
a + b (mm)
Not less Not more
than
than
3.05
3.15
3.25
3.35
3.45
3.55
3.65
3.75
3.85
3.95
4.05
4.15
4.25
4.35
4.45
4.55
4.65
4.75
4.85
4.95
5.05
5.15
5.25
5.35
5.45
5.55
5.65
5.75
5.85
5.95
6.05
6.15
6.25
6.35
6.45
6.55
6.65
6.75
6.85
6.95
7.05
7.15
7.25
3.15
3.25
3.35
3.45
3.55
3.65
3.75
3.85
3.95
4.05
4.15
4.25
4.35
4.45
4.55
4.65
4.75
4.85
4.95
5.05
5.15
5.25
5.35
5.45
5.55
5.65
5.75
5.85
5.95
6.05
6.15
6.25
6.35
6.45
6.55
6.65
6.75
6.85
6.95
7.05
7.15
7.25
7.35
Number of shims to use

t=0.15
5
2
9
6
3
7
4
1
8
5
2
9
6
3
7
4
1
8
5
2
9
6
3
7
4
1
8
5
2
9
6
3
7
4
1
8
5
2
9
t=0.5
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
t=1.0
1
1
1
1
2
1
1
2
1
1
2
1
1
2
2
1
2
2
1
2
2
1
2
2
3
2
2
3
2
2
3
3
2
3
3
2
3
3
2
3
3
2
Total
Thickness
of shims
(mm)
1.75
1.80
1.85
1.90
1.95
2.00
2.05
2.10
2.15
2.20
2.25
2.30
2.35
2.40
2.45
2.50
2.55
2.60
2.65
2.70
2.75
2.80
2.85
2.90
2.95
3.00
3.05
3.10
3.15
3.20
3.25
3.30
3.35
3.40
3.45
3.50
3.55
3.60
3.65
3.70
3.75
3.80
3.85
2) Install the O-ring and shaft assembly (41) to

the case.
2
3
Mounting bolt:
Mounting bolt:
235 285 Nm {23.5 29.5 kgm}
3) Using push tool [18], press fit 2 outer races

(39) to hub (40).
2 16 kN {0.2 1.6 tons}
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).
D275AX-5E0
33
SEN02344-00
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}
6) Install gear (35) to hub (40).

2
3
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 having
a projection out of the machine
body.
Mounting bolt:
Mounting bolt:
235 285 Nm {23.5 29.5 kgm}

2
3
Mounting bolt:
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
3
6. Carrier assembly
1) Assemble the carrier assembly according to
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).
5 20 kN {0.5 2 tons}
34
Mounting bolt:
Thread tightenere (LT-2)
Mounting bolt:
455 565 Nm {46.5 58 kgm}
a After tightening the holder bolts, check

that the gear turns lightly.
D275AX-5E0
SEN02344-00
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.
Press fitting force for shaft:

103 156 kN {10.5 15.9 tons}
2
Mounting bolt:
3) Using push tool [22], press fit inner race (32)

to sun gear shaft (34).
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).
D275AX-5E0
35
SEN02344-00
5) Using tool J7, press fit floating seal (17) to

floating seal cover (16).
a Degrease the O-ring and O-ring fitting
surfaces thoroughly and dry them before installing.
a After installing the floating seal, check
that its slant is within 1mm.
6) Install the O-ring and floating seal cover

(16).
a Set the outside cut part of the floating
seal cover down.
7) Using a hanging bolt, install the O-ring and

cover assembly (15).
a The mating faces of the case and cover
must be free from bruise, rust, oil,
grease, dirt, and water.
3
36
10. Sprocket hub assembly

1) Using tool J7, press fit floating seal (14) to
floating seal cover (11).
a Degrease the O-ring and O-ring fitting
surfaces thoroughly and dry them before installing.
a After installing the floating seal, check
that its slant is within 1mm.
2) Using push tool [23] press fit outer races

(13) and (12).
17 36 kN {1.7 3.7 tons}
3) Install the O-ring and floating seal cover

(11).
Mounting bolt:
455 565 Nm {46.5 58 kgm}
D275AX-5E0
SEN02344-00
4) Set bearing (9) to sprocket hub assembly

(8).
5) Using hanging bolt [3], set sprocket hub assembly (8) to the cover.
a Check that the sliding surfaces of the
floating seal are free from dirt and apply
engine oil to them thinly.
6) Using tool J6, press fit bearing (9).
a Press fit the bearing, turning the sprocket hub assembly.
11 53 kN {1.1 5.4 tons}
11. Hub
1) Using hanging bolt [2], install hub (6).
2
3
Mounting bolt:
Mounting bolt:
235 285 Nm {23.5 29.5 kgm}
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
3
D275AX-5E0
Mounting bolt:
Mounting bolt:
235 285 Nm {23.5 29.5 kgm}
37
SEN02344-00
13. Sprocket, wear guard, and plate

3
Mounting bolt:
455 565 Nm {46.5 58 kgm}
2) Install wear guard (2).

3
Mounting bolt:
785 980 Nm {80 100 kgm}
3) Install sprocket (1).

3
Mounting bolt:
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
38
Drain plug:
127 176 Nm {13 18 kgm}
Final drive case: 40 l
D275AX-5E0
D275AX-5E0
SEN02344-00
39
SEN02344-00
40
D275AX-5E0
SEN02345-00
BULLDOZER
1SHOP MANUAL
D275AX-5E0
Machine model
Serial number
D275AX-5E0
30001 and up

Removal and installation of track frame assembly.......................................................................................... 2
Removal and installation of recoil spring assembly ........................................................................................ 7
Disassembly and assembly of recoil spring assembly ...................................................................................11
Removal and installation of idler assembly ................................................................................................... 13
Disassembly and assembly of idler assembly .............................................................................................. 14
Removal and installation of track roller assembly ......................................................................................... 18
Disassembly and assembly of track roller assembly .................................................................................... 21
Removal and installation of carrier roller assembly ...................................................................................... 25
Disassembly and assembly of carrier roller assembly .................................................................................. 26
Removal and installation of 1st bogie assembly ........................................................................................... 30
Removal and installation of 2nd, 3rd and 4th bogie assembly...................................................................... 36
Disassembly and assembly of bogie assembly ............................................................................................ 44
D275AX-5E0
SEN02345-00

track frame assembly
L14 791T-630-1380
Bracket
t 6
Sketch
Part name
New/Remodel
Part No.
Q'ty
Sym
bol
Necessity
Special tool
2) Set stands [2] on both sides of the front main

frame of the machine body.
3) Set hydraulic jack [3] under the center of the
equalizer bar and raise the front part of the
machine body.
4) Set a block under the raised front part of the
track frame to secure safety during work.
a After setting stands [1] and [2], set the jacks
or ripper again as auxiliary supports.
Removal
1. Remove the blade assembly. For details, see
"Removal of blade assembly".
3. Using tool L14, secure the bogie assembly.
5. Temporarily sling the track frame assembly to be

removed.
4. Raise the machine body according to the following procedure.

1) Raise the machine body with a jack or the
ripper and set stands [1] under both sides of
the frame to float the rear part of the machine body.
D275AX-5E0
SEN02345-00
7. Remove the mounting nuts and cover (2).

[*1]
8. Disconnect grease tube (3).
10. Pull out pin (5).

[*2]
a If the equalizer bar hole is not aligned with
the track frame hole, the pin cannot be
pulled out easily. Accordingly, adjust the
slinging height of the track frame when pulling out the pin.
k If the track frame assembly on the opposite side is raised before the pin is pulled
out, support it with a block.
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
single tilt specification or both track frames
of the dual tilt specification.
14. Remove the mounting bolts and pull out cover
(11).
a Take care since hoses are connected inside
the cover.
11. Remove guards (6) and (7).

4
Guard (7): 30 kg
D275AX-5E0
SEN02345-00
15. Disconnect hoses (12) and (13) connected inside cover (11) pulled out and remove cover
(11).
18. Remove spacer (16).
19. Remove the mounting bolts and disconnect cover (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
Pivot shaft case: 10l

l
20. Lift off track frame assembly (18).

4
[*5]
Track frame assembly: 5,050 kg
17. Remove seal (15) and cover (14) together. [*3]

D275AX-5E0
Installation
[*1]
Installation procedure for cover (4)
1) Tighten the mounting bolts of cover (4) with fingers.
2) Install cover (2) and secure it with the nuts.
3) Tighten the mounting bolts of cover (4) securely.
4) Install grease tube (3).
SEN02345-00
[*4]
a Degrease the fitting face of the seal and apply
gasket sealant (LG-6) to it.
a Do not install the track frame with torsional deformation left in seal (19).
[*5]
[*2]
k
When aligning the pin holes, never insert

your fingers in the pin holes.
a Direct the grease holes of the pins down.
Left pin: Outside of machine body
Right pin: Inside of machine body
2
Equalizer bar side bushing: Grease (G2-LI)
Bushing contact surface of pivot shaft:

Lubricant containing molybdenum disulfide (LM-P)
a When replacing the pivot shaft bushing of the

track frame assembly, press fit a new bushing
with the bushing mating face up.
Refilling with oil (Pivot shaft case)

3
5
Plug: 127 177Nm {13 18kgm}
Pivot shaft case: 10l

l (EO30-CD)
[*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.
D275AX-5E0
SEN02345-00

Bracket L14
D275AX-5E0
SEN02345-00
Removal and installation of recoil

spring assembly
1
791-730-1110
Bolt
t 6
1 01580-12722
Nut
t 6
01643-32780
Washer
t 6
791-630-1100
Installer
t 1
Cylinder
(686kN {70ton})
t 1
Pump
t 1
2 790-101-1600
790-101-1102
Sketch
Part name
New/Remodel
Part No.
Q'ty
Sym
bol
Necessity
Special tools
6. Remove covers (4).

a Remove both inside and outside covers.
[*2]
7. Using hanging bolt [1], pull out pin (5).
[*3]
Removal
k Never stand in front of the idler yoke to
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
D275AX-5E0
SEN02345-00
9. Disconnect recoil spring assembly (8) from idler

yoke assembly (7) according to the following
procedure.
[*4]
1) Lower idler yoke assembly (8) to the ground
and sling recoil cylinder assembly (7).
a At this time, check that the welded parts of
recoil cylinder assembly (7) are not damaged.
a Protect the chromium-plated bushing by
covering it with cloths.
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 prevent danger.
Since the installed load of about 372,700

N {38,000 kg} for the recoil spring is applied to the idler yoke, do not loosen the
mounting bolts suddenly but loosen
them gradually until clearance (a) between the idler yoke and recoil spring becomes 8 12 mm.
3) Check that the loosening torque of the bolts
has lowered suddenly and the installed load
for the recoil spring is not applied to the
bolts, remove the all bolts.
a If the loosening torque increases (If the installed load for the recoil spring is applied)
during the work, stop the work and remove
the bolts according to the following procedure.
If the loosening torque does not lower after steps 2) and 3) above, recoil spring
set bolt (10) may be broken or shaft end
nut (11) may have come off. Since the
idler yoke assembly can jump out forward in this case, remove the bolts according to the following procedure.
Do not stand in front of the idler yoke and
at the rear of the recoil cylinder until the
idler yoke assembly and recoil cylinder
assembly are disassembled and the recoil spring is taken out and the safety is
confirmed.
i)
Prepare the following parts (Tool M1).

Bolt [2] (6 pieces): 791-730-1110
Nut [3] (6 pieces): 01580-12722
Washer [4] (6 pieces): 01643-32780 (Reused)
ii) Remove the 6 bolts marked with * and install
bolts [2], nuts [3], and washers [4].
D275AX-5E0

a Check that dimension (L) is less than 361
mm.
a Tighten bolts [2] until they come in contact
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 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 expanded fully and the loosening torque on
them lowers totally, then remove bolts [2].
SEN02345-00
11. Supply grease through lubricator (13) and remove cylinder (14) and piston assembly (15).
[*6]
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).
D275AX-5E0
SEN02345-00
14. Remove holder (20) from the recoil spring assembly.
[*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]
Idler yoke assembly mounting bolt:

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 loosen the lubricator.
iii) Push in the piston until it is stopped by the stopper to discharge air and excessive grease.
iv) Tighten the lubricator.
15. Remove bushing (21).
Lubricator: 59 88 Nm {6 9 kgm}
[*7]
a Using tool M2, press fit bushing (21).
Press fitting force:
44.1 228.3 kN {4.5 23.3 tons}
2
Installation
Case to press fit: Thread tightener (LT-2)
[*1]
a Adjust the clearance of the idler. For details, see
Testing and adjusting, "Adjusting clearance of
idler".
[*2]
2
3
Cover mounting bolt:

Cover mounting bolt:
245 309 Nm {25 31.5 kgm}
[*3]

a Before inserting the pin, align the recoil cylinder
hole with the track frame hole.
10
Refilling with oil

Pour engine oil (EO30) in the spring chamber up
to the center.
3
5
Plug: 127 177 Nm {13 18 kgm}
Recoil spring chamber (Each side):

Approx. 83l
l
D275AX-5E0
SEN02345-00

recoil spring assembly
4. Remove rear pilot (5), spacer (6), bolt (7), and

pilot (8) from spring (4).
Compressor
t 1
790-201-2780
Spacer
t 1
791-635-3160
Extension
t 1
790-101-1600
Cylinder
(686kN {70ton})
t 1
790-101-1102
Pump
t 1
791-685-8502
M 3
Sketch
New/Remodel
Part name
Q'ty
Part No.
Necessity
Special tools
Sym
bol
3. Release the oil pressure gradually to reduce the

spring tension to 0 (zero).
Disassembly
1. Set recoil spring assembly (1) to tool M3.
k Since the installed load of the spring is
large and dangerous, set the spring assembly securely.
a Installed load of spring:
372,700 N {38,000 kg}
Assembly
1. Install pilot (8), bolt (7), spacer (6), and rear pilot
(5) to spring (4) and set them to M3.
k Since the installed load of the spring is
large and dangerous, set each part securely.
2. Apply oil pressure gradually and compress the
spring to the standard length.
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).
D275AX-5E0
11
SEN02345-00
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) between 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.
12
D275AX-5E0
Removal and installation

of idler assembly
SEN02345-00
Installation
Removal
1. Remove the blade assembly. For details, see
"Removal of blade assembly".
3. Remove covers (1) and (2).
[*1]
a Install both idler assemblies with the oil supply
plugs directed to the left.
a Tighten the idler cap mounting bolts in the following order.
Tightening order:
1) 2 bolts on (a) side
2) 2 bolts on (b) side
3) 2 bolts on (a) side
4) Tighten the all bolts to the specified torque.
2
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
D275AX-5E0
13
SEN02345-00
Disassembly and assembly

of idler assembly
6. Using puller [4], remove seal guide (6), retainer

(7), and plate (8).
Sketch
Plate
t 1 N Q
791-630-1220
Rod
t 4
790-101-2510
Block
t 2
790-101-2570
1 01643-31445
Plate
t 4
Washer
t 4
01580-01411
Nut
t 4
790-101-2102
Puller
(294kN {30ton})
t 1
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
791T-630-1310
Part name
New/Remodel
Part No.
Q'ty
Sym
bol
Necessity
Special tools
7. Remove seal guides (2) and (6) from retainers

(3) and (7).
Disassembly
1. Remove the oil filler plug and drain the oil.
6
Idler: 0.8 0.9l

l (G0140)
2. Set idler assembly (1) to block [1].

3. Remove the mounting bolts, then remove seal
guide (2), retainer (3), and plate (4), using forcing screw [2].
8. Remove floating seals (9) from seal guides (2)

and (6).
a Keep the floating seals so that they will not
be damaged.
and (7).
be damaged.
4. Turn over the idler assembly.

5. Remove the mounting bolts, then remove shaft
(5) and retainer, using hanging bolt [3].
14
D275AX-5E0
SEN02345-00
10. Remove bushing (11) from idler (12).
Assembly
3. Fit the O-ring and install retainer [3] and plate (4)
to the idler.

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.
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 retainers (3) and (7).
a When installing the floating seals, thoroughly degrease and dry the contact surfaces of
them and O-rings (hatched portion). Take
care that dirt will not stick to the contact surfaces 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.
D275AX-5E0
15
SEN02345-00
7. Using tool L2, install floating seals (9) to seal

guides (2) and (6).
a For precautions for installing the floating
seals, see a in step 2 above.
9. Using tool L4, supply the specified quantity of oil

and tighten the oil filler plug.
5
Idler: 0.8 0.9l

l (G0140)
Oil filler plug:

156.8 254.8 Nm {16 26 kgm}
8. Set seal guide (2) to the shaft and press fit seal
guide (2) by using tools L1 and L3.
Press fitting force for seal guide:
49 83.4 kN {5 8.5 tons}
a Press fit the seal guide so that distance (b)

from the shaft end to the seal guide top will
be as follows.
Press fitting distance (b): 96 0.2 mm
a Turn over the idler assembly and press fit
seal guide (6) on the opposite side similarly.
16
D275AX-5E0
SEN02345-00

Bracket L1
D275AX-5E0
17
SEN02345-00

790-401-1700
Lifting toolt
t 1
790-401-1761
Adapter
t 1
790-401-1540
Shackle
t 2
790-401-1770
T-bolt
t 2
Bracket
t 4
14 791T-630-1380
Sketch
Part name
New/Remodel
Part No.
Q'ty
Sym
bol
Necessity
Special tools
Removal
Note 2: Sling and secure 1st bogie assembly

(1) with a lever block, etc.
A fixing tool can not be used for the 1st
bogie assembly.
1. Loosen the track shoe tension. For details, see

"Expanding track shoe assembly".
2. Install tool L14 and secure bogie assembly (1).
a When removing track roller assembly (2),

secure the related bogie assemblies according to the following table.
Track roller
assembly to be
removed
1st roller
2nd roller
3rd roller
4th roller
5th roller
6th roller
7th roller
Bogie assembly to be
secured with tool
Location
Related bogie
Note 1
2nd bogie
2nd bogie
Note 2
2nd bogie
3rd bogie
3rd bogie
2nd bogie
3rd bogie
4th bogie
4th bogie
3rd bogie
4th bogie
3. Operate the blade and ripper to raise the machine body until track roller assembly (2) is floated above the track shoe.
a Operate the blade and ripper slowly with the
engine at low speed.
4. Loosen the mounting bolts of roller cap (3).
[*1]
a Loosen both inside and outside mounting
bolts.
a Do not remove the mounting bolts.
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.
18
D275AX-5E0
SEN02345-00
5. Operate the blade and ripper to lower the machine body.

a Operate the blade and ripper slowly.
Roller cap mounting bolt:

824 1,030 Nm {84 105 kgm}
6. Remove the mounting bolts and roller cap. [*2]

a Take care not to damage the dowel pin.
7. Operate the blade and ripper to raise the machine body until track roller assembly (2) is separated 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
4
Track roller assembly (Single frange):

150 kg
Track roller assembly (Double frange):
165 kg
Installation
[*1] [*2]
Install the track roller assembly according to the following procedure.
1. Set the track roller assembly on the track shoe.
a irect the oil filler of the track roller assembly
out of the machine body.
[*4]
When installing the 1st track roller assembly (single
flange) by using tool L5;
1) Set tool L5 under the track roller assembly.
2) Sling 1st track roller assembly (2) and set it to
the track frame.
2. Lower the machine body until the roller cap bolts

can be installed and install roller cap (3) temporarily.
a Direct roller cap protector (a) out of the bogie.
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

D275AX-5E0
19
SEN02345-00

Bracket L14
20
D275AX-5E0
SEN02345-00

7. Remove seal guides (2) and (6) from the retainers (3) and (7).
Sketch
New/Remodel
Part name
Q'ty
Part No.
Necessity
Special tools
Sym
bol
6. Using a press, remove seal guide (6), retainer

(7), and plate (8) from the shaft.
6 791T-630-1320
Plate
t 1 N Q
7 791T-630-1330
Push tool
t 1 N Q
8 791-651-1510
Installer
t 1
9 791-601-1000
Oil pump
t 1
Disassembly
6
Track roller: Approx. 0.75 0.85l

l
2. Set track roller assembly (1) to block [1].

3. Remove the mounting bolts and remove seal
guide (2), retainer (3), and plate (4) together by
using forcing screw [2].
4. Turn over the track roller assembly.

and (6).
be damaged.
and (7).
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).
D275AX-5E0
21
SEN02345-00
Assembly
damage.
1. Set roller (12) to a press and press fit bushing
(11) by using tool L6.
a Center the bushing with a plastic hammer
first, then press fit it with the press.
a Press fit the bushing so that distance (a)
from the roller end to the bushing top will be
as follows.
Press fitting distance (a): 17 0.5 mm
Press fitting force for bushing:
29 132 kN {3 13.5 tons}
5. Using tool L7, install floating seals (9) to seal

guides (2) and (6).
them (hatched portion) and O-rings. Take
is 7 - 11 mm.
2. Set shaft (5) to the roller.
6. Using tool L8, press fit seal guide (2) to the

shaft.
Press fitting force for seal guide:
39 69 kN {4 7 tons}
3. Using tool L7, install floating seals (10) to retainers (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 smoothly with hand.
22
D275AX-5E0
SEN02345-00
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
Track roller: 0.75 0.85l

l (G0140)
Oil filler plug:

156.8 254.8 Nm {16 26 kgm}
D275AX-5E0
23
SEN02345-00

Plate L6
Bush tool L7
24
D275AX-5E0
SEN02345-00

carrier roller assembly
Removal
2. Using hydraulic jack [1], raise the track shoe.
3. Lift off carrier roller assembly (1).
4
[*1]
Carrier roller assembly: 60 kg
Installation
[*1]
Carrier roller assembly mounting bolt:

D275AX-5E0
25
SEN02345-00

carrier roller assembly
7. Remove bearing outer race (7) from the roller.
10 790-102-1891
L
Nut wrench
t 1
Sketch
Part name
New/Remodel
Part No.
Q'ty
Sym
bol
Necessity
Special tools
8. Using puller [3], remove seal guide (8) and bearing inner race (9) together.
11 791-675-1510
Installer
t 1
12 791T-630-2410
Push tool
t 1 N Q
13 791-601-1000
Oil pump
t 1
Disassembly
a Drain the oil, turning the shaft.
6
9. Remove floating seal (10) from seal guide (8).
Carrier roller: Approx. 0.6 0.7l

l
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.
26
D275AX-5E0
SEN02345-00
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
roller. Continue press fitting until the roller
becomes heavy to turn.
8. Using tool L11, install floating seal (10) to seal

guide (8).
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 between the bearing and nut) is 0 0.22 mm.
D275AX-5E0
27
SEN02345-00
9. Fit the O-ring and install seal guide (8), matching it to the dowel pin.
12. Using tool L13, supply the specified quantity of

oil and tighten the oil filler plug.
5
Carrier roller: 0.6 0.7 l (GO140)
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.
28
D275AX-5E0
SEN02345-00

Push tool L12
D275AX-5E0
29
SEN02345-00
Removal and installation of 1st

bogie assembly
1
Bracket
t 2
790-401-1700
Lifting tool
t 1
790-401-1761
Adapter
t 1
791-630-1860
Bracket
t 1
791-630-1870
Bracket
t 1
14 791T-630-1380
L
22
23
Sketch
Part name
New/Remodel
Part No.
Q'ty
Sym
bol
Necessity
Special tools
8. Set tool L22 and remove roller caps (3).
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

4. Operate the blade and ripper to raise the machine body until the track roller of 2nd bogie assembly (1) is floated above the track link.
k Set stands or blocks under the front and
rear parts of the frame so that the machine body will not lower.
5. Set block [1] between the 1st track roller and
2nd track roller so that 1st bogie assembly (2)
will not lower.
6. Loosen the mounting bolts of roller caps (3) by
about 20 mm.
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).
30
D275AX-5E0
SEN02345-00
11. Using tool L23, sling and hold the 1st bogie.
12. Pull out the shaft and ring.

1) Set tool L15.
2) Push shaft (8) with tool L15 to push out ring
(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.
Pushing force (Reference):
275 490 kN {28 50 tons}
D275AX-5E0
3) Remove floating seals (10) from the end faces of rings (9) and (12).
be damaged.
4) Set pulling out tool L16.
31
SEN02345-00
5) Pull out spacer (11) and rings (12) and (13).

Pulling out force (Reference):
275 490 kN {28 50 tons}

7) Remove spacer (14) and floating seal (14)
between rings (12) and (13).
be damaged.
8) Remove the shaft and rings from the bogie

on the opposite side according to steps 1) 7) above.
13. Sling 1st bogie (16) and pull it out.
a When the 1st bogie is removed, it interferes
with 2nd bogie assembly (1). To prevent
this, lower the 2nd bogie assembly.
4
32
Installation
1. Assemble the cartridge pin.
1) Using tool L17, install floating seals (10) to

rings (9) and (12) and install floating seal
(15) to the opposite side of ring (12) and ring
(13).
is 3 5 mm.
Bogie assembly: 100 kg
D275AX-5E0
2) Install spacer (11) and ring (12) to shaft (8)

and ring (9).
3) Install spacer (14) to ring (12) and press fit
ring (13) with tool [2].
Press fitting force for ring (13):
4.9 35.3 kN {0.5 3.6 tons}
2
SEN02345-00
k

4. Support 1st bogie (16) with hydraulic jack [2]

and remove guide tool L19 and sling tool L23.
Between shaft (8) ring (13):

Lubricant containing
molybdenum disulfide (LM-P)
4) Using tool L18, check the airtightness of the

floating seal.
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).
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.
D275AX-5E0
33
SEN02345-00
a Press fit the cartridge pin assembly to the

machined surface (c) of the bogie.
5
Outside surface of pin:
Lubricant containing molybdenum

disulfide (LM-P)
a Press fitting force for cartridge pin assembly: 275 490 kN {28 50 tons}
11. Install covers (7).

a Install 2 covers, outside and inside ones.

oil to the cartridge pin assembly.
a Oil supply pressure: 0.49 MPa {5kg/cm2}
5
Cartridge pin assembly (81 95% of full level): 61 71 cc (GO-140)
12. Using tool L22, sling and set track roller assembly (6).
a When setting the track roller assembly, balance it.
4
Track roller assembly: 150 kg
8. Press fit the cartridge pin assembly on the opposite 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 bogie assembly (1) so that 1st bogie (16) will not
lower.
34
D275AX-5E0
13. Install roller cap (3) and secure it with the bolts
temporarily.
a Direct roller cap protectors (b) out of the bogie.
SEN02345-00
14. Align the dowel pin holes and tighten the bolts.
2
3

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".

Bracket L14
D275AX-5E0
35
SEN02345-00
Removal and installation of 2nd,

3rd and 4th bogie assembly
1
Bracket
t 2
791-630-1360
Spacer
t 1 N
790-101-2310
Block
t 1
790-101-2360
Plate
t 2
790-445-4130
Screw
t 2
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 N
791-630-1370
Adapter
t 1
790-434-1060
Screw
t 2
01580-13024
Nut
t 2
01643-33080
Washer
t 1
790-101-4000
Puller
(490kN {50ton})
t 1
790-101-1102
Pump
t 1
17 796-230-1120
Installer
t 1
18 790-701-3000
Seal checker
t 1
19 791T-630-1390
Guide
t 1 N Q
790-101-2310
Block
t 1
790-445-4130
Screw
t 2
796T-470-1130
Plate
t 1
790-101-2360
Plate
t 2
791-112-1180
Nut
t 2
790-101-4000
Puller
(490kN {50ton})
t 1
790-101-1102
Pump
t 1
Oil pump
t 1
14 791T-630-1380
15
16
L
20
21 791-601-1000

a Remove the cover on the opposite side, too.
Sketch
Part name
New/Remodel
Part No.
Q'ty
Sym
bol
Necessity
Special tools
3. Using tool L14, secure bogie assembly (1).
5. Operate the blade and ripper to raise the machine body until the track roller is floated above
the track link.
k Set a block between the track roller and
track link so that the machine body will
not lower.
6. Set steel plate [4] on the track shoe and block
[3].
a Set block [3] according to the height of the
track link.
7. Operate the blade and ripper to lower the machine body until the track roller of the bogie assembly comes in contact with steel plate [4].
a Operate the blade and ripper slowly.
Removal
2. Remove the undercovers.
a Remove the following undercovers which
will be obstacles to removal of the bogie assembly.
4
4
36
Engine undercover: 250 kg

Power train undercover: 320 kg
D275AX-5E0
8. Remove the shaft and ring.

1) Set tool L15.
2) Push shaft (3) with tool L15 to push out ring
(4) to the opposite side.
Pushing force (Reference):
275 490 kN {28 50 tons}
SEN02345-00
4) Set pulling out tool L16.
5) Pull out spacer (6) and rings (7) and (8).

Pulling out force (Reference):
275 490 kN {28 50 tons}
3) Remove floating seals (5) from the ends of

rings (4) and (7).
a Keep the floating seals so that they will
not be damaged.
D275AX-5E0

7) Remove spacer (9) and floating seal (10)
between rings (7) and (8).
a Keep the floating seals so that they will
not be damaged.
37
SEN02345-00
8) Remove the shaft and rings from the bogie

on the opposite side according to steps 1) 7) above.
Installation
1. Assemble the cartridge pin assembly.
9. Operate the blade and ripper to raise the machine body until the bogie assembly can be
pulled out.
k Set a block between the track roller and track
link 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.
38
D275AX-5E0
2) Install spacer (6) and ring (7) to shaft (3) and

ring (4).
3) Install spacer (9) to ring (7) and press fit ring
(8) with tool [5].
Press fitting force for ring (8):
4.9 35.3 kN {0.5 3.6 tons}
2
SEN02345-00
2. Lift off bogie assembly (1) onto block [3] and

steel plate [4].
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.
5. Operate the blade and ripper to raise the machine body.

6. Adjustment procedure for cartridge pin hole.
1) Set block [2] and hydraulic jack [7] on the
rear side of the machine body.
D275AX-5E0
39
SEN02345-00
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).
4) Adjust front and rear hydraulic jacks [7] to

align the pin holes of the track frame and bogie assembly.
k When aligning the pin holes, never insert
a If the pin holes cannot be aligned by adjusting the front and rear hydraulic jacks, align
them by slinging the front part of the opposite track or applying a hydraulic jack to the
bogie assembly.
40
7. Insert cartridge pin assembly (11) in the pin

hole.
(b) on its end face up (in the mounting state
D275AX-5E0
SEN02345-00
8. Using tool L20, press fit cartridge pin assembly

(11).
a Press fit the cartridge pin assembly to machined surface (c) of the bogie.
2
Outside surface of pin:

disulfide (LM-P)
10. Press fit the cartridge pin assembly on the opposite side according to steps 6-5) 9 above.
11. Install cartridge pin assembly covers (2) and
tighten the bolts.
12. Adjust the track shoe tension. For details, see

5
Cartridge pin assembly

(81 95% of full level):
61 71 cc (GO-140)
D275AX-5E0
41
SEN02345-00

Bracket L14
Guide L19
42
D275AX-5E0
SEN02345-00
Plate L20
D275AX-5E0
43
SEN02345-00

bogie assembly
20
790-101-2310
Block
t 1
790-445-4130
Screw
t 2
796T-470-1130
Plate
t 1
790-101-2360
Plate
t 2
791-112-1180
Nut
t 2
790-101-4000
Puller
(490kN {50ton})
t 1
790-101-1102
Pump
t 1
Oil pump
t 1
21 791-601-1000
Sketch
Part name
New/Remodel
Part No.
Q'ty
Sym
bol
Necessity
Special tools
3. Cartridge pin assembly

Remove cartridge pin assembly (4) according to
the procedure in Removal of bogie assembly.
a See step 8.
4. Bogie
Disconnect inner bogie (5) and outer bogie (6).
Disassembly
1. Track roller assembly
1) Turn over bogie assembly (1).
2) Remove the roller cap and lift off 2 track roller assemblies (2).
4
4

150 kg
165 kg
Assembly
1. Assembly of cartridge pin assembly
Assemble the cartridge pin assembly according
to the procedure in Installation of bogie assembly.
a See step 1.
2. Cover
Remove cover (3).
44
D275AX-5E0
2. Bogie
Set inner bogie (5) to outer bogie (6).
3. Cartridge pin assembly
1) Set tool L20.
2) Press fit cartridge pin assembly (4).

a Press fit the cartridge pin assembly with the
cover.
(a) on its end face up (in the mounting state
a Press fit the cartridge pin assembly to the
machined surface of the bogie.
2 Outside surface of pin:
disulfide (LM-P)
D275AX-5E0
SEN02345-00
4. Refilling with oil

Using tool L21, supply the specified quantity of
5
Cartridge pin assembly (81 95% of full level): 61 71 cc (GO-140)
5. Cartridge pin assembly (Opposite side)

Press fit the cartridge pin assembly on the opposite side according to steps 3 4 above.
a After press fitting the cartridge pin assembly,
adjust it so that the inner bogie can slide
lightly.
6. Covers
Install covers (3).
45
SEN02345-00
7. Track roller assembly

1) Sling 2 track roller assemblies (2) and set
them on the bogie.
a Install the track roller assemblies with the oil
fillers out.
4
4

150 kg
165 kg
2) Install the roller caps to track roller assemblies (2) and secure them with the mounting
bolts.
a Direct roller cap protectors (b) out of the bogie.
2
3

824 1,030 Nm {84 105 kgm}
46
D275AX-5E0
SEN02345-00

Plate L20
D275AX-5E0
47
SEN02345-00
48
D275AX-5E0
SEN02346-00
BULLDOZER
1SHOP MANUAL
D275AX-5E0
Machine model
Serial number
D275AX-5E0
30001 and up

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 ................................................................................... 32
D275AX-5E0
SEN02346-00
Expanding and installing

track shoe assembly
Check before expanding track shoe

assembly
k
Since it may be very dangerous to expand

the track shoe assembly, check the following
items in advance.
Do not loosen the lubricator more than 1
turn. If the grease does not come out well,
move the machine forward and in reverse.
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. After the shoe is loosened, perform Expanding

track shoe assembly (Normal).
Expanding track shoe assembly

(Normal)
a If Checking before removal of track shoe assembly shows that there is no abnormality, do
as follows.
1. Set master link (3) in position.
a Bring the master link above the idler (just behind the center).
a Set blocks [1] and [2] at the front end of the
idler and between the carrier rollers so that
the mating faces of the master link will not
open until the master bolt is removed.
2. Relieve track shoe tension.

[*1]
k Never loosen lubricator (1) more than
one turn.
a If the track is not relieved by loosening the
lubricator, move the machine backwards
and forwards.
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 trouble (damage of the recoil spring or recoil
spring set bolt, fall of the shaft end nut, etc.)
3. Remove track shoe (2).

[*2]
a Loosen each of the 4 bolts by 1 2 turns.
Check that the 4 bolts can be turned lightly,
then pull them out. Do not pull out only 1 bolt
without loosening the other three.
D275AX-5E0

a If a bolt is turned forcibly while it cannot be
turned lightly, the threads of it and master
link (3) may be damaged.
SEN02346-00
2. Loosen the track shoe.

[*1]
k Do not loosen the lubricator more than 1
turn.
a If the track shoe is not loosened by loosening the lubricator, move the machine forward
and in reverse to discharge the grease.
a Check that the all grease has been discharged.
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 machine of the similar size of the machine to be repaired, if available) to press the track shoe on
the idler side. When the recoil spring and track
shoe are distorted, stop and apply the brake. At
this time, set the master link between the idler
and front carrier roller.
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 following 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 serious result. Accordingly, expand the track
shoe according to the following procedure.
4. Remove track shoe (4) and disconnect master

link (3).
[*2]
1. Remove the work equipment. For details, see

"Removal of work equipment assembly".
5. Move the machine slowly in reverse to expand

track shoe assembly.
D275AX-5E0
SEN02346-00
Installation
Carry out expansion (normal) in the reverse order 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
3
3
Shoe mounting bolt: Anti-seizure agent

(Maruzen MOLYMAX No. 2 or equivalent)
Shoe mounting bolt:
1st time: 490 49 Nm {50 50 kgm}
2nd time: Retighten by 180 10
a Tighten the all 4 bolts with fingers until the master link mating faces are fitted.
a If the bolts are tightened forcibly before the master link mating faces are fitted, the threads of the
bolts and master link may be damaged.
D275AX-5E0
SEN02346-00
Whole disassembly and whole assembly of track shoe assembly
1 791-646-7531
2 791-660-7460
3 791-646-7900
4 791-932-1110
790-701-3000
791-601-1000
6 791-632-1070
5
791-680-9802
791-680-1520
7 790-101-4200
790-101-4300
790-101-1102
791-632-1500
791-632-1420
791-632-1430
791-632-1440
791-632-1450
8
791-632-1460
791-632-1470
R
791-632-1480
791-685-5730
01252-30650
01580-01210
791-632-1400
791-632-1410
791-632-1430
791-632-1440
791-632-1450
9
791-632-1460
791-632-1470
791-632-1480
791-685-5730
01252-30650
01580-01210
791-632-1490
10
791-685-5740
790-434-1110
790-434-1610
11
195-32-61210
01010-51440
D275AX-5E0
Plug remover
Pin brush
Push tool
(For large plug)
Push tool
(For small plug)
Seal checker
Oil pump
Installer
Remover and
installer
Guide
Puller
(294kN {30ton})
Cylinder
(1,470 kN {150ton})
Hydraulic pump
Push tool
assembly
Adapter
Ring
Plate
Ring
Push tool
Adapter
Spring
Bar
Bolt
Nut
Push tool
assembly
Adapter
Ring
Plate
Ring
Push tool
Adapter
Spring
Bar
Bolt
Nut
Push tool
Push tool
Adapter
Guide
Bolt (Shoe bolt may
be used)
Bolt
t 1
t 1
t 1
t 1
t 1
t 1 N
t 1
t 1
790-101-4300
790-101-1102
791-685-9510
791-685-9520
791-685-9530
791-685-9550
791-685-9560
13 790-434-1120
01010-51030
04530-12030
790-101-4300
t 1
t 1
t 1
t 1 N
N
N
N
N
N
N
N
790-101-1102
791-685-9540
14
791-685-9550
791-685-9510
791-685-9520
791-685-9530
791-685-9550
791-685-9560
791-126-0150
791-680-5520
R 15 791-126-0140
790-434-1120
01010-51030
04530-12030
791-685-9620
t 1 N
790-101-4300
1
1
1
1
1
1
1
1
1
1
1
1
1
1
790-101-1102
791-680-1630
t
t
t
t
t 1
t 2
N
N
N
N
N
N
N
16 790-101-4200
790-101-1102
791-680-5541
791-680-9630
17
790-101-4300
790-101-1102
18 790-434-1130
791-685-9510
791-685-9520
19 791-685-9530
791-685-9540
791-685-9550
Cylinder
(1,470 kN {150ton})
Hydraulic pump
Frame
Frame
Rod
Nut
Bolt
Adapter
Bolt
Eyebolt
Cylinder
(1,470 kN {150ton})
Hydraulic pump
Rod
Nut
Frame
Frame
Rod
Nut
Bolt
Adapter
Guide
Pusher
Adapter
Bolt
Eyebolt
Extension
Cylinder
(1,470 kN {150ton})
Hydraulic pump
Spacer
Puller
(294kN {30ton})
Hydraulic pump
Adapter (For pin)
Adapter
(For bushing)
Puller
(294kN {30ton})
Hydraulic pump
Guide
Frame
Frame
Rod
Rod
Nut
Sketch
New/Remodel
Part name
Q'ty
Part No.
Necessity
Sym
bol
12
t 1
1
1
1
1
1
1
1
1
1
1
Sketch
Part name
New/Remodel
Part No.
Q'ty
Sym
bol
Necessity
Special tools
t 1
t
t
t
t
t
t
t
t
t
1
1
1
1
1
4
1
1
1
t 1
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
1
1
1
1
1
1
2
4
1
1
1
1
1
1
1
t 1
t 1
t
t 1
t 1
t 1
t 1
t 1
t
t
t
t
t
t
t
1
1
1
1
1
1
3
791-685-9560
791-126-0150
01010-51030
791-685-9620
19 791-680-5541
791-680-5550
790-101-4300
790-101-1102
791-685-9510
791-685-9520
791-685-9530
791-685-9540
791-685-9550
791-685-9560
791-126-0150
20 01010-51030
791-685-9620
791-680-5550
790-434-1140
791-680-9630
R
790-101-4300
790-101-1102
21
790-101-4200
790-101-1102
22 790-434-1160
791-685-9510
791-685-9520
791-685-9530
791-685-9540
791-685-9550
791-685-9560
791-126-0150
23
790-434-1150
790-434-1120
01010-51030
790-434-1160
790-101-4300
790-101-1102
Bolt
Adapter
Bolt
Extension
Adapter
Guide
Cylinder
(1,470 kN {150ton})
Hydraulic pump
Frame
Frame
Rod
Rod
Nut
Bolt
Adapter
Bolt
Extension
Guider
Adapter
Adapter
Cylinder
(1,470kN {150ton})
Hydraulic pump
Puller
(294kN {30ton})
Hydraulic pump
Guide
Frame
Frame
Rod
Rod
Nut
Bolt
Adapter
Guide
Adapter
Bolt
Guide
Cylinder
(1,470kN {150ton})
Hydraulic pump
t
t
t
t
t
t
4
1
1
1
1
1
Whole disassembly
Sketch
Part name
New/Remodel
Part No.
Q'ty
Sym
bol
Necessity
SEN02346-00
t 1
t
t
t
t
t
t
t
t
t
t
t
t
t
1
1
1
1
1
3
4
1
1
1
1
1
1
1. Removal of shoe
Sling the shoe assembly and set it with the shoe
up on the floor and remove the shoe by using a
shoe bolt impact wrench.
a If a shoe bolt is not loosened after it is unscrewed by 1 turn (If its torque is not reduced to 0), loosen the other bolts first, and
it will be removed smoothly.
a If a shoe bolt is turned forcibly while its
torque is not 0, bolt and link will adhere to
each other and they will need to be repaired.
a When moving the shoe assembly, take care
not to damage the master link.
a If it is obliged to cut a shoe nut with gas,
keep the seal temperature below 80C to
prevent thermal deterioration of the seal and
take measures to prevent the spatters from
entering through the clearances among the
links.
t 1
t 1
t 1
t
t
t
t
t
t
t
t
t
t
t
t
t
1
1
1
1
1
1
3
4
1
1
1
1
1
2. Disassembly of link
1) Set the link assembly on a link press (Tool
R7) and hit it with a hammer so that the
bushing will be fitted to the jaw.
t 1
t 1
a When disassembling the track shoe, see "Parts

judgment guide, Undercarriage, Lubricated
track" and "Parts judgment guide, Undercarriage, Reversing procedure for lubricated track".
D275AX-5E0
SEN02346-00
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 disassembly 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 assembly 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 edges, take care not to cut your hands with
them.
2) Operate the left cylinder to pull out the pin
and bushing from the left link simultaneously.
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 obtained when reversed and assembled again.
a The wedge link is broken with a bang. This
sound does not indicate abnormality.
D275AX-5E0
SEN02346-00
3. Inspection
Check the parts for the following items to see if
they can be used for a lubricated track or a
grease-filled track, then examine them generally
and determine to use them for a lubricated track
or grease-filled track.
a For judgment of reuse of the parts, see
"Parts judgment guide, Undercarriage, Lubricated track".
1) Check the parts visually for damage. If a
part seems to be damaged, check it by dye
penetrant test or magnaflux inspection. If it
has any crack, it cannot be used again. Discard it.

a Precautions for storage
1) Store the seal without removing it from the link
so that the counterbore portion will not be rusted
and take care not to damage the seal lip.
2) Apply rust-preventive oil to the pin and bushing
fitting parts, shoe mating surface, and master
link mating surface of the link.
3) When storing, apply rust-preventive oil to the all
surfaces of the pin, bushing, and spacer. Take
care not to damage the ends of the bushing in
particular.
Whole assembly
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
parts of the link with a micrometer and a cylinder gauge to see if the allowable fitting allowance is obtained. When using the pin,
bushing, and link for a lubricated track, however, secure the standard fitting allowance
between the pin and link.
a If the allowable fitting allowance is not obtained, replace the parts with new ones.
a For the dimensional criteria, see Maintenance standard.
a For the whole assembly of the track shoe, see

"Parts judgment guide, Undercarriage, Reversing procedure for pin bushing".
When recycling for lubricated 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 deteriorated easily by the cleaning liquid (trichloroethylene etc.), clean them quickly. After
cleaning them, wipe off the cleaning agent
from them.
D275AX-5E0
2) When reusing the pin, chamfer its end corners smoothly with a grinder. Remove the
nodules sticking to the press fitting parts
with the grinder, too.
a If the ends are worn and sharpened, they
may scuff the press fitting parts and cause
oil leakage.
3) If the link, pin, bushing, and spacer are dirty,

clean them. Remove the nodules sticking to
the link and bushing with the grinder, too.
a Since these parts rust easily, clean them just
before assembling them.
a Do not polish the bushing ends. If they are
polished, oil may leak.
4) If the large plug was pulled out, drive it in by
using tool R3.
a Using tool R2, clean the pin hole in advance.
SEN02346-00
iv) Drive in the bar with a hammer.

a Driving distance (a) from pin end: 10 1 mm
a If the chamfered part of the pin hole has
been worn, chamfer it with a small-sized
grinder (grindstone tip angle: 45 60) so
that the plug will not be damaged.
a Coat the plug with GO90 and drive it with the
small diameter end ahead.
5) 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 oil is sticking to the counterbore portion of
the link or seal assembly, the seal will turn
and its sealing performance will lower. Accordingly, do not apply any oil. When inserting the seal in the counterbore portion, take
care that oil not stick to the seal and counterbore 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.
D275AX-5E0
SEN02346-00
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 installed dimensions of the seal within the
standard range.
a For the standard dimensions, see Dimensions 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 dimensions 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 faces 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}
Pushing force
1.8 x Average pressure
(Adjust the relief pressure of the link press to
set the press cutting force.)
2. Assembly of link
1) Apply oil (GO90) to the mating surfaces of
the pin and bushing with a clean brush and
assemble 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 bushing with the worn outside surface up on the
link press).
10
3) Using the shoe bolt hole pitch gauge, press

fit the master links until the distance between the shoe bolt holes of both links is the
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.
D275AX-5E0
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.
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.
SEN02346-00
8) Set the right link and install the spacer to the

pin.
a Check that the seal surface and bushing
end are free from dirt and apply oil (GO90)
to them with a clean cloth or brush.
a When installing the spacer, wipe it with a
clean cloth.
9) Set the right jig on the receiving side and the

left one on the pushing side and press fit the
pin and bushing simultaneously.
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 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 fitting parts.
D275AX-5E0
11
SEN02346-00
10) Using the spacer for fine adjustment, press

fit the pin and bushing until the pin end is fitted to the bottom of the receiving jig.
a Adjust the depth of the receiving jig hole so
that the projections of the pin on both sides
will be even.
13) Press fit until the link, spacer, and bushing

are fitted together.
a Actually, you cannot see from outside if the
above parts are fitted. Accordingly, control
the hydraulic pressure of the link press. Set
the relief pressure to a proper level and
heighten the hydraulic pressure to that level.
For setting of the relief pressure, see Preparation work.
a Check that adjacent 2 links can turn around
each other.
11) Set the left link and install the spacer to the
pin.
a Apply oil similarly to the right link.
12) Set the left jig on the receiving side and the
right one on the pushing side and press fit
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
14) Using a shoe bolt hole pitch gauge, measure 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, disassemble 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 allowable limit. In this case, disassemble and
replace the parts.
D275AX-5E0
15) Install the ring to jig R8.
16) Align the jig with plug hole and push it slowly
until a click is heard.
a A click is heard when the ring slides down on
the jig and fits to the pin.
SEN02346-00
18) Using jig R10, push in the ring.

Pushing force for ring:
245 304 kN {25 31 tons}
19) After each link is assembled, bleed air from

the pin by using tool R5 and check the sealing performance.
a Keep the degree of vacuum inside the pin at
91 95 kPa {680 710 mmHg} for 5 seconds and check that the pressure does not
change. If the pressure changes, disassemble and check the seal. If the seal is free
from abnormality, assemble again.
17) Using jig R9, insert the ring in the pin groove
on the opposite side similarly.
D275AX-5E0
13
SEN02346-00
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 Komatsu genuine oil (150-09-19270 or 195-3261990) having better low-temperature characteristics 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.
a Supply oil so that depth (L) of the hollow of

the pin hole will be in the following range
when the link is left with the small plug side
up (when the link assembly is placed on its
side) for 30 minutes.
Dimension (L): 50 80 mm
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
3
Shoe bolt: Lubricant containing molybdenum disulfide (LM-P)

Shoe bolt (Regular link)
Initial torque:
784 78 Nm {80 8 kgm}
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
D275AX-5E0
SEN02346-00
2) When installing a double track, place the assembled double shoes on a level place in 1
line with the shoe side up.
3) Pull pin-side master link (1) and bushingside master link (2) together and set them to
each other by the mating faces.
4) Place shoe (3) on the links and fits the mating 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 corners carefully with a grinder so that it will be
press fitted smoothly.
2
3
Shoe bolt:
Anti-friction compound (LM-P)
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 deteriorated easily by the cleaning liquid, clean
them quickly. After cleaning them, wipe off
the cleaning agent from them.
D275AX-5E0
15
SEN02346-00
3) Drive in the large and small plugs by using

tools R3 and R5.
i) Insert each plug through the plug insertion 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
shoe was disassembled, reuse them as they
are.
4) If the outside of the pin, surfaces of the
spacer, and ends and inside of the bushing
are dirty, clean them.
5) Apply grease to the outside of the pin and
surfaces of the spacer.
7) 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 dimensions of the seal within the
standard range.
a For the standard dimensions, see Dimensions table of fitting jig of link press.
6) Installation of seal assembly

Clean the counterbore portion of the link
carefully and push in the seal to the bottom
by using tool R6.
a If grease is sticking to the counterbore portion of the link or seal assembly, the seal will
turn and its sealing performance will lower.
Accordingly, do not apply any oil.
16
D275AX-5E0
SEN02346-00
2. Assembly of link
1) Apply lithium grease (G2-LI) to the mating
surfaces of the pin and bushing and assemble 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 bushing 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 faces 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 traction side. In this case, install the pin so that
its side hole will be the link tread side, too.
3) Using the shoe bolt hole pitch gauge, press
fit the master links until the distance between the shoe bolt holes of both links is the
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.
D275AX-5E0
17
SEN02346-00
7) Set both links and operate both pushing jigs

to press fit the pin and bushing simultaneously.
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.)
9) Install the ring to jig R8.
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, measure the distance between the shoe bolt
holes. When the distance is in the standard
range, stop press fitting.
11) Using jig R10, push in the ring.

Pushing force for ring:
245 304 kN {25 31 tons}
12) Assemble the master link on the pin side at

last.
a Check that the master links on both sides
are press fitted in parallel.
18
D275AX-5E0
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
3
3

Shoe bolt (Regular link)
Initial torque: 784 78 Nm {80 8 kgm}
SEN02346-00
2
3
3

Initial torque: 490 49 Nm {50 5 kgm}
a Tighten the bolts in the order of [1] [4].
2) When a 2-piece track is used, place the assembled 2 shoes on a level place in 1 line
with the shoe side up.
3) Pull pin-side master link (1) and bushingside master link (2) together and set them to
each other by the mating faces.
4) Place shoe (3) on the links and fits the mating faces of the links.
5) Check that shoe bolts (4) can be tightened
bolts.
D275AX-5E0
19
SEN02346-00
Dimensions table of fitting jig of link press
Unit: mm
Dimensions of jig
a
4.2
2.0
44.5
Precaution
1. The link receiving faces of jaw (5) must be vertical.
2. Replaceable wear plate (6) is desirable.
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 dimensions of the seal within the standard range.
20
D275AX-5E0
Disassembly of 1 link in the field

k
Only how to use the tools is explained below.

For details of Disassembly and assembly,
see "Whole disassembly (or assembly) of
track shoe".
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.
2. Assemble tools R12 and R13, then sling them

together and set them on the track.
SEN02346-00
4. Set tool R15 and apply oil pressure to pull out

pin (3).
a After the cylinder reaches the stroke end, install extension tool R15 between the adapter and guide, then repeat the work.
5. Set tool R16 and spacer [1] at the center of roller

tread side of the link to be disassembled and apply oil pressure to the puller to open the link by
(a) (5 6 mm) to disconnect it.
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).
D275AX-5E0
21
SEN02346-00
Assembly of 1 link in the field

1. Assembly of link sub-assembly
1) Set tool R17 to the link end and press fit
bushing (1).
137 274 kN {14 28 tons}
2) Set tool R17 to the link end (on the pin side)
and press fit pin (2).
a Set the pin with side hole (a) toward link
tread (b).
a Press fitting force for pin:
147 245 kN {15 25 tons}
3. Set link (4) on the opposite side and support it

with tool R18.
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.
147 245 kN {15 25 tons}
137 274 kN {14 28 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 connected.
22
D275AX-5E0
SEN02346-00
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.
D275AX-5E0
23
SEN02346-00
Disassembly of master link

a For the method of using tool R7, see Disassembly 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 bushing side with gas
Cut the parts marked
with gas and remove the parts marked
. Move master
links (5) and (6) in the direction of and
to pull them out. Then, push pins (8) and (9)
out of regular link (7) in the directions of
and with a press.
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 remove the parts marked
. Push pin (10)
out of link (11) in the direction of
with a
press. Then, pull pin (10) and link (12) together out of bushing (13).
Necessary special tools:
1. Gas cutting machine
2. Tool R7
24
D275AX-5E0
Assembly of master link

a For the method of using tool R7, see Disassembly of 1 link in the field.
1. Assembly of bushing-side link
1) Press fit bushing-side master link (1) to
bushing (2) with a press.
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
L2
D1
D2
184.15 0.7
234.95 0.7
Drill 30 in
diameter
27 x 2.0
2. Installation of bushing-side link

1) Expand the center of the link tread with tool
R7 as shown in the figure. (Expand the link
end by 10 mm.)
(a): 5 mm
SEN02346-00
2) Set spacer (3) and seal assembly (4) to the

counterbore of the link of the connecting
part.
3) Match the pin hole and bushing hole to each

other and connect the pin and bushing with
guide pin [1].
4) Press fit pin (5) with tool R7 and install bushing-side master link (1).
2
Apply gasket sealant (198-32-19890)

to the pin hole of the link.
a Set the pin with its side hole on the link tread
side.
D275AX-5E0
25
SEN02346-00
5) Using tools R7, R8, R9, and R10, install the

ring.
a For the procedure, see Assembly of link.
6) Install the shoe to the link of the connecting
part.
7) Drive large plug (6) with tool R3 and supply
oil with tool R5, then drive small plug (7) with
tool R4.
a When press fitting both master links,
take care that they will be in parallel with
each other (Bushing side and pin side).
a Do not damage the mating surfaces of
the master links and end faces of the
bushing.
a Take care that dirt and sand will not stick
to the seal, spacer, end of bushing, and
tap-hole mating face of the master link.
3. Assembly of pin-side link

1) Set spacer (3) and seal assembly (4) to the
counterbore of the master link.
2) Pass pin (10) through bushing (9) and set

and press fit pin-side master links (11) from
both sides with tool R7.
3) Using tools R7, R8, R9, and R10, install the
ring.
a For the procedure, see steps 9) - 12) in
Assembly of link.
4) Drive large plug (13) with tool R3 and supply
oil with tool R5, then drive small plug (14)
with tool R4.
4. Connection of master links

1) When a 2-piece track is used, place the assembled 2 shoes on a level place in 1 line
with the shoe side up.
2) Pull pin-side master link (15) and bushingside master link (16) together and set them
to each other by the mating faces.
3) Place the shoe on the links and fits the mating faces of the links.
4) Check that the shoe bolts can be tightened
bolts.
2
26
Shoe bolt:
disulfide (LM-P)
Initial torque:
490 49 Nm {50 5 kgm}
D275AX-5E0
SEN02346-00

pivot shaft assembly
Installation
Lifting tool
t 1
Installer
t 1
2 790-101-4200
Puller
(294kN {30ton})
t 1
790-101-1102
Hydraulic pump
t 1
1 790-401-1700
791-650-1700
P
[*1]
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools

a Using tool P2, press fit seal (2) to the pivot
shaft.
Press fitting face of seal:

a Check that press fitting distance (a) of the

seal from the shaft end is as follows.
Press fitting distance (a):
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).
D275AX-5E0
[*1]
27
SEN02346-00

equalizer bar assembly
4. Remove mounting nuts and cover (2).
Spacer
t 1 N Q
792-900-1520
Plate
t 1
791-520-4140
Screw
t 1
Adapter
t 1
Washer
t 1
791-112-1180
Nut
t 1
790-101-2102
Puller
(294kN {30ton})
t 1
790-101-1102
Hydraulic pump
t 1
791T-650-1930
790-101-2470
N 1 790-101-2540
Removal
1. Remove the engine undercover and power train
undercover.
4 Engine
4
5. Disconnect grease tube (3).
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
[*1]
undercover: 250 kg
7. Pull out side pin (5).

[*2]
the track frame hole, the pin cannot be
height of the equalizer bar side with hydraulic jack [2].
a Remove the pin on the opposite side by repeating steps 3 7.
2. Set stand [1] and hydraulic jack [2] under the radiator guard.
28
D275AX-5E0
8. Operate hydraulic jack [2] slowly to lower the

machine body until the equalizer bar touches
both track frames.
9. Disconnect lubrication tube (6).
SEN02346-00
13. Sling equalizer bar (8) and lower it, bypassing

both track frames.
k After remove the equalizer bar, do not
lower the machine body.
4
Equalizer bar: 275 kg
10. Remove lock plate (7).
Installation
11. Using tool N1, remove center pin (8).
[*3]
the main frame hole, the pin cannot be
height of the main frame side with the hydraulic jack.
[*1]
Installation procedure for cover (2)
1) Tighten the 5 mounting bolts of cover (4) lightly.
2) Install cover (2) and secure it with the 2 nuts.
3) Tighten the mounting bolts of cover (4) permanently.
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.
D275AX-5E0
29
SEN02346-00
[*2]
k

a Before installing the side pin, operate the hydraulic 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.
Left pin: Outside of machine body
Right pin: Inside of machine body
2
Equalizer bar side bushing:

Grease (G2-LI)
[*3]

a Before installing the center pin, sling the equalizer bar and align the equalizer bar hole with the
main frame hole.
2
30
Equalizer bar center bushing and main frame

bushing: Grease (G2-LI)
D275AX-5E0
SEN02346-00

Spacer N1
D275AX-5E0
31
SEN02346-00

equalizer bar bushing
3) Using tool N2, remove spherical bushing (5)

from equalizer bar (6).
a Remove the parts on the opposite similarly.
Remover
t 1
N 2 790-101-2102
Puller
(294kN {30ton})
t 1
790-101-1102
Hydraulic pump
t 1
791-650-1800
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
Disassembly
1. Center bushing
Remove center bushing (1).
Assembly
1. Side bushing
1) Set spherical bushing (5) and tool N2 and
press fit spherical bushing (5) to equalizer
bar (6).
2. Side bushing
1) Remove ring (2) and seal (3).
2) Remove ring (4).
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.
32
D275AX-5E0
SEN02346-00
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.
Seal lip: Grease (G2-LI)
2. Center bushing
Using the press, press fit center bushing (1).
D275AX-5E0
33
SEN02346-00
34
D275AX-5E0
SEN02347-00
BULLDOZER
1SHOP MANUAL
D275AX-5E0
Machine model
Serial number
D275AX-5E0
30001 and up

Hydraulic system
Removal and installation of HSS pump assembly .......................................................................................... 2
Removal and installation of work equipment and HSS charge pump assembly ............................................. 4
Removal and installation of power train and lubricating oil pump assembly ................................................... 6
Removal and installation of HSS motor assembly .......................................................................................... 8
Removal and installation of fan pump assembly............................................................................................. 9
Removal and installation of control valve assembly ......................................................................................11
Disassembly and assembly of work equipment control valve assembly....................................................... 15
Disassembly and assembly of hydraulic cylinder assembly ......................................................................... 16
D275AX-5E0
SEN02347-00
Removal and installation of HSS

pump assembly
1
5. Remove floor plate (6).

4
Floor plate: 35 kg
Removal
k

1. Remove the mounting bolts and open undercover (1).

4
6. Disconnect wiring connectors PUPA (7) and

PUPB (8).
7. Disconnect HSS pump hoses (9), (10), (11).

(9): Pump hose port PCD
(10): Pump hose port PC
(11): Drain hose port Pd1
3. Disconnect wiring connectors DCL (3) and BRK

(4).
4. Disconnect brake linkage (5) from the turnbuckle.
[*1]
a Before disconnecting the linkage, measure
its installed length.
D275AX-5E0
8. Disconnect hose clamps (12), (13), and (14).
SEN02347-00
12. Lift off HSS pump assembly (20).

a Install wires to the HSS pump assembly and
connect 2 nylon rings to them. Sling the nylon rings taken out of both sides of the operator's cab to lift off the HSS pump assembly
slowly.
4
HSS pump assembly: 110 kg
9. Disconnect drain hose ports Pd2 (17) and (18).

10. Disconnect 2 pump hose, (17) and (18).
(17): Pump hose (Port PB)
(18): Pump hose (Port PA)
Installation
[*1]
11. Remove 2 HSS pump mounting bolts (19).
D275AX-5E0
Bleeding air
Bleed air from the HSS pump. For details, see
Testing and adjusting, "Bleeding air from HSS
pump".
SEN02347-00
Removal and installation of work

equipment and HSS charge pump
assembly
1

4
Floor plate: 35 kg
Removal
k

4
Undercover: 320 kg
6. Disconnect the hose clamps and hose plates

(7), (8), (9), (10), (11), and (12).
7. Disconnect suction tube (13) and discharge

hose (14).
8. Remove the mounting bolts and charge pump
assembly (15).
9. Disconnect suction tubes (16) and (17).
(4).
10. Disconnect load pressure input hose (18).

[*1]
D275AX-5E0
SEN02347-00
11. Disconnect discharge hose (20) and drain hose

(21).
12. Remove the 2 mounting bolts and lift off work

equipment pump assembly (22).
4
Work equipment pump assembly: 75 kg
Installation
[*1]
D275AX-5E0
SEN02347-00
Removal and installation of power

train and lubricating oil pump
assembly
1
Removal
k


4
Undercover: 320 kg
a Plate (6) may be removed together 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

(9).
[*1]
4
Floor plate: 35 kg
3. Disconnect plate (4).

4. Remove the mounting bolts and operator's seat
sliding plate (5).
a Operator's seat sliding plate (5) may be removed together with plate (6).
4
4
Operator's seat sliding plate (5): 25 kg

Operator's seat sliding plate (5) and plate
(6): 40 kg
D275AX-5E0
10. Disconnect suction tube (12).
SEN02347-00
Installation
[*1]
11. Disconnect hose clamps (13) and (14).

12. Disconnect discharge hoses (15), (16).
13. Remove the 2 mounting bolts and lift off power

train and lubricating oil pump assembly (17).
4
Power train and lubricating oil pump assembly: 30 kg
D275AX-5E0
SEN02347-00
Removal and installation of HSS

motor assembly
1
Installation
Removal
k

1. Remove the fuel tank assembly. For details, see

"Removal of fuel tank assembly".
2. Disconnect wiring connectors ST1 (1) and ST2
(2).
(3): Drain hose (Port T1)
(4): Pilot hose (Port P)
(5): Charge filter hose (Port C)
(6): Cooler hose (Port CD)

motor assembly (9).
4
HSS motor assembly: 65 kg
D275AX-5E0
SEN02347-00

pump assembly
1
Removal
k


4
Undercover: 320 kg

a Plate (6) may be removed together with operator's seat sliding plate (5).
2. Remove mounting nuts (2) and operator's seat

assembly (3).
4

(9).
[*1]
4
Floor plate: 35 kg
3. Disconnect plate (4).

4. Remove the mounting bolts and operator's seat
sliding plate (5).
a Operator's seat sliding plate (5) may be removed together with plate (6).
4
4
Operator's seat sliding plate (5): 25 kg

Operator's seat sliding plate (5) and plate
(6): 40 kg
D275AX-5E0
SEN02347-00
10. Disconnect hose clamps (12), (13), and (14).
Installation
[*1]
Bleeding air
Bleed air from the fan pump. For details, see
Testing and adjusting, "Bleeding air from fan
pump".
11. Disconnect wiring connectors FAC (15).

12. Disconnect EPC valve main pressure hoses
(16) and (17).
13. Disconnect suction tube (18).
14. Disconnect discharge hose (19) and drain hose
(20).
15. Remove the 4 mounting bolts and fan pump assembly (21).
4
10
Fan pump assembly: 30 kg
D275AX-5E0

control valve assembly
SEN02347-00
4. Disconnect 3 PPC hose clamps and plate (5).
Removal
k

k Lower the work equipment to the ground and
release the residual pressure from the piping, referring to Testing and adjusting, Rel e a s i ng r e s i d ua l pr e s s u r e f r om w o r k
equipment cylinders. Then, set the lock lever in the LOCK position.
a Plug the disconnected pipes and hoses to prevent foreign matter from entering them.
a Put tags to the disconnected pipes to prevent a
mistake in re-connecting them.
1. Drain the oil from the hydraulic tank.
6
5. Disconnect hydraulic tank return hose (6).

6. Disconnect blade PPC hose (7) and ripper PPC
hose (8).
(7): Coupler (Color band: Blue)
(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).
D275AX-5E0
11
SEN02347-00
7. Disconnect PPC hoses (9) on the right side.

[*1]
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
(Dual tilt machine).
Ripper tilt BACK hose
(Color band: Brown) (Coupler) (Port PA5)
Ripper lift LOWER hose
(Color band: Black) (Coupler) (Port PA4)
LEFT tilt cylinder hose
(Color band: Yellow) (Port PA3)
Blade lift LOWER hose
(Color band: Not colored) (Port PA2)
RIGHT tilt cylinder hose
(Color band: Brown) (Coupler) (Port PA1)
9. Disconnect accumulator hose (PPC main pressure port) (11).
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 (Dual tilt machine).
Ripper tilt BACK hose
(Color band: White) (Coupler) (Port PB5)
Ripper RAISE hose
(Color band: Not colored) (Coupler) (Port
PB4)
LEFT tilt cylinder hose
(Color band: Green) (Port PB3)
Blade lift RAISE hose
(Color band: Black) (Coupler) (Port PB2)
RIGHT tilt cylinder hose
(Color band: White) (Port PB1)
12
D275AX-5E0
11. Disconnect the work equipment hoses.

a There are 10 work equipment hoses for the
dual tilt machine and 8 for the single tilt machine.
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)
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)
SEN02347-00
16. Remove the 4 mounting bolts. Using hanging

bolt [1], lift off control valve assembly (20).
4
Control valve assembly: 155 kg
Installation
[*1], [*2]
a Since the connecting positions of the PPC hoses are indicated by their band colors, check the
band colors when connecting those hoses.
PPC hose band colors (Dual tilt machine)
12. Disconnect work equipment pump hoses (Port

P1) (15) and (Port PC) (16).
13. Disconnect PPC main pressure hose (Port PR)
(17).
14. Disconnect drain hose (Port TS) (18).
15. Disconnect work equipment pump hose (Port
LS) (19).
D275AX-5E0
PPC hose band colors (Single tilt machine)
13
SEN02347-00

14
Bleeding air
Bleed air from the piping. For details, see Testing and adjusting, "Bleeding air from work
equipment cylinders".
D275AX-5E0

work equipment control valve
assembly
SEN02347-00
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 described below.
a For the tightening torque for each part, see
Structure and operation, Maintenance standard.
Assembly
damage. Coat their sliding surfaces with engine oil before installing.
a When assembling the suction valve, check
that the spring is installed in the sleeve normally.
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 periphery of the backup ring.
a After installing the main relief valve assembly, adjust it. For details, see Testing and
adjusting, "Testing and adjusting work
equipment oil pressure".
D275AX-5E0
15
SEN02347-00

hydraulic cylinder assembly
Disassembly
790-502-1003
Cylinder repair
stand
t 1
790-101-1102
Pump
t 1
790-102-2303
Wrench
790-102-3802
Wrench Blade lift
t 1
790-102-4300
t 1
790-102-4310
Wrench Ripper lift

Ripper tilt
Pin
790-201-1702
Push tool kit
t 1
790-101-5021
Grip
01010-50816
Bolt
4 790-201-1831
Blade lift
790-201-1841
Ripper tilt
Push tool kit
790-101-5021
Grip
01010-50816
5 790-201-1640
Bolt
Plate
790-201-1660
t 1
1
1
Blade lift
Blade tilt
Ripper lift
Ripper tilt
Expander
t 1
796-720-1670
Ring
t 1
07281-01279
Clamp
796-720-1690
Ring
6 790-720-1000
Push Blade tilt

tool Ripper lift
790-201-1500
Blade lift
3. Piston rod assembly

Blade lift cylinder
1) Set the cylinder assembly to tool U1.
2) Using a hydraulic pump or a power wrench
and tool U2, remove head assembly (8).
3) Pull piston rod assembly (9) out of cylinder
(10).
a Put an oil pan under the cylinder to receive the oil.
t 1
07281-01919
Blade tilt t 1
Clamp Ripper lift t 1
796-720-1680
Ring
07281-01589
Clamp
Ripper tilt
2. Quick drop valve

Perform this procedure for only the blade
lift cylinder.
1) Remove quick drop valve (1).
2) Disassemble the quick drop valve assembly
i) Remove block (2).
ii) Remove spring (3), spacer (4), valves
(5) and (6), and collar (7).
t 2
790-201-1851
790-201-1650
16
Other than
t 1
blade lift
Sketch
Part name
New/Remodel
Part No.
Q'ty
Sym
bol
Necessity
Special tools
1. Cylinder tube
Remove the cylinder tube.
t 1
t 1
D275AX-5E0
SEN02347-00
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.
Ripper lift and ripper tilt cylinders

1) Set piston rod assembly (12) to tool U1.
4. Piston assembly
Blade lift cylinder and blade tilt cylinder
1) Remove the mounting bolts and 2 spacers
(14).
2) Remove 4 valves (15).
3) Remove piston assembly (16) from piston
rod (17).
4) Remove retainer (18).
2) Remove lock screw (24) of piston assembly

(23).
Screw size: M12 x Pitch 1.75
5) Disassemble the piston assembly according

i) Remove wear rings (19).
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).
D275AX-5E0
17
SEN02347-00
a If screw (24) is crushed so much that it
cannot be removed, tighten it and cut
threads of the screw hole, then remove
it.
3) Using tool U3, remove piston assembly (23)

from piston rod (25).
4) Disassemble the piston assembly according

i) Remove backup ring and O-ring (26).
ii) Remove wear ring (27).
iii) Remove piston ring (28).
18
5. Head assembly
1) Remove head assembly (8) or (11) from piston rod (17) or (25).
2) Disassemble the head assembly according

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).
6. O-ring and backup ring

lift cylinder and blade tilt cylinder.
Remove O-ring and backup ring (35) from
piston rod (17).
D275AX-5E0
SEN02347-00
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
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 60C.
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
i) Using tool U4, press fit bushing (34).
ii) Install buffer ring (33) and packing (32).
iii) Using tool U5, install dust seal (31)
iv) Install snap ring (30).
v) Install O-ring and backup ring (29).
a When installing the backup ring,
warm it in water at 50 60C.
D275AX-5E0
3. Assembly of piston assembly

1) Set piston ring (28) to tool U6 and turn the
handle of the tool by 8 10 turns to expand
the piston ring.
2) Remove piston ring (28) from tool U6 and install it to the piston.
3) Using tool U7, shrink piston ring (28).
19
SEN02347-00
4) Install wear ring (27).

5) Install backup ring and O-ring (26).
a When installing the backup ring, warm it in
water at 50 60C.
ii) Install screw (24).

a Before installing the screw, degrease and
dry it well.
a After installing the screw, bend 4 places of
the periphery of the screw.
2
3
Threads:
Adhesive (LOCTITE No. 262)
Screw:
58.9 73.6 Nm {6 7.5 kgm}
4. Piston assembly
Ripper lift cylinder and ripper tilt cylinder
1) Install piston assembly (23) to piston rod
(25) and set them to tool U1.
3) When either or both of piston rod (25) and
piston assembly (23) are new, install them
i) Using tool U3, tighten piston assembly
(23).
3
2) When reusing piston rod (25) and piston assembly (23), install them according to the
a Remove burrs and fins from the threads with
a file.
a Clean the parts thoroughly and remove metal chips and dirt.
i) Using tool U3, tighten piston assembly
(23) in piston rod (25) until the screw
holes are matched.
20
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
threads horizontally.
Thread cutting dimensions (mm):
Tap drill diameter: 10.3
Tap drill depth: 27
Tap size: 12 x 1.75
Tapping depth: 20
iii) After making the screw hole, remove
chips and dirt and clean thoroughly.
D275AX-5E0
iv) Install screw (24).

a Before installing the screw, degrease and
dry it well.
a After installing the screw, bend 4 places of
the periphery of the screw.
2
Threads:
Adhesive
(LOCTITE No. 262 or equivalent)
Screw:
58.9 73.6 Nm {6 7.5 kgm}
SEN02347-00
5. Piston rod assembly

Blade tilt cylinder, ripper lift cylinder, and
ripper tilt cylinder
1) Insert piston rod assembly (12) in the cylinder (13).
H Push in the piston rod to the stroke end.
2
2) Tighten the mounting bolts of head assembly (11).

3
3
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).
a Clean and degrease the piston and threads
of the mounting bolts thoroughly.
a After tightening the mounting bolts, leave
them for about 30 minutes.
2
D275AX-5E0
Apply hardener (LOCTITE Primer T or

equivalent) to the piston and 6 mounting bolts, then apply adhesive (LOCTITE No. 262 or equivalent) to the
piston and 6 mounting bolts by 0.5
0.7 cc each.
Sealing part: Grease (G2-LI)
Mounting bolt (Ripper tilt):

250 24.5 Nm {25.5 2.5 kgm}
Mounting bolt
(Blade tilt, ripper lift):
343 34.3 Nm {35 3.5 kgm}
Blade lift cylinder

1) Set cylinder (10) to tool U1.
2) Install piston rod assembly (9) to cylinder
(10).
a Push in the piston rod to the stroke end.
2
Sealing part: Grease (G2-LI)
3) Using tool U2, tighten head assembly (8).

3
Head assembly:
1,010 2.9 Nm {103 0.3 kgm}
Mounting bolt:
98.1 122.6 Nm {10 12.5 kgm}
21
SEN02347-00
6. Quick drop valve

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).
22
D275AX-5E0
D275AX-5E0
SEN02347-00
23
SEN02347-00
24
D275AX-5E0
SEN02348-00
BULLDOZER
1SHOP MANUAL
D275AX-5E0
Machine model
Serial number
D275AX-5E0
30001 and up

Work equipment
Removal and installation of blade assembly ................................................................................................... 2
Disassembly and assembly of ripper assembly .............................................................................................. 4
D275AX-5E0
SEN02348-00
Removal and installation of blade

assembly
1
Removal
k
3. Using plate (3), fix the lift cylinder assembly to

the radiator guard.
a Bind the piston rod with wires so that it will
not come out.
Lower the work equipment to a level place

and set blocks [1] under both straight frames
securely.
1. Remove cap (1) from the lift cylinder.

[*1]
a Check the quantity and thickness of the inserted shims.
4. Similarly, disconnect the lift cylinder assembly

on the opposite side from the blade.
k After stopping the engine, release the residual pressure from the piping, referring to
Test and adjusting, Releasing residual pressure from hydraulic circuit.
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.
D275AX-5E0
8. Remove blade assembly (7).

[*3]
a Start the engine and move the machine in
reverse slowly to disconnect the blade assembly from the trunnion.
SEN02348-00
[*3]
a Adjust height (b) and width (c) of both straight
frames to the following values with block [1], etc.
Trunnion height (b): Approx. 860 mm
Frame width (c): Approx. 2,930 mm
Installation
[*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.
a After installing the blade, adjust its tilting distance, referring to Testing and adjusting, Adjusting blade.

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.
D275AX-5E0
SEN02348-00

ripper assembly
5. Set stand [2] between the arm and beam.
Disassembly
1. Remove right step (1).
6. Sling lift cylinder assembly (3) temporarily.

7. Remove the lock plate and pin (4).
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 assembly.
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.
4. Start the engine and raise the ripper assembly
fully, then lower and remove shank (2) gradually.
4
4
Shank (Multi-shank ripper):

350 kg (1 piece)
Shank (Giant ripper): 500 kg
a Remove the pins on the opposite side similarly.

10. Sling beam (7) temporarily and remove the lock
plate.
11. Using forcing screw [3], pull out both pins (8).
12. Lift off beam (7).
4
Beam: 1,750 kg
D275AX-5E0

k
SEN02348-00
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 opposite 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 opposite side similarly.
D275AX-5E0
SEN02348-00
Assembly
1. Set a stand under arm (13) and set arm (13) in
position.
6. Connect lift cylinder hose (10) and tilt cylinder

hose (9).
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 cylinder to (a) (50) at the all 4 places.
3. Set lift cylinder assembly (3) in position and install pin (12).
a After installing the lift cylinder assembly,
lower it onto the arm.
a Install the lift cylinder on the opposite side
similarly.
4. Set tilt cylinder assembly (5) in position.
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
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.
D275AX-5E0
7. Set beam (7) in position.

8. Install pins (8) to both sides and secure them
with the lock plates.
SEN02348-00
17. Pass a wire through the shank holder and raise

shank (2) slowly to align it with the pin hole.
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.
a Install the pin on the opposite side similarly.
20. Install right step cover (1).
12. Sling lift cylinder assembly (3) temporarily.

13. Start the engine and extend the piston rod to
align the pin holes.
a Install the pin on the opposite side similarly.
D
Bleeding air
a Bleed air from the work equipment cylinders. 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 fully.
D275AX-5E0
SEN02348-00
D275AX-5E0
SEN02349-00
BULLDOZER
1SHOP MANUAL
D275AX-5E0
Machine model
Serial number
D275AX-5E0
30001 and up

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 floor frame assembly ........................................................................................ 14
D275AX-5E0
SEN02349-00
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: 580 kg
Installation
[*1]
Mounting bolt:
1,180 1,470 Nm {120 150 kgm}
D275AX-5E0

operator's cab assembly
SEN02349-00
Removal
k
6. Remove step (8) and covers (9) and (10).

a Remove these parts from both sides.

1. Remove the ROPS guard. For details, see "Removal of rops guard".
2. Open operator's cab left cover (1).
7. Remove mounting bolts (11) under the operator's cab.

a Remove the bolts from both sides.
3. Disconnect intermediate wiring connectors (CN19) (2) and cab power supply connectors (CN20) (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.
D275AX-5E0
8. Remove mounting bolts (12) on the front side

and mounting bolts (13) inside the operator's
cab.
SEN02349-00
9. Remove cigarette lighter cover (14) and disconnect accessory socket wiring connector CN-D.
10. Remove garnishes (15), (16), and (17).
Installation
[*1]
a When connecting the windshield washer hoses,
match the colors of their bands.
11. Remove mounting bolts (18) inside the operator'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
D275AX-5E0
SEN02349-00
Removal and installation of operator's cab glass (Stuck glass)
Among the panes of window glass of the operator's cab, the 3 panes of (1) and (2) on both
sides are stuck. In this section, the procedure
for replacing the stuck glass is explained.
D275AX-5E0
(1): Front window glass

(2): Left door window glass
: Right door window glass
(3): Both-sided adhesive tape
(4): Trim seal
(5): Door handle
SEN02349-00
X 1 793-498-1210
Lifter
(Suction cup)
(The following figure shows the operator's cab

of a wheel loader.)
Sketch
Part name
New/Remodel
Part No.
Q'ty
Sym
bol
Necessity
Special tools
t 2
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 screwdriver.
a Widening the cut with a screwdriver, cut the
adhesive and both-sided adhesive tape
with knife [4].
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 frictional heat, apply lubricant to it.
2. Remove the window glass.
D275AX-5E0
Installation
1. Using a knife and scraper [5], remove the
remaining adhesive and both-sided adhesive
tape from the metal sheets (glass sticking surfaces) of the operator's cab.
a Remove the adhesive and both-sided adhesive tape to a degree that they will not affect
adhesion of the new adhesive. Take care
not to scratch the painted surfaces.
(If the painted surfaces are scratched,
adhesion will be lowered.)
of a wheel loader.)
SEN02349-00
3. Stick both-sided adhesive tape (3) along the

inside edges of the front window glass sticking
section and both door window glass sticking
sections.
a Do not remove the release tape of the bothsided adhesive tape on the glass sticking
side before sticking the glass.
a When sticking the both-sided adhesive
tape, do not touch the cleaned surface as
long as possible.
a Take care that the both-sided adhesive tape
will not float at each corner of the window
frame.
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 surfaces 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.
D275AX-5E0
SEN02349-00
4. Install trim seals (4) to both door window

glasses (2).
a Install each trim seal (4) so that its finishing

end and starting end will be jointed at position (c) and dimension (b) between the corner and position (c) will be 90 mm.
5. Position the new window glass.

1) Using tool X1, set the window glass to the
sticking position. Check the clearance
between the window glass and the operator'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 operator'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
window glass so that the positional relationship between it and door metal
sheet will be even all around the window.
2) After positioning the glasses, stick tapes [6]
between front window glass (1) and operator'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 window glasses and operator's cab before
installing the window glasses.
D275AX-5E0
SEN02349-00
1) Break aluminum seal (11) of the outlet of

adhesive cartridge (10) and install the nozzle.
6. Apply adhesive.
2
a
a
a
a
a
Adhesive: Sikaflex 256HV manufactured

by Sika Japan
Do not use primer.
The using limit of the adhesive is 6 months
after the date of manufacture. Do not use
the adhesive after this limit.
Keep the adhesive in a dark place where
the temperature is below 25C.
Never heat the adhesive higher than 30C.
When reusing the adhesive, remove the all
hardened part from the nozzle tip.
2) Cut the tip of the adhesive nozzle (12) so

that dimensions (f) and (g) will be as follows.
Dimension (f) : 10 mm
Dimension (g): 15 mm
3) Set adhesive cartridge (10) to caulking gun

[7].
a An electric caulking gun is more efficient.
D275AX-5E0
SEN02349-00
4) Remove release tape of the both-sided

adhesive tape (3a) on the glass side.

a Apply adhesive (13) to dimensions (h) and
(j) of both-sided adhesive tape (3) of operator's cab (7).
Dimension (h): 10 mm
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 bothsided 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
D275AX-5E0
SEN02349-00
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 caulking 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.
5) After applying caulking material (14) to front

window glass (1), form it with the fingers as
shown in the following figure.
a Use rubber spatula [9] to form the
caulking material around the handrail,
etc. where it is difficult to form with the
fingers.
D275AX-5E0
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
around it until it is stuck to the both-sided
adhesive tape.
a Press the corners of each window glass
firmly.
11
SEN02349-00
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].
3) Fill the clearance between each door window glass and trim in the range of dimension (k).
i) Mask the range of dimension (k) of
each door window glass.
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
12
9. Fix the window glasses.

1) Using styrene foam blocks [10] and rubber
bands [11], fix the front window glass to fit it
completely.
a You may use sealing tapes to fix the
front window glass.
(The figure shows the operator's cab of a
hydraulic excavator.)
Caulking material:
SEKISUI SILICONE SEALANT
D275AX-5E0
SEN02349-00
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 operator'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 20C and humidity
of 60%).
2) After applying the adhesive, wait for at least
24 hours, before operating the machine
actually.
D275AX-5E0
13
SEN02349-00
Removal and installation of floor

frame assembly
1
799-703-1200
Service tool kit
t 1
799-703-1100
Vacuum pump
(100 V)
t 1
799-703-1110
Vacuum pump
(220 V)
t 1
799-703-1120
Vacuum pump
(240 V)
t 1
799-703-1401
Sketch
Part name
New/Remodel
Part No.
Q'ty
Sym
bol
Necessity
Special tools
4. Remove left cover (8), armrest (9), and right

cover (10).
Removal
k
k

release the residual pressure from the piping, referring to Testing and adjusting, Rel e a s i ng r e s i d ua l pr e s s u r e f r om w o r k
equipment cylinders.
1. Remove the operator's cab. For details, see

"Removal of operator's cab".
2. Remove covers (1), (2), (3), and (4).
3. Disconnect intermediate wiring connectors 101

(5), E21 (6), and E22 (7).
14
D275AX-5E0
7. Disconnect wiring connectors DCI (13) and BRK

(14).
SEN02349-00
12. Lift off floor plate (17).

4
Flower plate: 35 kg

[*1]
13. Disconnect brake lever linkage (19).
9. Remove the mounting bolts of lower plate (16).

10. Remove the mounting bolts of floor plate (17).
11. Lift off operator's seat assembly (18).

a Remove the operator's seat assembly and
lower plate (16) together.
4
D275AX-5E0
15
SEN02349-00
14. Remove cover (20) and duct hose (21).

a Loosen the bracket of receiver tank.
19. Disconnect wiring connectors PPA (35) and

PDS-b (36).
15. Disconnect receiver tank hose (23) and air conditioner compressor hose (24).
[*2]
a Discharge the refrigerant (gas) from the air
conditioner curcuit before disconnecting the
air conditioner hoses.
16. Disconnect heater hoses (25) and (26).
a Close the heater hose valve on the engine
side.
a Plug the disconnected hoses.
20. Disconnect 5 blade PPC hoses (37), 5 ripper
PPC hoses (38), and accumulator hose (39).
[*3]
21. Disconnect floor front support ground wire (40)

on the right side of the machine body.
18. Disconnect intermediate wiring connectors

PWR (28), USB (29), PL4 (30), PL5 (31), PL1
(32), PL2 (33), and FE2 (34).
16
D275AX-5E0
22. Disconnect 2 front mount bolts (41).

23. Remove 5 rear mount bolts (42) from each side.
SEN02349-00
Installation
[*1]
and adjusting, "Adjusting brake pedal and parking lever".
24. Lift off floor frame (43).

4
Floor frame: 550 kg
[*2]
them.
a Before tightening each air conditioner hose connector, check that the O-ring is fitted to it.
a Apply compressor oil (Showa-Shell, Suniso 4G
or 5G) sufficiently to the O-rings.
Thread size :
Tightening torque
16-1.5
11.8 14.7Nm {1.2 1.5kgm}
22-1.5
19.6 24.5Nm {2 2.5kgm}
24-1.5
29.4 34.3Nm {3 3.5kgm}
[*3]
a Since the connecting positions of the PPC hoses are indicated by their clamp colors, check the
clamp colors when connecting those hoses.
Blade PPC hose clamp colors
(Dual tilt machine)
Green (44): Solenoid valve hose (Outside of
machine body)
Yellow (45): Solenoid valve hose (Inside of machine body)
Not colored (46): Work equipment control valve
hose (port PA2)
Black (47): Work equipment control valve hose
(port PB2)
Blue (48): Drain centralized block hose (Rear
side of machine body)
D275AX-5E0
17
SEN02349-00
Ripper PPC hose clamp colors

(Dual tilt machine)
Brown (49): Work equipment control valve hose
(port PA5)
(port PA4)
White (51): Work equipment control valve hose
(port PB5)
hose (port PB4)
Blue (53): Drain centralized block hose (Front
side of machine body)
Clamp colors between block and work equipment control valve (Dual tilt machine)
Yellow (54): Work equipment control valve hose
Green (56): Work equipment control valve hose
Ripper PPC hose clamp colors

(Single tilt machine)
hose
a Hose clamp colors seen from the right of the

machine body are shown.

a Hose clamp colors seen from the right of the

machine body are shown.
18
Blade PPC hose clamp colors

(Single tilt machine)
hose
Green (58): Work equipment control valve hose
Yellow (59): Work equipment control valve hose
D275AX-5E0
D275AX-5E0
SEN02349-00
19
SEN02349-00
20
D275AX-5E0
SEN02350-00
BULLDOZER
1SHOP MANUAL
D275AX-5E0
Machine model
Serial number
D275AX-5E0
30001 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 air conditioner unit assembly .............................................................................. 5
Removal and installation of monitor panel assembly ...................................................................................... 8
D275AX-5E0
SEN02350-00

transmission controller
assembly
Removal
k

1. Remove operator's seat rear cover (1).
2. Disconnect 3 wiring connectors TMCN1,

TMCN2, and TMCN3 of the transmission controller assembly.
3. Remove the mounting bolts and transmission
controller assembly (2).
[*1]
Installation
[*1]
Screw: 2.82 Nm {0.288 kgm}
D275AX-5E0

steering controller assembly
SEN02350-00
Removal
k

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 controller assembly (2).
[*1]
Installation
[*1]
Screw: 2.82 Nm {0.288 kgm}
D275AX-5E0
SEN02350-00

engine controller assembly
5. Remove the mounting bolts and engine controller assembly (6).
Removal
1. Remove the left lower side cover. For details,
see "Removal and installation of fuel supply
pump assembly".
2. Remove right engine oil filter (1).
Installation
[*1]
3. Remove controller box cover (2).
Screw: 2.82 Nm {0.288 kgm}
4. Disconnect wiring connectors EGC3 (3), EGC1

(4) and EGC2 (5).
[*1]
D275AX-5E0
SEN02350-00
Removal and installation of air

conditioner unit assembly
799-703-1200
Service tool kit
t 1
799-703-1100
Vacuum pump
t 1
799-703-1111
Vacuum pump
t 1
799-703-1121
Vacuum pump
t 1
799-703-1401
Sketch
Part name
New/Remodel
Part No.
Q'ty
Sym
bol
Necessity
Special tools
5. Disconnect wiring connectors (CN-213) (6),

(CN-214) (7), (CN-215) (8), (CN-216) (9), and
(CN-DL1) (10).
Removal
1. Remove the operator's cab assembly. For details, see Removal of operator's cab assembly.
2. Remove covers (1), (2), and (3).
3. Disconnect 2 air conditioner hoses (4).

[*1]
a Collect all refrigerant gas (R134a), then disconnect the hose.
a Disconnect the hoses from the air conditioner 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 Orings.
4. Disconnect 2 heater hoses (5).
a Close the heater valve on the engine side.
D275AX-5E0
SEN02350-00
7. Remove steps (13) and covers (14).
12. Disconnect bracket (22) and clamp (23).
8. Remove panel (15) and cover (16).
9. Remove ducts (17) and (18).
10. Remove monitor (19) and cover (20).
13. Disconnect relays (CN-R1) (24), (CN-R2) (25),

and (CN-R3) (26) in the right part of the dashboard and connector (CN-M26) (27).
14. Remove air conditioner unit (28).

15. Remove blower motor (29).
11. Remove inside filter (21).
D275AX-5E0
Installation
SEN02350-00


Add water through the water filler to the specified level. Run the engine to circulate the water
through the system. Then, check the water level
again.
[*1]
a Connect the hoses so carefully that they will not
be twisted.
a When installing the air conditioner circuit hoses,
take care that dirt, dust, or water will not enter
them.
a When connecting the air conditioner hoses,
check that the O-rings are fitted to their adapters.
Apply sufficient amount of compressor oil
(Showa-Shell Sniso 4G or 5G) to the O-rings.
Tightening torque for air conditioner refrigerant piping
Thread size
Tightening torque
16 x 1.5
12.23 1.47Nm {1.35 0.15kgm}
22 x 1.5
22.05 2.45Nm {2.25 0.25kgm}
24 x 1.5
31.85 2.45Nm {3.25 0.25kgm}
M6 bolt (for receiver) 5.39 1.47Nm {0.55 0.15kgm}

M6 bolt
(for compressor)
D275AX-5E0
9.8 1.96Nm {1.0 0.2kgm}
SEN02350-00

monitor panel assembly
Removal
k

1. Remove mounting bolts, then open monitor panel assembly (1).
2. Disconnect connectors (CN-1, CN-2, CN-3, CN4, CN-5, CN-S01, CN-S02) (2).
3. Remove monitor panel assembly.
Installation
D275AX-5E0
D275AX-5E0
SEN02350-00
SEN02350-00
10
D275AX-5E0
SEN00941-00
BULLDOZER
D275AX-5E0
Machine model
Serial number
D275AX-5E0
30001 and up
Hydraulic circuit diagram

Hydraulic circuit diagram................................................................................................................................. 3
Hydraulic circuit diagram...................................................................................................................... 3
Power train hydraulic circuit diagram ................................................................................................... 5
D275AX-5E0

D275AX-5E0

D275AX-5E0
1
1
SEN00941-00
Power train hydraulic circuit diagram
D275AX-5E0
SEN00941-00
Power train hydraulic circuit diagram

D275AX-5E0
SEN00941-00
D275AX-5E0
SEN00942-01
BULLDOZER
D275AX-5E0
Machine model
Serial number
D275AX-5E0
30001 and up

Electrical circuit diagram (1/12)....................................................................................................................... 3
Electrical circuit diagram (5/12)......................................................................................................................11
Electrical circuit diagram (6/12)..................................................................................................................... 13
Electrical circuit diagram (10/12)................................................................................................................... 21
Electrical circuit diagram (11/12) ................................................................................................................... 23
Electrical circuit diagram (12/12)................................................................................................................... 25
Electrical circuit diagram for inside cab ........................................................................................................ 27
Air conditioner unit electrical circuit diagram................................................................................................. 29
Connectors table and arrangement drawing................................................................................................. 31
D275AX-5E0
SEN00942-01
D275AX-5E0
Electrical circuit diagram (1/12)
D275AX-5E0

D275AX-5E0
SEN00942-01
D275AX-5E0

D275AX-5E0
SEN00942-01
D275AX-5E0

D275AX-5E0
SEN00942-01
D275AX-5E0

D275AX-5E0
SEN00942-01
D275AX-5E0

D275AX-5E0
SEN00942-01
11
D275AX-5E0

D275AX-5E0
SEN00942-01
13
D275AX-5E0

D275AX-5E0
SEN00942-01
15
D275AX-5E0

D275AX-5E0
SEN00942-01
17
D275AX-5E0

D275AX-5E0
SEN00942-01
19
D275AX-5E0

D275AX-5E0
SEN00942-01
21
D275AX-5E0

D275AX-5E0
SEN00942-01
23
D275AX-5E0

D275AX-5E0
SEN00942-01
25
Electrical circuit diagram for inside cab
D275AX-5E0
SEN00942-01
Electrical circuit diagram for inside cab

D275AX-5E0
27
Air conditioner unit electrical circuit diagram
D275AX-5E0
SEN00942-01
1
1
29
SEN00942-01
30
D275AX-5E0
Connectors table and arrangement drawing
D275AX-5E0
Connectors table and arrangement drawing

D275AX-5E0
Connector No.
Type of
connector
Number
of pin
DT
Terminal
3
4
Address
Connector No.
Type of
connector
Number
of pin
Intermediate connector
Q-3
PNL
24-31
31
Switch for emergency
AI-9
Q-1
POIL
FRAMATOME
Engine oil pressure sensor
AF-6
Address
Connector No.
Type of
connector
Number
of pin
H-9
DS4
DT-D
12
Rear speaker RH
H-9
DS5
DT-D
12
Terminal
Rear speaker RH
H-9
E22
DT
AF-6
PPL
DT
Pin puller solenoid
YAZAKI
Rear wiper motor
G-9
EG1
DTP
AH-8
PRE
DT
Pre-lubrication connector
AB-7
Terminal
Rear speaker LH
G-9
EG2
DT-B
12
AH-8
PRS
DT
Pre-lubrication connector
AB-8
Terminal
Rear speaker LH
G-9
EG4
DT-A
12
C-7
PRT
DT-A
12
Q-2
Location
Location
Location
Address
J-3
KES1
Front wiper motor
D-8
EGC1
DRC
60
Engine controller
AG-7
PT1
DT
Pitch angle sensor
A-8
10
Radio
H-9
EGC2
DRC
50
Engine controller
AH-7
PUPA
DT
HSS Pump solenoid RH
AJ-2
11
KES1
L.H Wiper switch
E-9
EGC3
DTP
Engine controller
AG-7
PUPB
DT
HSS Pump solenoid LH
AI-3
12
KES1
Front Wiper switch
E-9
EGR
DT
EGR valve
AC-5
PWR
DTHD
Main power
X-2
13
KES1
R.H Wiper switch
E-9
EHL
Relay
Engine hold relay
Z-7
RDG
DT-A
12
14
KES1
Rear Wiper switch
F-9
ESD
DT
Service connector(for engine option)
AA-7
RES
DT
Pull up resister
AF-9
15
Rear lamp switch
F-9
F1T
DT
Transmission 1st clutch ECMV (Fill switch)
AK-7
RHT
Terminal
Ribbon heater
AC-9
17
YAZAKI
Wiper motor for right door
E-8
F2T
DT
Transmission 2nd clutch ECMV (Fill switch)
AK-7
RPD
DT
Ripper down switch(SSC specification)
18
YAZAKI
Wiper motor for left door
I-9
F32
Terminal
Circuit breaker(30A)
K-1
RPNL
Resister
AK-9
19
DT
J-2
F3T
DT
Transmission 3rd clutch ECMV (Fill switch)
AJ-6
RPU
DT
Ripper up switch(SSC specification)
U-8
20
DTHD
ACC power supply
V-1
F96
Terminal
K-1
RSD
DT
DIODE
21
DTHD
Battery power supply
V-1
FAC
DT
Fan pump
AL-2
RTI
DT
Ripper tilt in switch(SSC specification)
T-8
B-7
T-8
22
Lighter power supply terminal
I-9
FAN1
Fan clean mode switch
Q-5
RWL
Rear work lamp switch
Q-4
23
Front lamp switch
F-9
FAN2
Fan reverse mode switch
Q-5
S01
AMP040
12
Machine monitor
R-7
25
DT
Rotary lamp
I-9
FAR
DT
Fan reverse solenoid
B-2
S02
Machine monitor
Q-6
26
Rotary lamp switch
F-9
FD1
24-31
31
Y-2
S03
AMP070
20
Machine monitor
R-7
81
KES1
Room lamp
E-9
FD5
DT
W-1
S04
AMP070
12
Machine monitor
R-6
217
DT
Caution buzzer
R-1
FFT
DT
Transmission F clutch ECMV (Fill switch)
AL-8
S1T
DT
Transmission 1st clutch ECMV (Solenoid)
AJ-6
241
DT-A
12
AI-6
FLB
DT
Brake ECMV LH (Fill switch)
AM-7
S24
Service switch
R-1
242
DT
Work lamp RH
C-7
FLV
DT
Fuel gauge
J-9
S2T
DT
Transmission 2nd clutch ECMV (Solenoid)
245
DT
I-9
FRB
DT
Brake ECMV RH (Fill switch)
AN-7
S3T
DT
Transmission 3rd clutch ECMV (Solenoid)
AJ-7
250
Terminal
Starting switch(Terminal B)
P-5
FRT
DT
Transmission R clutch ECMV (Fill switch)
AL-8
SBP
DT
AD-9
255
Terminal
Starting switch(Terminal R1)
P-4
FS11
Fuse box
AA-9
SDS
DT
260
Terminal
Starting switch(Terminal BR)
O-4
FS12
Fuse box
AA-9
SEGR
DT
AK-7
D-8
AD-9
AN-3
262
DT
Horn switch
S-7
FS21
Fuse box
AB-9
SFT
DT
Transmission F clutch ECMV (Solenoid)
263
DT
Pin puller switch
T-8
FS22
Fuse box
AB-9
SFTD
Shift down switch
Y-5
265
Terminal
Horn switch
S-7
FS31
Fuse box
AB-8
SFTU
Shift up switch
Y-5
266
Terminal
Horn switch
S-7
FS32
Fuse box
AB-8
SLB
DT
Brake ECMV LH (Solenoid)
270
Terminal
Starting switch(Terminal ACC)
O-5
FSB
24-31
31
U-1
SM1
SHINAGAWA
Connector for relay
280
Terminal
Starting switch(Terminal C)
O-5
FTU
Pivot turn switch
Q-5
SRB
DT
Brake ECMV RH (Solenoid)
AN-7
360
DT
Washer motor
L-2
FWL
Front work lamp switch
Q-4
SRT
DT
Transmission R clutch ECMV (Solenoid)
AJ-7
369
DT
Washer motor
L-2
Bkup sensor
AE-5
SRV
DT-A
12
Service connector
S-1
406
DT
HSS charge pressure sensor
D-8
GND1
Terminal
Ground(Floor)
452
DT
Hydraulic oil temperature sensor
AN-6
GND11
Terminal
Ground(Engine)
453
DT
Torque converter oil Temperature sensor
AL-2
GND2
Terminal
653
DT
Lock up solenoid
AI-6
GND3
Terminal
800
Terminal
Input terminal
W-1
GND5
801
Terminal
Input terminal
W-1
GND6
12S1
YAZAKI
12V Soket1
Y-7
12S2
YAZAKI
12V Soket2
Y-7
SUMITOMO
AM-8
-
Y-3
SSA
DT
Acceleration sensor(SSC specification)
AF-6
ST
DT
"Starting motor terminal R,S"
AG-1
A-8
Ground(Floor)
Y-3
ST/B
Terminal
Starting motor terminal B
AG-1
Ground
Y-3
ST1
DT
Sterring pressure sensor1
AM-8
Terminal
Ground(Fender)
J-9
ST2
DT
Sterring pressure sensor2
AM-8
Terminal
Ground(Floor)
ST8
DT
Sudden stop prevent valve
AM-8
GND7
Terminal
Ground(Dash board)
Q-3
STCN1
DRC26
24
steering controller
Y-5
H01
Plug
connector
U-9
STCN2
DRC26
40
steering controller
Y-7
STCN3
DRC26
40
steering controller
X-8
V-9
STF
Boot program
X-8
SW
Terminal
Battery relay(Coil signal terminal)
B-8
SX8
Terminal
Ground(Fender)
L-1
12V
DT
12V Power supply terminal
V-1
12VS
DT
12V Power supply
J-9
H02
Plug
connector
A/C1
DT
AH-8
HDT
DT
Diode
A/C2
DT
Air conditioner compressor
AF-6
HHP
DT
Work equipment hydraulic pressure sensor
C-8
ACT
Relay
ACC cut relay
Z-7
HRN
Terminal
Horn
C-2
T0F
DT
O-9
Heater switch
Q-4
HT
Terminal
Heater relay(Terminal C)
B-9
T0M
DT
O-9
B-7
HT/A
Terminal
Heater relay(Terminal A)
B-9
T1F
DT
P-7
DT
P-7
ADH
AF1
DT
Air cleaner crogged switch
AL/B
Terminal
Alternator terminal B
AH-1
HT/B
Terminal
Heater relay(Terminal B)
AG-9
T1M
AL/R
Terminal
Alternator terminal R
AH-2
J1939
DT
Service connector
AE-9
TFUEL
PACKARD
AF-9
AL1
DT
Front lamp LH
JM01
Junction wiring harness
TIM
PACKARD
Boost temperature sensor
AG-9
AL2
DT
Front lamp RH
JM02
TL1
24-23
23
U-1
AL3
DT
Front lamp L.R
JM03
TL2
DT-B
Steering/directional/gearshift lever
Y-4
AL4
DT
Front lamp R.R
JM04
TL3
DT
Y-4
AL5
DT
Rear lamp LH
JM05
TM1
DT
Bevel revolution sensor
AN-6
AL6
DT
Rear lamp RH
JM06
TMCN1
DRC26
24
Transmisson controller
W-8
Auto shift down switch
Q-5
JM07
TMCN2
DRC26
40
W-9
JM08
TMCN3
DRC26
40
V-9
Boot program
W-8
ASD
ASUS
DT
Service connector(for suspention seat)
X-8
B105HL
Terminal
J-1
KEY
DT
Starting switch
Q-6
TMF
B105HS
Terminal
J-2
KOM1
DRC26-40
40
KOMTRAX controller
Q-7
TMV
24-23
23
AL-8
B105S
Terminal
J-2
KOM2
KOMTRAX controller
Q-7
TWTR
PACKARD
Water temperature sensor
AF-1
B30S
Terminal
K-2
KOM3
KOMTRAX controller
Q-8
USB
DTHD
Unswitched power
W-1
B7L
Terminal
K-1
KOM4
GPS Antenna
WLV
DT
Coolant level sensor
A-4
B7S
Terminal
J-2
KOM5
Orbcomm Antenna
WNBL
YAZAKI
Pitch sellect switch
BKA
Relay
Back alarm relay
Z-8
LHD
DT
A-5
WNBU
YAZAKI
Dual tilt sellect switch
BKAL
DT
Back alarm
BP
DT
Bypass valve
J-9
LHDL
DT
Front lamp LH
B-6
AC-5
BRB
Terminal
LHDR
DT
Front lamp RH
A-6
Battery relay(Contact input terminal)
B-9
BRC
Terminal
LMFL
Relay
Front lamp relay(LH)
Z-8
Battery relay(Contact output terminal)
B-9
BRE
LMFR
Relay
Front lamp relay(RH)
Z-7
Terminal
Battery relay(Coil ground terminal)
C-8
LMW
Relay
Work lamp relay
Z-7
BRK
DT
Brake pedal
T-1
LREL
DT
Rear lamp LH
K-3
Q-6
LRER
DT
Rear lamp RH
G-9
LWKL
DT
BUZ
CA1
DT
CAN Terminal resistance
CAN
DT-A
12
P-9
M26
CB1
Z-9
MFR
CB2
Z-9
CB3
Z-9
CB4
Z-9
NSW
DT
Parking switch
CB5
Z-8
P03
DT
T-8
CB6
Z-8
PA
DT
Dual sellect solenoid
D-8
CN1
DT
Injector#1
AG-6
PAMB
FRAMATOME
Ambient pressure sensor
CN2
DT
Injector#2
AF-5
PB
DT
Pitch sellect solenoid
CN3
DT
Injector#3
AF-5
PCV1
SUMITOMO
Supply pump#1
AE-5
CN4
DT
Injector#4
AE-5
PCV2
SUMITOMO
Supply pump#2
AE-6
CN5
DT
Injector#5
AE-5
PEVA
FRAMATOME
AC-9
CN6
DT
Injector#6
AD-4
PFUEL
AMP
AF-6
CONV
DT
Converter(DC24V-12V)
V-1
PHR
Relay
Pre-heater relay
AA-7
CT1
DT
CAN Terminal resistance
Q-6
PIM
CANNON
Boost pressure sensor
AG-9
Cursor switch
Q-5
Y-3
CUR
Work lamp LH
G-1
Air conditioner controller
Q-1
DT
Motor free solenoid
AM-3
NE
FRAMATOME
Ne sensor
AH-7
NSF
Relay
Neutral saft relay
Z-7
AA-7
AG-6
D-8
PL1
24-23
23
DCL
DT
Decel pedal
T-1
PL1F
24-23
23
Switch harness for emergency
AK-8
DIAL
Fuel dial
Y-4
PL1M
24-23
23
AK-8
DPNL
Diode
AJ-8
PL2
24-31
31
DS1
DT-B
12
Q-3
PL2
24-31
31
DS2
DT-C
12
Q-2
PL4
DT-B
12
Y-2
DS3
DT-A
12
Q-2
PL5
DT-A
12
X-2
Y-2
AK-8
SEN00942-01
D275AX-5E0
31
D275AX-5E0
SEN00942-01
33
SEN00942-01
34
D275AX-5E0

275ax 5eo

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275ax 5eo

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SEN00919-02

D275AX-5E0 30001 and up

Copyright 2007 Komatsu

00 Index and foreword

00 Index and foreword

Composition of shop manual

Shop Manual, contents binder, binder label and tabs

00 Index and foreword

10 Structure, function and maintenance standard

20 Standard value table

30 Testing and adjusting

00 Index and foreword

Troubleshooting by failure and error codes, Part 4

50 Disassembly and assembly

90 Diagrams and drawings

00 Index and foreword

00 Index and foreword

00 Index and foreword

00 Index and foreword

00 Index and foreword

Testing control circuit main pressure........................................................................................... 32

00 Index and foreword

Failure code [AB00MA] Battery charge abnormal ....................................................................... 34

00 Index and foreword

Troubleshooting by failure and error codes, Part 3

00 Index and foreword

00 Index and foreword

Failure code [DK57KB] F-R potentiometer (2) short circuit......................................................... 52

00 Index and foreword

Troubleshooting of electrical system (E-mode)

00 Index and foreword

00 Index and foreword

Power train, Part 2

00 Index and foreword

Electrical diagrams and drawings

00 Index and foreword

00 Index and foreword

Foreword and general information

00 Index and foreword

Important safety notice

If welding repairs are needed, always

Prohibition of operation and handling by

6 Safety check before starting work

Wearing protective goggles

Wearing shielding goggles and protectors

9 Good physical condition and preparation

Precautions against work which you are

Preparations for work

00 Index and foreword

When disassembling or assembling, support the machine with blocks, jacks, or

Precautions during work

When removing piping, stop the fuel or oil

Precautions for sling work and making

00 Index and foreword

When installing wire ropes to an angular

11) Do not use twisted or kinked wire ropes.

00 Index and foreword

If the load is unstable or the wire rope

Precautions for using mobile crane

Selecting wire ropes

The allowable load is one-sixth of the

Collect the air conditioner refrigerant

Example of O-ring (Fitted to every joint of