Komatsu D575-A3 Super Dozer Shop Manual Seb D 022001

SEBM022001
MACHINE MODEL SERIAL NUMBER
D575A-3 SUPER DOZER 10101 and up
• This shop manual may contain attachiments and optional equipment that are not available in your
area. Please consult your local Komatsu distributor for those items you may require.
Materials and specifications are subject to change without notice.
• D575A-3 Super Dozer mount the SA12V170E-2 engine.

For details of the engine, see the 12V170-2 Series Engine Shop Manual.
© 2001
All Rights Reserved
Printed in Japan 04-01(02) 00-1
➀
CONTENTS
No. of page
01 GENERAL ........................................................................................................................... 01-1
10 STRUCTURE AND FUNCTION,

MAINTENANCE STANDARD ...................................................... 10-1
20 TESTING AND ADJUSTING ............................................................................... 20-1
30 DISASSEMBLY AND ASSEMBLY................................................................ 30-1
90 OTHERS ............................................................................................................................... 90-1
00-2 D575A-3 SD
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The affected pages are indicated by the use of the
Mark Indication Action required
following marks. It is requested that necessary
actions be taken to these pages according to the ! Page to be newly added Add
table below.
" Page to be replaced Replace
( ) Page to be deleted Discard
Pages having no marks are those previously revised

or made aditions.
LIST OF REVISED PAGES

Revision Revision Revision Revision Revision
Mark Page Mark Page Mark Page Mark Page Mark Page
number number number number number
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00-2-2 D575A-3 SD
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D575A-3 SD 00-2-3
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00-2-4 D575A-3 SD
➀
SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The
service and repair techniques recommended by Komatsu and described in this manual
are both effective and safe. Some of these techniques require the use of tools specially
designed by Komatsu for the specific purpose.
To prevent injury to workers, the symbol ¤ is used to mark safety precautions in this
manual. The cautions accompanying these symbols should always be followed care-
fully. If any dangerous situation arises or may possibly arise, first consider safety, and
take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to

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

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

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

This section explains the procedures for removing, installing, disassembling and assembling
each component, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any
time and without any advance notice. Use the specifications given in the book
with the latest date.
00-5
F O R EW OR D HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL

VOLUMES REVISED EDITION MARK
Shop manuals are issued as a guide to carrying When a manual is revised, an edition mark
out repairs. They are divided as follows: (123....) is recorded on the bottom of the
Chassis volume: Issued for every machine model pages.
Engine volume: Issued for each engine series
Electrical volume:
Attachments volume: } Each issued as one
volume to cover all
models
REVISIONS
Revised pages are shown in the LIST OF RE-
These various volumes are designed to avoid VISED PAGES next to the CONTENTS page.
duplicating the same information. Therefore, to
deal with all repairs for any model , it is neces-
sary that chassis, engine, electrical and attach-
SYMBOLS
ment volumes be available.
So that the shop manual can be of ample prac-
DISTRIBUTION AND UPDATING tical use, important safety and quality portions
are marked with the following symbols.
Any additions, amendments or other changes
will be sent to KOMATSU distributors. Get the
most up-to-date information before you start any
work.
FILING METHOD
1. See the page number on the bottom of the Symbol Item Remarks
page. File the pages in correct order.
2. Following examples show how to read the Special safety precautions are
page number. ¤ Safety necessary when performing
the work.
Example 1 (Chassis volume):
Special technical precautions
10 - 3
or other precautions for pre-
Item number (10. Structure

fl Caution serving standards are neces-
sary when performing the
and Function) work.
Consecutive page number for
Weight of parts of systems.
each item. Caution necessary when se-
Example 2 (Engine volume):

4 Weight lecting hoisting wire, or when
working posture is important,
etc.
12 - 5
Tightening Places that require special at-
Unit number (1. Engine) 3 tention for the tightening
torque torque during assembly.
Item number (2. Testing and
Adjusting) Places to be coated with ad-
Consecutive page number for 2 Coat
hesives and lubricants, etc.
each item.
Places where oil, water or fuel
5 Oil, water must be added, and the ca-
3. Additional pages: Additional pages are indi- pacity.
cated by a hyphen (-) and number after the
Places where oil or water
page number. File as in the example. 6 Drain must be drained, and quan-
Example: tity to be drained.
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
F O R EW OR D HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Slinging near the edge of the hook may
 Heavy parts (25 kg or more) must be cause the rope to slip off the hook during
lifted with a hoist, etc. In the DISAS- hoisting, and a serious accident can re-
SEMBLY AND ASSEMBLY section, sult. Hooks have maximum strength at
every part weighing 25 kg or more is the middle portion.
indicated clearly with the symbol 4
• If a part cannot be smoothly removed from

the machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening 100% 88% 79% 71% 41%
the part to the relative parts. SAD00479
2) Check for existence of another part caus- 3) Do not sling a heavy load with one rope
ing interference with the part to be re- alone, but sling with two or more ropes
moved. symmetrically wound onto the load.
¤ Slinging with one rope may cause
turning of the load during hoisting,
WIRE ROPES untwisting of the rope, or slipping of
the rope from its original winding
1) Use adequate ropes depending on the
position on the load, which can re-
weight of parts to be hoisted, referring to
sult in a dangerous accident.
the table below:
Wire ropes 4) Do not sling a heavy load with ropes form-
(Standard "Z" or "S" twist ropes ing a wide hanging angle from the hook.
without galvanizing) When hoisting a load with two or more
ropes, the force subjected to each rope
Rope diameter Allowable load will increase with the hanging angles. The
table below shows the variation of allow-
mm kN tons
able load kN {kg} when hoisting is made
10 9.8 1.0 with two ropes, each of which is allowed
11.2 13.7 1.4 to sling up to 9.8 kN {1000 kg} vertically,
at various hanging angles.
12.5 15.7 1.6
When two ropes sling a load vertically, up
14 21.6 2.2 to 19.6 kN {2000 kg} of total weight can be
16 27.5 2.8 suspended. This weight becomes 9.8 kN
18 35.3 3.6 {1000 kg} when two ropes make a 120°
20 43.1 4.4 hanging angle. On the other hand, two
ropes are subjected to an excessive force
22.4 54.9 5.6
as large as 39.2 kN {4000 kg} if they sling
30 98.1 10.0
a 19.6 kN {2000 kg} load at a lifting angle
40 176.5 18.0 of 150°.
50 274.6 28.0 °
60 392.2 40.0
fl The allowable load value is estimated to

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

of the hook.
00-7
F O R EW OR D METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

fl There are 2 types of push-pull type coupler. The method of disassembling and connecting is differ-
ent, so see the table below when disassembling and connecting the coupler.
Type 1 Type 2
1) Hold the mouthpiece of the tightening por- 1) Hold the mouthpiece of the tightening por-
tion and push body (2) in straight until slid- tion and push body (2) in straight until slid-
ing prevention ring (1) contacts contact sur- ing prevention ring (1) contacts contact sur-
face a of the hexagonal portion at the male face a of the hexagonal portion at the male
end. end.
2) Hold in the condition in Step 1), and push 2) Hold in the condition in Step 1), and turn
until cover (3) contacts contact surface a of lever (4) to the right (clockwise).
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
00-8
F O R EW OR D METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 1 Type 2
• Hold the mouthpiece of the tightening por- • Hold the mouthpiece of the tightening por-
tion and push body (2) in straight until slid- tion and push body (2) in straight until slid-
ing prevention ring (1) contacts contact sur- ing prevention ring (1) contacts contact sur-
face a of the hexagonal portion at the male face a of the hexagonal portion at the male
end to connect it. end to connect it.
Connection
00-9
F O R EW OR D COATING MATERIALS
COATING MATERIALS
¡ The recommended coating materials such as adhesives, gasket sealants and greases used for
disassembly and assembly are listed below.
¡ For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q'ty Container Main applications, features
• Used to prevent rubber gaskets, rubber

LT–1A 790–129–9030 150 g Tube cushions, and cock plug from coming out.
• Used in places requiring an immediately
effective, strong adhesive. Used for plas-
790–129–9050 20 g Polyethylene
LT–1B tics (except polyethylene, polyprophylene,
(2 pes.) container
tetrafluoroethlene and vinyl chloride), rub-
ber, metal and non-metal.
• Features: Resistance to heat and chemi-

Polyethylene cals
LT–2 09940–00030 50 g
container • Used for anti-loosening and sealant pur-
pose for bolts and plugs.
790–129–9060 Adhesive: • Used as adhesive or sealant for metal, glass

(Set of adhe- 1 kg and plastic.
LT–3 sive and Hardening Can
hardening agent:
agent) 500 g
Adhesives
Polyethylene • Used as sealant for machined holes.
LT–4 790–129–9040 250 g
container
Holtz • Used as heat-resisting sealant for repair-
790–126–9120 75 g Tube
MH 705 ing engine.
• Quick hardening type adhesive

Three bond Polyethylene • Cure time: within 5 sec. to 3 min.
790–129–9140 50 g
1735 container • Used mainly for adhesion of metals, rub-
bers, plastics and woods.
• Quick hardening type adhesive

• Quick cure type (max. strength after 30 min-
Aron-alpha Polyethylene
790–129–9130 2g utes)
201 container
• Used mainly for adhesion of rubbers, plas-
tics and metals.
• Features: Resistance to heat, chemicals

Loctite Polyethylene • Used at joint portions subject to high tem-
648-50 79A–129–9110 50 cc
container peratures.
• Used as adhesive or sealant for gaskets

LG-1 790–129–9010 200 g Tube
and packing of power train case, etc.
• Used as sealant for various threads, pipe

Polyethylene joints, flanges.
LG-5 790–129–9080 1 kg
container • Used as sealant for tapered plugs, elbows,
Gasket nipples of hydraulic piping.
sealant
• Features: Silicon based, resistance to heat,
cold
LG-6 790–129-9020 200 g Tube • Used as sealant for flange surface, tread.
• Used as sealant for oil pan, final drive case,
etc.
00-10
F O R EW OR D COATING MATERIALS
Category Komatsu code Part No. Q'ty Container Main applications, features
• Features: Silicon based, quick hardening

type
LG-7 790-129-9070 1 kg Tube • Used as sealant for flywheel housing, in-
Gasket take manifold, oil an, thermostat housing,
sealant etc.
Three bond • Used as heat-resisting sealant for repairing

790–129–9090 100 g Tube engine.
1211
• Used as lubricant for sliding portion (to pre-

Molybde- LM-G 09940-00051 60 g Can vent from squeaking).
num
disulphide • Used to prevent seizure or scuffling of the
lubricant LM-P 09940-00040 200 g Tube thread when press fitting or shrink fitting.
• Used as lubricant for linkage, bearings, etc.
SYG2-400LI • General purpose type

SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
• Used for normal temperature, light load

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

disulphide SYG2-400M (10 per Belows type
lubricant case)
00-11
F O R EW OR D STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)

fl In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque
given in the table below.
Thread diameter Width

of bolt across flats
mm mm Nm kgm
6 10 13.2 ± 1.4 1.35 ± 0.15
8 13 31 ± 3 3.2 ± 0.3
10 17 66 ± 7 6.7 ± 0.7
12 19 113 ± 10 11.5 ± 1
14 22 177 ± 19 18 ± 2
16 24 279 ± 30 28.5 ± 3
18 27 382 ± 39 39 ± 4
20 30 549 ± 59 56 ± 6
22 32 745 ± 83 76 ± 8.5
24 36 927 ± 103 94.5 ± 10.5
27 41 1320 ± 140 135 ± 15
30 46 1720 ± 190 175 ± 20
33 50 2210 ± 240 225 ± 25
36 55 2750 ± 290 280 ± 30
39 60 3290 ± 340 335 ± 35
Thread diameter Width

of bolt across flats
mm mm Nm kgm
6 10 7.85 ± 1.95 0.8 ± 0.2
8 13 18.6 ± 4.9 1.9 ± 0.5
10 14 40.2 ± 5.9 4.1 ± 0.6
12 27 82.35 ± 7.85 8.4 ± 0.8
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

fl In the case of flared nuts for which there is no special
instruction, tighten to the torque given in the table below.
SAD00483
Thread diameter Width across flat Tightening torque

mm mm Nm kgm
14 19 24.5 ± 4.9 2.5 ± 0.5
18 24 49 ± 19.6 5±2
22 27 78.5 ± 19.6 8±2
24 32 137.3 ± 29.4 14 ± 3
30 36 176.5 ± 29.4 18 ± 3
33 41 196.1 ± 49 20 ± 5
36 46 245.2 ± 49 25 ± 5
42 55 294.2 ± 49 30 ± 5
00-12
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

fl In the case of split flange bolts for which there is no special instruction, tighten to the torque
given in the table below.

mm mm Nm kgm
10 14 65.7 ± 6.8 6.7 ± 0.7
12 17 112 ± 9.8 11.5 ± 1
16 22 279 ± 29 28.5 ± 3
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

fl Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.

Nominal No.
mm mm Nm kgm
02 14 34.3 ± 4.9 3.5 ± 0.5
03, 04 20 Varies depending on 93.1 ± 9.8 9.5 ± 1
05, 06 24 type of connector. 142.1 ± 19.6 14.5 ± 2
10, 12 33 421.4 ± 58.8 43 ± 6
14 42 877.1 ± 132.3 89.5 ± 13.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

fl Unless there are special instructions, tighten the O-ring boss plugs to the torque below.

Nominal No.
mm mm Nm kgm
08 8 14 7.35 ± 1.47 0.75 ± 0.15
10 10 17 11.27 ± 1.47 1.15 ± 0.15
12 12 19 17.64 ± 1.96 1.8 ± 0.2
14 14 22 22.54 ± 1.96 2.3 ± 0.2
16 16 24 29.4 ± 4.9 3 ± 0.5
18 18 27 39.2 ± 4.9 4 ± 0.5
20 20 30 49 ± 4.9 5 ± 0.5
24 24 32 68.6 ± 9.8 7± 1
30 30 32 107.8 ± 14.7 11 ± 1.5
33 33 — 127.4 ± 19.6 13 ± 2
36 36 36 151.9 ± 24.5 15.5 ± 2.5
42 42 — 210.7 ± 29.4 21.5 ± 3
52 52 — 323.4 ± 44.1 33 ± 4.5
00-13
TIGHTENING TORQUE FOR 102 ENGINE SERIIES (BOLT AND NUTS)

Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque

mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
TIGHTENING TORQUE FOR 102 ENGINE SERIIES (EYE JOINTS)

Use these torques for eye joints (unit: mm) of Cummins Engine.

mm Nm kgm
6 8 ± 2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
TIGHTENING TORQUE FOR 102 ENGINE SERIIES (TAPERED SCREWS)

Use these torques for tapered screws (unit: inch) of Cummins Engine.

inch Nm kgm
1 / 16 3 ± 1 0.31 ± 0.10
1/8 8 ± 2 0.81 ± 0.20
1/4 12 ± 2 1.22 ± 0.20
3/8 15 ± 2 1.53 ± 0.41
1/2 24 ± 4 2.45 ± 0.41
3/4 36 ± 5 3.67 ± 0.51
1 60 ± 9 6.12 ± 0.92
00-14
F O R EW OR D ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Nominal Cable O.D. Current rating
number Number of Dia. of strands Cross section (mm) (A) Applicable circuit
strands (mm) (mm2)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE
Circuits
Prior- Charging Ground Starting Lighting Instrument Signal Other
ity Classi-
fication
Pri- Code W B B R Y G L
1 mary
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2
Color White & Red — Black & White Red & White Yellow & Red Green & White Blue & White
Code WB — BY RB YB GR LR
3
Color White & Black — Black & Yellow Red & Black Yellow & Black Green & Red Blue & Red
Auxi- Code WL — BR RY YG GY LY
4 liary
Color White & Blue — Black & Red Red & Yellow Yellow & Green Green & Yellow Blue & Yellow
Code WG — — RG YL GB LB
5
Color White & Green — — Red & Green Yellow & Blue Green & Black Blue & Black
Code — — — RL YW GL —
6
Color — — — Red & Blue Yellow & White Green & Blue —
00-15
F O R EW OR D CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For
details of the method of using the Conversion Table, see the example given below.
EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as A, then draw a horizontal
line from A.
(2) Locate the number 5 in the row across the top, take this as B, then draw a perpendicular line
down from B.
(3) Take the point where the two lines cross as C. This point C gives the value when converting
from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
B
Millimeters to inches
..........................................
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

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

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

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

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

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

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

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

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

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

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

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

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

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

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

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

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-21
F O R EW OR D UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kw/rpm {HP/rpm}
g/kwh {g/HPh}
00-22
01 GENERAL
Specification drawing .......................................... 01-2

Specifications ...................................................... 01-4
Weight table ........................................................ 01-8
Table of fuel, coolant and lubricants .................. 01-10
D575A-3 SD 01-1
GENERAL SPECIFICATION DRAWING
SPECIFICATION DRAWING
Unit: mm
01-2 D575A-3 SD
GENERAL SPECIFICATIONS
SPECIFICATIONS
Machine model D575A-3 Super dozer
Serial Number 10101 and up
Operating weight 114,580

Weight
• bare tractor
kg
• with super blade (HD type) +
155,000
counterweight + ROPS cab
Minimum turning radius m 6.3
Gradeability deg 30
Stability (Front, rear, left, right) deg 35
Forward 1st 3.7 [3.4]
Forward 2nd Km/h 6.8 [6.3]

Performance
Speed ranges
Forward 3rd 12.0 [ — ]
Reverse 1st 0 – 4.5 [4.0]
Reverse 2nd Km/h 0 – 8.0 [7.4]
Reverse 3rd 0 – 13.8 [ — ]
Bare tractor 118.7 {1.21}

pressure
Ground
2
KPa {kg/cm }
With super blade + counter- 158.9 (1.62)
weight + ROPS cab
Bare tractor 7,695

Overall
length
mm
With super blade + counter-
weight 11,724
Overall
Bare tractor 4,180

width
mm
With super blade 7,400
Dimensions
Overall height
To top of ROPS 4,880
To top of exhaust pipe mm 4,495
Except exhaust pipe 3,980
Track gauge 3,220
Length of track on ground 5,485

mm
Track shoe width 860
Minimum ground clearance 745
¡ Tha figures in [ ] indicate at torque converter Lock-up.
01-4 D575A-3 SD
Name SA12V170E-2
4-cycle, water-cooled, V-type, direct injection,

Type of engine
with turbocharger and aftercooler
No. of cylinders – Bore × Stroke mm 12 – 170 × 170
Piston displacement l {cc} 46,3 {46,300}
Flywheel horsepower kW {HP}/rpm 858 {1,150} /1,800

Performance
Max. torque Nm {kgm}/rpm 5,658 {577} /1,300

Engine
Max. speed at no load rpm 2,000 ± 50
Min. speed at no load rpm 650 ± 50
Min. fuel consumption ratio g/kWh {g/HPh} 216 {160}
Starting motor 24V, 11 kW × 2
Alternator 24V, 75A
Battery 12V, 200Ah × 4
Radiator core type D type
Power train pump Gear type: SAL(4) – 140 + 125
Power train lubrication pump Gear type: SAR(4) – 250
Final drive lubrication pump Gear type: Left and right (1 each)
Power train system
Torque converter 3-element, 1-stage, single phase
Planetary gear, multiple disc clutch, hydraulically actuated,

Transmission
force-feed lubrication pump, forward 3-speed, reverse 3-speed
Bevel gear Spiral bevel gear, force-feed lubrication pump
Wet type, multiple clutch disc, spring boosted, hydraulically

Steering clutch
actuated (manual type), interconnected with brake
Wet type, multiple clutch disc, spring boosted, hydraulically

Steering brake
actuated (pedal operated, manual type), interconnected with clutch
Spur gear 2-stage, planetary gear 1-stage reduction,

Final drive
force-feed lubrication pump
D575A-3 SD 01-5
Suspension Soft, equalizing type

Undercarriage
Carrier roller 2 each side

Track roller 8 each side
Assembly type, single grouser, 49 each side
Track shoe
Pitch: 317.5 mm, width: 860 mm
Max. pressure MPa {kg/cm2} 20.6 {210}
Gear type: SAL(4) – 200 + 200

Hydraulic pump
Max. delivery: 1,258 l/1,800 rpm
Pitch assist + pilot pump Gear type: SAR(4) – 125 + 125 + (1) – 32
Control
Work equipment hydraulic system
valve
Type 2-spool type

Control method Hydraulic assist
Type Reciprocal, piston type

blade lift cylinder
Cylinder bore mm 225

Dimensions of
Piston rod outer diameter mm 120

Hydraulic cylinder
Max. piston stroke mm 1,458

Max. distance between pins mm 2,775
Min. distance between pins mm 1,310
blade pitch cylinder
Cylinder bore mm 300

Dimensions of
Piston rod outer diameter mm 180

Max. piston stroke mm 906
Max. distance between pins mm 2,872
Min. distance between pins mm 1,966
Hydraulic tank Box shape, sealed type (with intake, exhaust valve)
Type Hydraulic super dozer

Blade support method Center link type
Blade capacity m3 60.4

Work equipment
Performance
Blade lifting height

(from ground) mm 1,740
Blade lowering depth
(from ground) mm 800
Blade tilt mm 1,000

Dimensions
Blade width mm 7,400

Blade height mm 3,246
Blade cutting angle deg 55
01-6 D575A-3 SD
GENERAL WEIGHT TABLE
WEIGHT TABLE
b This weight table is a guide for use when transporting or handling components.
Unit: kg
Engine, damper assembly 7,355
• Engine damper assembly (included mount parts) 7,140
• Damper assembly 215
Radiator assembly 887
Power train cooler (each) 200
Hydraulic cooler (each) 30
Fuel tank assembly (when full) 821 (2,570)
Power train unit 7,400
• Torque converter, PTO assembly 1,108
• Transmission assembly 2,100
• Transmission valve assembly 82
• Steering clutch, brake assembly 3,240
• Steering valve assembly 44
Final drive assembly (each side) 6,000
Main frame assembly 16,900
Track group assembly (each side) 16,172
• Track frame (incl. bogie) (each side) 9,410
• Recoil spring assembly (each side) 2,690
• Idler assembly (each side) 1,326
• Track roller assembly (single flange x1) 298
• Track roller assembly (double flange x1) 323
• Carrier roller assembly (each) 131
Track shoe assembly (860 mm width) (each side) 9,475
Track shoe assembly (910 mm width) (each side) —
Pivot shaft assembly (each side) 706
Equalizer bar 555
Hydraulic tank assembly 438
01-8 D575A-3 SD
GENERAL WEIGHT TABLE
Unit: kg
Blade lift cylinder assembly (each side) 562
Pitch cylinder assembly (each side) 1,220
Super dozer assembly 31,354
• Blade 20,834
• Straight frame (left) 3,661

• Straight frame (right) 3,661
• Pitch cylinder assembly 1,220 × 2
Counterweight assembly 5,800
Cylinder yoke (each side) 185
Cylinder stay 1,047
Cylinder support (each side) 1,600
Radiator guard assembly 3,170
• Radiator guard 1,470
Radiator mask (incl. grill) (each side) 153
Engine underguard (front) 510
Hood 210
Fender (left) 1,540
Fender (right) 1,620
ROPS 1,800
Floor frame assembly 830
Cab assembly 485
Operator’s seat assembly 65
D575A-3 SD 01-9
GENERAL TABLE OF FUEL, COOLANT AND LUBRICANTS
TABLE OF FUEL, COOLANT AND LUBRICANTS
AMBIENT TEMPERATURE CAPACITY (l)

RESERVOIR KIND OF
FLUID –22 –4 14 32 50 68 86 104°F
–30 –20 –10 0 10 20 30 40°C Specified Refill
SAE 30
SAE 10W
Engine oil pan 212 195
SAE 10W-30
SAE 15W-40
Power train oil pan

(incl. transmission, SAE 30
torque converter 490 345
and bevel gear SAE 10W
cases)
Engine oil
Damper case 2.4 2.4

SAE 30
Pivot shaft (each) 18 —
SAE 10W
Hydraulic system SAE 10W-30 700 300
SAE 15W-40
SAE 140
Final drive case SAE 85W-140 160 160
(each)
SAE 80
Gear coupling Gear oil AGMA 8EP 1.5 —

(each)
Idler (each) 3.5 – 3.8 —
Track roller (each) 2.00 – 2.02 —

GO 140B
Carrier roller (each) 1.4 – 1.5 —
Bogie (each) 0.99 – 1.01 —
ASTM D975 No. 2

Fuel tank Diesel fuel 2,100 —
ASTM D975 No. 1
Cooling system Coolant Add antifreeze 298 —
01-10 D575A-3 SD
GENERAL TABLE OF FUEL, COOLANT AND LUBRICANTS
NOTE:
(1) When fuel sulphur content is less than 0.5 %,
change oil in the oil pan every periodic mainte-
nance hours described in this manual.
Change oil according to the following table if
fuel sulphur content is above 0.5 %.
Change interval of
Fuel sulphur content oil in engine oil pan
0.5 to 1.0 % 1/2 of regular interval
Above 1.0 % 1/4 of regular interval
(2) When starting the engine in an atmospheric

temperature of lower than 0°C, be sure to use
e n g i n e o i l o f S A E 1 0 W, S A E 1 0 W - 3 0 a n d
SAE15W-40 even though an atmospheric tem-
perature goes up to 10°C more or less in the
day time.
(3) Use API classification CD as engine oil and if
API classification CC, reduce the engine oil
change interval to half.
(4) There is no problem if single grade oil is mixed
with multigrade oil (SAE10W-30, 15W-40), but
be sure to add single grade oil that matches the
temperature in the table on the left.
(5) We recommend Komatsu genuine oil which has
been specifically formulated and approved for
use in engine and hydraulic work equipment
applications.
ASTM: American Society of Testing and Material

SAE: Society of Automotive Engineers
API: American Petroleum Institute
AGMA: American Gear Manufacture Asociation
Specified capacity: Total amount of oil including oil

for components and oil in pip-
ing.
Refill capacity: Amount of oil needed to refill sys-
tem during normal inspection and
maintenance.
D575A-3 SD 01-11
10 STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD
Radiator, oil cooler......................................... 10-2 Hydraulic tank............................................ 10-104

Engine control ............................................... 10-4 Pitch, tilt selector solenoid valve
Power train system........................................ 10-5 assembly ................................................. 10-105
Power train skelton........................................ 10-6 PPC valve.................................................. 10-108
Power train hydraulic piping .......................... 10-7 Safety lock valve,
Damper.......................................................... 10-9 PPC accumulator..................................... 10-112
Torque converter, PTO .................................10-11 PPC relief valve ......................................... 10-113
Torque converter valve ................................ 10-18 Main control valve...................................... 10-114
Torque converter lock-up control system..... 10-28 Pitch selector solenoid valve ..................... 10-120
Torque converter filter.................................. 10-31 Pitch priority solenoid valve ....................... 10-121
Transmission control ................................... 10-32 Pitch assist solenoid valve......................... 10-122
Transmission ............................................... 10-33 Blade control knob..................................... 10-123
Transmission control valve .......................... 10-42 Piston valve ............................................... 10-124
Lubrication relief valve................................. 10-52 Quick drop valve........................................ 10-125
Steering clutch, brake control...................... 10-54 Work equipment cylinder ........................... 10-126
Steering control valve.................................. 10-55 Cylinder stay, yoke..................................... 10-128
Steering clutch, steering brake.................... 10-61 Work equipment......................................... 10-130
Final drive.................................................... 10-70 Counterweight ........................................... 10-135
Track frame ................................................. 10-78 Air conditioner............................................ 10-137
Idler ............................................................. 10-82 Engine control system ............................... 10-139
Carrier roller ................................................ 10-84 Engine control system with electronic engine
Track roller................................................... 10-86 throttle controller...................................... 10-146
Track shoe................................................... 10-88 Monitor system .......................................... 10-149
Recoil spring................................................ 10-92 Sensor ....................................................... 10-155
Track roller bogie......................................... 10-94 Mode selection system .............................. 10-160
Suspension.................................................. 10-96 Blade control system ................................. 10-163
Hydraulic piping diagram for Actual electrical wiring diagram ................. 10-168
work equipment ....................................... 10-100
Centralized oil pressure detection
piping diagram........................................ 10-103
D575A-3 SD 10-1
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD RADIATOR, OIL COOLER
RADIATOR, OIL COOLER
1. Radiator 12. Power train oil cooler

2. Upper tank 13. Fan support
3. Pressure valve 14. Hydraulic oil cooler
4. Radiator water level sensor 15. Fan pulley
5. Inlet tube 16. Fan drive universal joint
6. Water filler cap
7. Aeration hose OUTLINE
8. Drain valve • The cooling fan is driven by a fan belt using the
9. Lower tank power of the engine.
10. Oil inlet tube
11. Cooling fan
10-2 D575A-3 SD
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD RADIATOR, OIL COOLER
D575A-3 SD 10-3
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD ENGINE CONTROL
ENGINE CONTROL
1. Battery relay (Right) OUTLINE

2. Battery (Right) • Engine control is carried out in the following two
3. Decelerator pedal systems.
4. Starting switch 1. When the fuel control dial and decelerator
5. Throttle potentiometer pedal are operated, it controls the fuel injec-
6. Steering controller tion pump with an electric signal.
7. Engine controller 2. When mode selection system is actuated .
8. Transmission controller The throttle signal and fuel control dial signal
9. Fuel control dial enter the machine controller, are processed
10. Battery (left) together with other data, and are sent to the
11. Battery relay (left) electronic engine throttle controller as the
12. Starting motor throttle command.
13. Fuel injection pump (left) The electronic engine throttle controller con-
(electronic engine throttle controller) trols the fuel injection pump accrrding to the
command.
• A fuel injection pump with electronic governor is
employed. (For details, see ENGINE CONTROL
SYSTEM WITH ELECTRONIC ENGINE
THROTTLE CONTROLLER.)
10-4 D575A-3 SD
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD POWER TRAIN SYSTEM
POWER TRAIN SYSTEM
OUTLINE
• The motive force generated by engine (1) has its Steering clutch (18) engages and disengages
twisting vibration reduced by damper (2), and the motive force from the bevel gear shaft to the
then it passes through universal joint (3) and is final drive to control the direction of travel of the
transmitted to torque converter (9). machine.
The torque converter transmits the motive force The direction of travel is changed by operating
from the engine in accordance with the change the steering lever to cut the transmission of
in the load through oil and sends it to the input motive force at the steering clutch on the side to
shaft (turbine shaft) of transmission (19). which the machine is to travel. The radius of the
There is a lock-up clutch assembled to the turn can be adjusted by using steering brake (17)
torque converter. If the speed beyond the torque that is installed to the outside of the steering
converter becomes faster, the lock-up clutch is clutch. Steering brake (17) uses discs in the
engaged and the drive case and turbine become same way as the steering clutch.
one unit, so the power from the engine is trans- The power coming out from the steering clutch
mitted directly to the transmission input shaft. enters final drive (11) and is reduced, and it then
Transmission (19) consists of three forward rotates sprocket (12).
gears and three reverse gears formed by the The final drive consists of a 2-stage spur gear, 1-
combination of the planetary gear system and stage planetary gear, and 2-stage reduction.
the hydraulic system. The speed range is The rotation of the sprocket drives track shoe
selected by the speed lever to match the change (13) and the undercarriage to drive the machine.
in the load. Two sets of clutches are engaged,
and the motive force from the torque converter is
transmitted from the output shaft to the bevel
pinion.
The motive force entering the bevel pinion is
reduced by the bevel gears on the bevel gear
shaft, and is divided off at right angles to the left
and right. This divided motive force is transmit-
ted to each steering clutch (18).
D575A-3 SD 10-5
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD POWER TRAIN SKELTON
POWER TRAIN SKELTON
1. Engine (SA12V170E-2) 7. PTO 15. Bevel gear

2. Damper 8. Power train lubrication pump 16. Lubrication pump
3. Universal joint (SAR(4)–250) 17. Steering brake
4. Work equipment pump 9. Torque converter 18. Steering clutch
(SAL(4)–200+200) 10. Gear coupling 19. Transmission
5. Pitch assist pump 11. Final drive
20. Scavenging pump
(SAR(4)–125+125+(1)–32) 12. Sprocket
6. Power train pump 13. Track shoe
(SAL(4)–140+125) 14. Bevel pinion
10-6 D575A-3 SD
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD POWER TRAIN HYDRAULIC PIPING
POWER TRAIN HYDRAULIC PIPING
1. Oil cooler
2. Hydraulic pump (SAL(4)–140+125)
(for power train)
3. Hydraulic pump (SAR(4)–250)
(for power train lubrication)
4. Filter
(for torque converter)
5. Filter
(for transmission)
6. Filter
(for transmission lubrication)
7. Strainer
8. Steering clutch and brake
9. Transmission
D575A-3 SD 10-7
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD POWER TRAIN HYDRAULIC PIPING
OUTLINE
• The power train hydraulic piping has been unit-
ized for the power train. Oil passages are pro-
vided inside the case, so there is little external
piping.
• The oil from the oil tank passes through oil
strainer (7), and is then sucked up by power train
pump (2) and transmission lubrication pump (3).
The oil from transmission lubrication pump (3)
passes through lubrication oil filter (6) and flows
to the lubrication circuits of the PTO and trans-
mission.
The oil from power train pump (2) passes
through power train oil filter (5), and flows to the
torque converter, transmission, and steering.
This circuit is set to 2.5 MPa {25 kg/cm2} by the
main relief valve. The other circuit .pa passes
torque converter filter (4) and flows to the torque
converter.
• The oil flowing to the torque converter circuit is
set to 0.87 MPa {8.7 kg/cm2} by the torque con-
verter relief valve. It enters the torque converter,
flows from the torque converter to oil cooler (1),
where it is cooled, and then flows to the steering
clutch and brake to carry out lubrication.
• The oil flowing to the transmission circuit enters
transmission control valve, and actuates each
clutch in the transmission.
• The oil flowing to the steering circuit enters
steering control valve and actuates the steering
clutches and brakes.
• The oil that has lubricated or actuated each com-
ponent returns to the oil tank at the bottom of the
torque converter case and steering case.
10-8 D575A-3 SD
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD DAMPER
DAMPER
1. Output shaft 4. Breather 7. Cover

2. Flywheel 5. Coupling 8. Rubber coupling
3. Outer body 6. Dipstick 9. Inner body
OUTLINE OPERATION
• The damper reduces the twisting vibration • The motive power from the engine passes
caused by changes in the engine torque and the through flywheel (2) and is transmitted to outer
impact torque generated when digging or accel- body (3). The twisting vibration of the engine is
erating suddenly. It acts to protect the torque absorbed by rubber coupling (8), and the power
converter, transmission, and other parts of the is transmitted to inner body (9), passes through
power train. the universal joint, and is transmitted to the
• The damper uses a rubber coupling, so the torque converter.
vibration can be absorbed by the internal damp-
ing effect of the rubber and the friction damping
effect provided by the deformation. Furthermore,
there are few component parts.
D575A-3 SD 10-9
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD DAMPER
Unit: mm
No. Check item Criteria Remedy

Tolerance Standard
Standard size Clearance limit
Clearance between flywheel Shaft Hole clearance
1
housing and cover
–0.024 +0.080 –0.024 –
647.7 0.2
–0.105 0 0.185
Clearance between flywheel –0.022 +0.070 –0.022 –

2 571.5 0.2 Replace
and damper –0.092 0 0.162
Outer diameter of oil seal con- Standard size Repair limit

3
tact face on coupling 125 124.9
Outer diameter of bearing

4 55 54.9
contact face on output shaft
10-10 D575A-3 SD
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD TORQUE CONVERTER, PTO
TORQUE CONVERTER, PTO

(1/3)
A. Power train pump mount

B. Hydraulic pump mount
C. Transmission lubrication pump mount
D. Alternator drive pulley mount
SPECIFICATIONS
Name: TCA56-10A
Model: 3-element, 1-stage, single phase
D575A-3 SD 10-11
(2/3)
1. Coupling 13. Bearing cage

2. Seal cage 14. Stator shaft
3. Input shaft (No. of teeth: 57) 15. Retainer
4. Front housing 16. Stator clutch piston
5. Idler gear (No. of teeth: 63) 17. Return spring
6. Idler gear shaft 18. Stator clutch housing
7. Clutch housing 19. Stator clutch plate
8. Drive case 20. Stator clutch disc
9. Turbine 21. Stator shaft boss
10. Rear housing 22. Shaft
11. Stator 23. Transmission input shaft
12. Pump 24. Turbine boss
10-12 D575A-3 SD
(3/3)
25. Lock-up clutch disc

26. Lock-up clutch plate
27. Lock-up clutch piston
28. Seal seat
29. Spacer
30. Strainer
31. Scavenging pump
32. Scavenging pump gear (No. of teeth: 34)
33. Cover
34. Hydraulic pump gear (No. of teeth: 49)
35. Cover
36. Power train pump gear (No. of teeth: 49)
37. Shaft
D575A-3 SD 10-13
OUTLINE OIL FLOW

• The torque converter is a 3-element, single- • Oil set to a pressure of 0.85MPa (8.7kg/cm2)
stage, 1-phase torque converter, and it forms a by the torque converter relief valve flows
single structure with the transmission. To from port A, passes through the oil hole
improve the fuel consumption and ease of opera- inside rear housing (10), and enters pump
tion and to reduce consumption of the engine (12).
horsepower, a wet-type, multiple-disc clutch type The pump is always rotating under the motive
torque converter lock-up device and a wet-type, force from the engine, so the oil entering the
double-disc stator clutch device are assembled pump is given centrifugal force, and enters tur-
inside it. bine (9). The turbine is rotated by the centrifugal
• When the machine is carrying out continuous force of the oil.
low-load dozing or grading operations, it is more The turbine forms one unit with transmission
efficient if the motive power of the engine is input shaft (23), so the motive force received by
transmitted directly to the transmission input the turbine is transmitted to the transmission.
shaft. The oil leaving the turbine is sent to stator (11),
To achieve this, a lock-up clutch actuated by and enters the pump again. However, part of the
hydraulic pressure is assembled inside the oil passes from the stator through port B and is
torque converter. sent to the oil cooler.
When the torque converter is locked up (the
pump and turbine form one unit), the oil supplied
from the torque converter relief valve does not
stop, so the oil leaving the turbine from the pump
is given unneeded direction by the stator, and
this resists the rotation of the pump and turbine
(the oil is churned).
To prevent this, a stator clutch similar to the lock-
up clutch is built in. This allows the stator to
rotate freely when the torque converter is locked
up. The oil then moves together with rotation of
the pump and turbine; it is discharged from the
pump and turbine with little resistance, and is
returned to the pump.
★ The condition for the torque converter to enter
the lock-up range and torque converter range
are as follows.
• Lock-up range
Torque converter output shaft
speed: More than 1,260 rpm
and less than 1,870 rpm Three
Transmission specified pressure: conditions
More than 1.91MPa {19.5kg/cm } 2 are
The transmission gear speed is satisfied.
the 1st gear and the 2nd gear.
• Torque converter range
Torque converter output shaft
speed: Less than 1,230 rpm Any one
and m ore than 1,930 rpm of three
Transm ission specified pressure: conditions
Less than 1.5 MPa {15kg/cm2} are
The transmission gear speed is satisfied.
the 3rd gear
10-14 D575A-3 SD
PATH OF TRANSMISSION OF MOTIVE

FORCE
1. Lock-up clutch OFF, stator clutch

ON
When the lock-up clutch is OFF, the
connection between drive case (8)
and turbine (9) is cut; and when the
stator clutch is ON, rear housing (10)
and stator shaft (13) are connected so
stator (11) is locked and the torque
converter provides the normal func-
tions of a torque converter.
The motive force generated by the
engine passes through the damper
and universal joint, and is transmitted
to coupling (1). Input shaft (3), clutch
housing (7), drive case (8), and pump
(12) rotate as one unit.
The motive force from the pump uses
oil to rotate turbine (9), and is trans-
mitted to transmission input shaft
(23), that forms one unit with the tur-
bine.
2. Lock-up clutch ON, stator clutch

OFF
When the lock-up clutch is ON, drive
case (8) and turbine (9) are con-
nected to form one unit; and when the
stator clutch is OFF, the connection
between rear housing (10) and stator
shaft (13) is cut, so stator (11) follows
the rotation of pump (12) and turbine
(9).
The motive force generated by the
engine passes through the damper
and universal joint, and is transmitted
to coupling (1). Input shaft (3), clutch
housing (7), drive case (8), and pump
(12) rotate as one unit. In addition,
the drive case and turbine (9) are
connected by the clutch, so the oil is
not used. The motive force is trans-
mitted directly to the turbine and
transmission input shaft (23).
D575A-3 SD 10-15
10-16 D575A-3 SD
Unit: mm

Standard size Tolerance Repair limit
Outside diameter of coupling
1 0
oil seal contact surface 125 124.8
–0.063
Repair hard
Inside diameter of seat seal +0.035
2 115 115.1 chrome
ring contact surface 0
plating or
Inside diameter of retainer +0.046 replace
3 210 210.5
seal ring contact surface 0
Inside diameter of sleeve seal +0.040

4 130 130.5
ring contact surface 0
Backlash between input shaft Standard clearance Clearance limit

5 gear and scavenging pump
drive gear 0.202 – 0.426 0.202 – 0.426
Backlash between input shaft

6 0.212 – 0.468 0.212 – 0.468
gear and driven gear
Standard size Repair limit

7 Wear of stator shaft seal ring Width : 5.95 Width : 5.45
Height : 6.50 Height : 5.85
Lock-up clutch
Thickness of disc 5.4 4.87
Thickness of plate 5.8 5.22

8
Replace
Total thickness of assem-
27.8 26.2
bly
Thickness of disc 5.4 4.87

Stator clutch
Thickness of plate 7.0 6.3

9
Total thickness of assem-
17.8 16.7
bly
Free length In stalled length Installed load Free length Installed load
10 Stator clutch spring
125.4 N 106.9 N
54.1 37.0 50.9
{12.8 kg} {10.9 kg}
D575A-3 SD 10-17
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD TORQUE CONVERTER VALVE
TORQUE CONVERTER VALVE
1. Valve body 19. Load piston P1. Stator clutch initial

2. Torque converter relief valve 20. Cover pressure pickup port
3. Valve spring 21. Cover P2. Torque converter relief
4. Valve spring 22. Valve spring pressure pickup port
5. Main relief valve 23. Valve body P3. Main relief pressure
6. Cover 24. Lock-up selector valve pickup port
7. Piston 25. Piston P4. Lock-up clutch initial
8. Piston spring 26. Cover pressure pickup port
9. Piston Lock-up solenoid valve assembly P5. Stator clutch pressure
10. Stator clutch modulating valve 27. Cover pickup port
11. Lock-up clutch modulating valve 28. Coil P6. Lock-up clutch pressure
12. Cover 29. Spring pickup port
13. Piston 30. Plunger
14. Piston spring (Small) 31. Valve seat holder
15. Piston 32. Valve seat
16. Valve spring (Outer) 33. Spring
17. Valve spring (Inner) 34. Valve seat
18. Stopper 35. Cap
10-18 D575A-3 SD
OUTLINE 4. Torque converter lock-up solenoid valve

• The torque converter valve is installed at the top Solenoid valve receives an electrical signal from
of the rear housing of the torque converter and the lock-up controller and switches the pilot pres-
consists of the following six types of valves. sure to lock-up selector valve (24). It operates
1. Main relief valve lock-up selector valve (24) and switches the two
Main relief valve (5) sets the hydraulic pressure clutches ON ↔ OFF.
to 2.35 – 2.5 MPa {24.0 – 26.0 kg/cm 2 } in the 5. Stator clutch modulating valve
transmission, steering clutch, brake and torque Modulating valve (10) sets the clutch pressure to
converter lock-up clutch, and stator clutch cir- 2.4 – 2.5 MPa {24 – 26 kg/cm2 } to protect the
cuits. stator clutch from abnormally high pressure and
2. Torque converter relief valve acts to raise the pressure of oil from lock-up
Torque converter relief vale (2) sets the inlet selector valve (24) gradually until it reaches the
pressure of the torque converter to within 0.87 set pressure.
MPa {8.7 kg/cm2} to protect the torque converter 6. Lock-up clutch modulating valve
from abnormally high pressure. Modulating valve (11) acts in the same way as
3. Torque converter lock-up valve stator clutch modulating valve (10) and sets the
Lock-up selector valve (24) acts to switch the clutch pressure to 1.55 – 1.65 MPa {15.5 – 16.5
lock-up clutch and stator clutch ON ↔ OFF. kg/cm2} to protect the stator clutch from abnor-
mally high pressure.
D575A-3 SD 10-19
OPERATION OF MAIN RELIEF VALVE

• The oil from the power train pump passes
through the oil filter, and enters port A of the
main relief valve. It then passes through orifice a
and enters port B.
When the oil from the pump fills the circuit, the
pressure starts to rise.
• When the pressure in the circuit rises, the oil
entering port B pushes piston (9). The reaction
force compresses spring (4), moves main relief
valve (5) to the left in the direction of the arrow,
and opens ports A and C.
When this happens, the oil from the pump is
relieved from port A to port C, and flows port C to
the torque converter.
The pressure in the circuit at this point is 2.35 –
2.5 MPa {24.0 – 26.0 kg/cm2}.
OPERATION OF TORQUE CONVERTER RELIEF

VALVE
• The oil relieved from the main relief valve flows
into the torque converter from port C, and at the
same time passes through orifice b and enters
port D.
When the oil fills the torque converter, the pres-
sure starts to rise.
• If the pressure in the torque converter rises
abnormally high, the oil entering port D pushes
piston (9). The reaction force compresses spring
(3), moves relief valve (2) to the right in the direc-
tion of the arrow, and opens ports C and E.
When this happens, the oil at port C is relieved to
port E, and is drained to the oil tank.
The pressure in the circuit at this point is below
0.87 MPa {8.7 kg/cm2}.
10-20 D575A-3 SD
OPERATION OF TORQUE CONVERTER LOCK-

UP VALVE, SOLENOID VALVE
• The torque converter lock-up valve supplies oil to
switch the lock-up and stator clutch built into the
torque converter ON ↔ OFF.
The lock-up valve is actuated by the pilot pres-
sure from the solenoid valve that is actuated
when it receives an electrical signal from the
lock-up controller.
• When the lock-up switch on the panel at the front
of the operator’s compartment is pressed ON
(the indicator lamp inside the switch lights up),
the auto-lock-up system is actuated, and when
the torque converter reaches the lock-up range,
the lock-up controller, which has received signals
from the two sensors, connects the solenoid to
the ground and current flows. The hydraulic cir-
cuit is switched and pilot pressure is sent to the
lock-up valve to lock up the torque converter.
D575A-3 SD 10-21
1. Travel in torque converter drive
When the machine is in the torque converter range, The oil from the pump flows ports P and N into port L
the solenoid valve is deactivated, so valves (32) is of the lock-up valve. When the pressure inside the
pushed to the left in the direction of the arrow by the circuit rises, piston (25) is pushed to the left in the
tension of spring (29). Ports N and P open. direction of the arrow, and the piston pushes out
lock-up selector valve (24) to the left.
10-22 D575A-3 SD
When lock-up selector valve (24) moves to the left in the stator clutch piston. When the pressure in the
the direction of the arrow, ports F and G and ports H circuit rises, the stator clutch is engaged.
and K close, and ports F and H and ports G and J At the same time, the oil that is the back pressure of
open. the lock-up clutch piston is drained from port G to
When this happens, the oil from the pump flows from port J, and the lock-up clutch is disengaged.
port F to port H, and becomes the back pressure of
2. Travel in direct drive
When the machine is in the direct drive range, the Ports F and H and ports G and J close, and ports F
solenoid valve is excited, so plunger (30) is pushed and G and ports H and K open.
to the right in the direction of the arrow and valve When this happens, the oil from the pump flows from
(32) is moved. Port P close and ports N and M open. port F to port G, and becomes the back pressure of
When this happens, oil from the pump stops at P. the lock-up clutch piston. When the pressure in the
The high-pressure oil at port L is drained from port N circuit rises, the lock-up clutch is engaged.
to port M. At the same time, the oil that is the back pressure of
When the pilot pressure at port L is lost, piston (25) the stator clutch piston is drained from port H to port
and lock-up selector valve (24) are returned to the K, and the stator clutch is disengaged.
right in the direction of the arrow by the tension of
spring (22).
D575A-3 SD 10-23
OPERATION OF STATOR CLUTCH, LOCK-UP

CLUTCH MODULATING VALVE
• The modulating valves are in the circuit between
the lock-up selector valve and the inlet ports of
the two sets of clutches. When the clutch is
switched ON, the modulating valve acts to raise
the pressure on the piston gradually until it
reaches the set pressure so that the clutch is
engaged smoothly, thereby reducing any shock
to the torque converter or transmission.
★ The following explanation of operation takes the
stator clutch as the example, but the operation of
the lock-up clutch is the same.
However, the oil flow to the clutch during direct
drive or torque converter drive is the reverse.
1. Travel in direct drive

When the machine enters the direct drive range,
the oil at port L of lock-up selector valve (24)
returns to the solenoid valve and is drained.
When this happens, lock-up selector valve (24)
is pushed to the right in the direction of the arrow
by the tension of spring (22). Ports F and H
close, and ports H and K open, and the oil at port
H is drained from port K.
When the hydraulic pressure at port H is lost,
modulating valve (10) is returned to the right in
the direction of the arrow by the tension of spring
(16), and ports H and Q open fully. At this point,
the actuating pressure of the stator clutch is
drained from port H to port K, and the clutch is
disengaged.
10-24 D575A-3 SD
2. Travel in torque converter drive

When the machine is in the torque converter
drive range, the oil from the solenoid valve
enters port L of lock-up selector valve (24) and
moves the lock-up selector valve to the left in the
direction of the arrow. Ports F and G, and ports
H and K close, and ports F and H open. A circuit
is then formed from port F through modulating
valve (10) to the stator clutch. The oil from the
pump flows from port F to the stator clutch, and
the pressure in the circuit starts to rise.
As the hydraulic pressure in the circuit rises, the
oil passing through orifice d in modulating valve
(10) pushes piston (13), and the reaction force
moves the modulating valve to the left in the
direction of the arrow to throttle ports Q and H.
Port Q is connected with port S that
applies back pressure to load piston (19),
and moves the load piston to the right in
the direction of the arrow to compress
spring (16). The tension of spring opens
port Q and H. This operation is repeated
intermittently to increase the load of
spring (16). While this is happening,
the hydraulic pressure gradually
increases, and finally stops at the
position where ports Q and H are closed
to complete the rise in hydraulic pressure.
The hydraulic pressure at this point is 2.5
± 0.1 MPa {25 ± 1 kg/cm2}.
The hydraulic pressure of the lock-up
2
clutch is 1.55 +0.1 +1
0 MPa {15.5 0 kg/cm }.
D575A-3 SD 10-25
10-26 D575A-3 SD
Unit: mm

Tolerance Standard
Clearance between main relief Shaft Hole clearance
1
valve and valve body
–0.035 +0.016 0.035 –
40 0.08
–0.045 0 0.061
Clearance between torque
–0.035 +0.016 0.035 –
2 converter relief valve and 40 0.08
–0.045 0 0.061
valve body
Clearance between stator
–0.035 +0.013 0.035 –
3 clutch modulating valve and 25 0.08
–0.045 0 0.058
valve body
Clearance between lock-up
–0.035 +0.013 0.035 –
4 clutch modulating valve and 25 0.08
–0.045 0 0.058
valve body
Clearance between lock-up –0.035 +0.016 0.035 –
5 40 0.08
valve and valve body –0.045 0 0.061
Replace
6 Main relief valve spring
1,417 N 1,346 N
120.3 102.0 116.7
{144.57 kg} {137.3 kg}
Torque converter relief valve 550.37 N 522.83 N
7 116.92 90.8 113.41
spring {56.16 kg} {53.35 kg}
Stator clutch modulating valve 160.52 N 152.49 N
8 103.5 94.7 100.4
spring {16.38 kg} {15.56 kg}
Lock-up clutch modulating 151.02 N 143.47 N
9 141.4 91.2 137.16
valve spring (outside) {15.41 kg} {14.64 kg}
Lock-up clutch modulating
10 80.5 80.5 — 78.09 —
valve spring (inside)
29.4 N 27.93 N
11 Lock-up valve spring 110.07 100.0 106.8
{3.0 kg} {2.85 kg}
D575A-3 SD 10-27
TORQUE CONVERTER
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD LOCK-UP CONTROL SYSTEM
TORQUE CONVERTER LOCK-UP CONTROL SYSTEM
10-28 D575A-3 SD
TORQUE CONVERTER
1. Monitor panel OUTLINE

2. System abnormality lamp • With the torque converter lock-up control sys-
3. Lock-up pilot lamp tem, the controller calculates the torque con-
4. Caution buzzer verter output shaft speed from the bevel gear
5. Lock-up mode switch speed and the transmission speed range pilot
6. Transmission controller pressure signal, and automatically engages the
7. Steering controller torque converter lock-up according to the load on
8. Torque converter lock up solenoid valve the machine.
9. Torque converter valve When the torque converter lock-up is engaged,
10. Transmission control valve the display lamp in the monitor panel lights up.
11. Steering control valve • The controller receives the bevel gear speed sig-
12. Torque converter lock-up clutch nal and transmission speed range and connects
13. Torque converter or disconnects the ground for the lock-up sole-
14. Transmission and steering unit noid and display lamp to switch the lock-up ON-
15. Right brake OFF.
16. Right steering clutch • The lock-up is switched ON-OFF if the result of
17. Left steering clutch the calculation of the signals fulfills the following
18. Left brake conditions.
19. Bevel gear speed sensor
Lock-up turned OFF (when any of the following
conditions are fulfilled)
1) When the lock-up mode switch is OFF
2) When the transmission speed range is F3 or
R3
3) When the transmission shift gear is changed.
4) When the torque converter output shaft
speed is less than 1,230 rpm or more than
1,930 rpm
Lock-up turned ON (when all of the following

conditions are fulfilled)
1) When none of the OFF conditions are ful-
filled (OFF conditions are given priority)
2) When the torque converter output shaft
speed is between 1,260 rpm and 1,870 rpm
3) When the transmission gear speeds are
F1,F2,R1 and R2
★ If any of the above conditions are not ful-
filled, the existing condition is main-
tained.
★ When the lock-up clutch is engaged, the
lock-up lamp lights up.
D575A-3 SD 10-29
TORQUE CONVERTER
BEVEL GEAR SPEED SENSOR
1. Magnet FUNCTION
2. Terminal • The bevel gear speed sensor is installed to the
3. Case bevel gear portion of the steering clutch housing.
4. Boot A pulse voltage is generated by the rotation of
5. Tube the gear teeth, and a signal is sent to the control-
6. Wire ler.
7. Connector
10-30 D575A-3 SD
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD TORQUE CONVERTER FILTER
TORQUE CONVERTER FILTER
1. Cover OUTLINE
2. Bypass valve • The torque converter filter uses an element to
3. Case clean the oil in the torque converter circuit.
4. Element • If the element becomes clogged and abnormal
pressure is generated in the filter, the bypass
A. From pump valve acts to bypass the oil to prevent damage to
B. To torque converter the element.
D575A-3 SD 10-31
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD TRANSMISSION CONTROL
TRANSMISSION CONTROL
1. Monitor panel (speed range display) 6. Transmission controller

2. Joystick 7. Steering controller
2A. Forward and reverse 8. Steering control valve
2B. Shift up switch 9. Bevel gear speed sensor
2C. Shift down switch 10. Transmission control valve
3. Parking lever 11. Torque convertor
4. Pitch angle sensor 11A.Torque convertor oil temperature
5. Engine controller 12. Engine speed sensor
10-32 D575A-3 SD
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD TRANSMISSION
TRANSMISSION
A. Lubrication port
B. Lubrication port
C. 1st clutch port
D. 2nd clutch port
E. 3rd clutch port
F. Forward clutch port
G. Reverse clutch port
D575A-3 SD 10-33
1.Input shaft
2.Pinion shaft
10-34
3.Clutch disc
4.Clutch plate
5.REVERSE planetary pinion
(No. of teeth: 29)
6.REVERSE clutch housing
7.REVERSE clutch piston
8.REVERSE ring gear (No. of teeth: 88)
9.FORWARD clutch housing
10.Pinion shaft
11. FORWARD planetary pinion
(No. of teeth: 28)
12.FORWARD ring gear
(No. of teeth: 94)
13.FORWARD clutch piston
14.3rd clutch housing
15.3rd clutch piston
16.3rd ring gear (No. of teeth: 94)
17.3rd planetary pinion
(No. of teeth: 28)
18.2nd clutch housing
19.2nd ring gear (No. of teeth: 94)
20.2nd clutch piston
21.2nd planetary pinion
(No. of teeth: 22)
22.Rear housing
23.Pinion shaft
24.1st clutch piston
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
25.1st clutch spring

26.Output shaft
27.1st clutch housing
28.2nd carrier and 1st clutch outer drum
(No. of teeth for 2nd carrier gear: 94)
29.1st clutch hub
30.2nd sun gear (No. of teeth: 50)
31.2nd clutch spring
32.3rd sun gear (No. of teeth: 38)
33.3rd clutch spring
34.FORWARD, 3rd carrier (No. of teeth for
FORWARD carrier gear: 88)
35.FORWARD sun gear
(No. of teeth: 38)
36.FORWARD clutch spring
37.REVERSE sun gear (No. of teeth: 30)
38.REVERSE ring gear
(No. of teeth: 165)
39.REVERSE carrier gear
(No. of teeth: 94)
40.REVERSE clutch spring
41.Tie bolt
42.Front housing
D575A-3 SD
TRANSMISSION
OUTLINE
• The transmission is a forward 3 gear, reverse 3
gear transmission that consists of a combination
of a planetary gear system and disc clutches.
• The transmission actuates the control valve to
use hydraulic pressure to fix two of the clutches
in the five sets of planetary gears and disc
clutches to select one rotating direction and one
gear speed.
• The clutches are locked as follows: No. 1 clutch
for REVERSE, No. 2 clutch for FORWARD, No.
3 clutch for 3rd, No. 4 clutch for 2nd and No. 5
clutch for 1st.
No. of plates and discs used

Clutch No. No. of plates No. of discs
No. 1 clutch 7 8
No. 2 clutch 8 9
No. 3 clutch 4 5
No. 4 clutch 3 4
No. 5 clutch 8 9
Gear speed, clutch combination, reduction ratio

Gear speed Clutch combination (engaged) Reduction ratio
FORWARD 1st No. 2 • No. 5 3.474
2nd No. 2 • No. 4 1.859
3rd No. 2 • No. 3 1.000
NEUTRAL No. 5 —
REVERSE 1st No. 1 • No. 5 2.933
2nd No. 1 • No. 4 1.570
3rd No. 1 • No. 3 0.844
D575A-3 SD 10-35
OPERATION
FORWARD 1st
1. When the transmission control lever is moved to 3. The rotation of input shaft (1) is transmitted to
F1, pressurized oil from the transmission control FORWARD sun gear (35), which is joined by a
valve actuates FORWARD clutch piston (13) and spline to the input shaft, and the rotation of the
1st clutch piston (24), and the clutches are sun gear rotates FORWARD planetary pinion
engaged. (11).
2. The FORWARD clutch locks FORWARD ring 4. The FORWARD clutch locks FORWARD ring
gear (12), and the 1st clutch locks 1st clutch hub gear (12), so the rotation of pinion shaft (10)
(29) and 2nd carrier and 1st clutch outer drive (carrier) is reduced, and it rotates in the same
(28), so these rotate together. direction as input shaft (1).
The 1st clutch hub is joined to output shaft (26) 5. The rotation of pinion shaft (10) (carrier) rotates
by a spline. 2nd carrier (28) is joined to pinion output shaft (26) in the same direction, and the
shaft (23) and 3rd ring gear (16), so when the 1st motive force is transferred.
clutch is engaged, output shaft (26) and 3rd ring
gear (16) rotate together. (They are secured in
relation to each other.)
10-36 D575A-3 SD
FORWARD 3rd
1. When the transmission control lever is moved to 5. Pinion shaft (10) (carrier) is common for both
F3, pressurized oil from the transmission control FORWARD and 3rd, so both the 3rd carrier and
valve actuates FORWARD clutch piston (13) and FORWARD carrier rotate in the same direction.
3rd clutch piston (15), and the clutches are 6. The 3rd clutch locks 3rd ring gear (16), so the
engaged. sp eed of r otati on of 3r d s un gea r (3 2) i s
2. The FORWARD clutch locks FORWARD ring increased.
gear (12), and the 3rd clutch locks 3rd ring gear 7. 3rd sun gear (32) is joined to output shaft (26) by
(16). a spline.
3. The rotation of input shaft (1) is transmitted to The rotation of the sun gear becomes the rota-
FORWARD sun gear (35), which is joined by a tion of the output shaft, and the motive force is
spline to the input shaft, and the rotation of the transferred.
sun gear rotates FORWARD planetary pinion
(11).
4. The FORWARD clutch locks FORWARD ring
gear (12), so the rotation of pinion shaft (10)
(carrier) is reduced, and it rotates in the same
direction as input shaft (1).
D575A-3 SD 10-37
REVERSE 2nd
1. When the transmission control lever is moved to 4. The REVERSE clutch locks pinion shaft (2) (car-
R2, pressurized oil from the transmission control rier), so planetary pinion (5) reduces the speed
valve actuates REVERSE clutch piston (7) and and rotates REVERSE ring gear (8) in the oppo-
2nd clutch piston (20), and the clutches are site direction to input shaft (1).
engaged. 5. REVERSE ring gear (8) rotates pinion shaft (10)
2. The REVERSE clutch locks pinion shaft (2) (car- (carrier), which is joined to the gear.
rier), and the 2nd clutch locks 2nd ring gear (19). 6. The 2nd clutch locks 2nd ring gear (19), so the
3. The rotation of input shaft (1) is transmitted to rotation of pinion shaft (10) (carrier) passes
REVERSE sun gear (37), which is joined by a through 3rd sun gear (32), and 3rd ring gear
spline to the input shaft, and the rotation of the (16), pinion shaft (23), 2nd planetary pinion (21),
sun gear rotates REVERSE planetary pinion (5). and pinion shaft (23), 2nd planetary pinion (21),
and 2nd sun gear (30), and rotates output shaft
(26).
10-38 D575A-3 SD
A
10-40 D575A-3 SD
Unit: mm

1 No. 1 clutch spring
379.3 N 322.4 N
133 94 125.02
{38.7 kg} {32.9 kg}
536.1 N 455.7 N
2 No. 2 clutch spring 168 106 157.92
{54.7 kg} {46.5 kg}
357.7 N 303.8 N
3 No. 3 clutch spring 68.8 55 64.67
{36.5 kg} {31.0 kg}
421.4 N 358.7 N
4 No. 4 clutch spring 56.9 43 53.49
{43 kg} {36.6 kg}
1,697 N 1,441.1 N
5 No. 5 clutch spring 9.5 5.83 8.93
{173 kg} {147.05 kg}
Total assembly thickness of Standard size Tolerance Repair limit

6
No. 1 clutch 83.8 ± 0.39 79.5
Total assembly thickness of

7
No. 2 clutch
95 ± 0.41 90.2

8 50.2 ± 0.30 47.5
No. 3 clutch

9
No. 4 clutch
39 ± 0.26 36.9

10 77.6 ± 0.41 72.8
No. 5 clutch
Thickness of No. 1 – 4 clutch

11 5.4 ± 0.1 4.87
discs
Replace
Thickness of No. 5 clutch
12
discs
4.8 ± 0.1 4.27
Thickness of No. 1 – 4 clutch

13 5.8 ± 0.1 5.22
plates
Thickness of No. 5 clutch

14 4.3 ± 0.1 3.87
plates
– 0.01
Wear of transmission input Width : 3.0 Width : – 0.03 Width : 2.7
15
shaft seal ring Thickness : 3.8 Thickness : ± 0.12 Thickness : 3.65
– 0.01
Wear of transmission output Width : 4.0 Width :– 0.03 Width : 3.6
16
shaft seal ring Thickness : 4.6 Thickness : ± 0.12 Thickness : 4.45
Width : 6.0 Width : – 0.01 Width : 5.5

17 Wear of No. 5 clutch seal ring – 0.03
Thickness : 6.8 Thickness : ± 0.15 Thickness : 6.65
Backlash of No. 1, 2, 3 sun Standard size Repair limit

18
gear and planetary pinion 0.16 – 0.40 —
Backlash of No. 1 planetary

19 pinion and inside teeth of ring 0.18 – 0.43 —
gear
Backlash of No. 2, 3 planetary

gear
Backlash of No. 4 sun gear

21 0.17 – 0.39 —
and planetary pinion
Backlash of No. 4 planetary

gear
D575A-3 SD 10-41
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
TRANSMISSION CONTROL VALVE
1. ECMV (R clutch) a. 1st clutch oil pressure ECMV clutch actuation tabl
2. ECMV (F clutch) measurement port ECMV
3. ECMV (3rd clutch) b. Transmission lubrication Speed R F 3rd 2nd 1st
range
4. ECMV (2nd clutch) relief valve oil pressure
5. Transmission lubrica- measurement port F1 ! !
tion relief valve c. 2nd clutch oil pressure F2 ! !
6. ECMV (1st clutch) measurement port F3 ! !
7. Pilot filter d. 3rd clutch oil pressure R1 ! !
8. Seat measurement port R2 ! !
e. F clutch oil pressure
R3 ! !
measurement port
f. R clutch oil pressure
measurement port
10-42 D575A-3 SD
ECMV
★ ECMV stands for Electronic Control Modulation Valve.
For Forward, 2nd, 3rd clutch
1. Connector 6. Proportional solenoid A. To clutch

2. Spring 7. Pressure control valve spool B. Drain
3. Flow sensor valve spool 8. Load piston C. From pump
4. Spring 9. Spring
5. Fill switch a. Clutch pressure
measurement port
D575A-3 SD 10-43
For Reverse, 1st clutch
1. Connector 6. Proportional solenoid A. To clutch

4. Spring 9. Spring
measurement port
10-44 D575A-3 SD
Structure of ECMV
The ECMV (Electronic Control Modulation Valve)
consists of 2 valves: a pressure control valve and a
flow detection valve. The ECMVs for the R and 1st
clutches have an additional flow detection valve to
allow a greater flow of oil.
• Pressure control valve
The pressure valve contains a proportional sole-
noid which takes the current sent from the trans-
mission controller and the pressure control valve
converts this current into hydraulic pressure.
• Flow sensor valve
This valve is actuated by a trigger from the pres-
sure control valve, and has following functions.
1) The valve is opened until the clutch is filled
with oil, thereby reducing the time (filling
time) taken for oil to fill the clutch.
2) When the clutch becomes full of oil, the valve
colses, and seends a signal (full signal) to
the controller to inform that filling is com-
pleted.
3) While there is hydraulic pressure applied to
the cultch, it outputs a signal (full signal) to
the controller to inform whether there is
hydraulic pressure or not.
ECMV and proportional solenoid

Each ECMV is equipped with one proportional sole-
noid.
The propulsion force shown in the diagram on the
right is generated according to the command curret
from the controller.
The propulsion force generated by the porpotional

solenoid acts on the pressure control valve spool
and this generates the hydraulic pressure shown in
the diagram on the right. In this way, by controlling
the command current, the propulsion force is
changed and this acts on the pressure control valve
to control the oil flow and hydraulic pressure.
ECMV and fill switch

Each ECMV is equipped with one fill switch.
When the clutch is completely filled, the flow sensor
valve acts to switch the fill switch on, As a result of
this signal, the oil pressure starts to build up.
D575A-3 SD 10-45
Operation of ECMV
The ECMV is controlled by the command current
from the transmission controller to the proportional
solenoid, and the output signal of the fill switch. The
relationship between the ECMV proportional sole-
noid command current and clutch input pressure and
the output signal of the fill switch is as shown in the
diagram Fig.1 on the right.
A range: Before gear shifting (drained)

B range: Filling starts (trigger issued)
C range: Filling completed
D range: Regulation
E range: Filling
1. Before shifting gear (drained) (A range of Fig. 1)

When no current is being sent to proportional
solenoid (6), the reaction force for spring (9) of
the pressure control valve pushes pressure con-
trol valve spool (7). As a result, proportional
solenoid (6) is pushed back, so pressure control
valve spool (7) connects the oil at clutch port C
to drain port E and drains the oil.
In this dondition, there is no hydraulic force act-
ing on spool (3) of the folw sensor valve, so the
reaction force of spring (4) for the fill switch
moves flow sensor valve spool (3) away from fill
switch (5), and stops it in a position where it is in
balanced with return spring (2) of the flow sensor
valve.
10-46 D575A-3 SD
2. Starting to fill (figger command input to pres-

sure control valve) (B range of Fig.1)
1) When there is no oil inside the clutch and the
trigger current is sent (maximum current is
applied) to proportional solenoid (6), the pro-
prtional solenoid moves the full stroke and pres-
sure control valve spool (7) moves to the left. As
a result of this, pump port A and pressure control
valve output port B are opened, and oil passes
through orifice "a" of flow sensor valve spool (3)
and starts to fill the clutch.
2) When this happens, a pressure difference is cre-

ated between the upstream and downstream
sides of orifice "a" of flow sensor valve spool (3).
Because of this difference in pressure, flow sen-
sor valve spool (3) moves to the left and com-
presses sensor valve return spring (2). As a
result, flow sensor valve spool (3) opens pump
port D, and oil flows from here through orifice "a"
and goes to the clutch port.
3. Filling completed (pressure control set to ini-

tial pressure) (C range of Fig.1)
1) When pump port D of the flow sensor valve
opens, and the oil flows out from here, a differ-
e nc e i n pr es su re i s c re ated b etwe en the
upstream and downstream sides of orifice "a" of
flow sensor valve spool (3). This continues to
push flow sensor valve spool (3) to the left.
When this happens, and the current of propor-
tional solenoid (6) is lowered momentarily to the
initial pressure level, almost the complete pump
pressure comes to bear on load piston (8). As a
result, pressure control valve spool (7) is pushed
back to the right, and a small amount of oil leaks
from pressure control valve outlet port B to drain
port E. However, only a small amount of oil
leaks, so almost all the oil from the pump flows to
the clutch, and flow sensor valve spool (3) con-
tinues to be pushed to the left.
D575A-3 SD 10-47
2) When the clutch is filled with oil, the flow of oil

from pump port D to clutch port C stops. The
size of areas receiving pressure on the left and
right sides of flow sensor valve spool (3) is differ-
ent (the area on the left side is larger), so when
the pressure on both sides becomes the same,
the spool is moved by hydraulic force to the right.
When this happens, pump port D and clutch port
C are closed. Because of this difference in area
on the left and right sides, and the force of return
spring (2) of the pressure control valve, flow sen-
sor valve (3) compresses fill switch spring (4)
and is pushed to the right. It then contacts fill
switch (5) and transmits the clutch filling com-
pleted signal to the shift controller. At this point,
the current for the initial pressure level is flowing
to proportional solenoid (6), so the hydraulic
pressure is set to the initial pressure by pressure
control valve spool (7).
4. Regulating (D range of Fig.1)

When current is sent to proportional solenoid (6),
the solenoid generates a force proprtional to the
current. This propulsion force of the solenoid,
and the sum of the propulsion force produced by
the hydraulic pressure at the clutch port applied
to load piston (8), and the reaction force of pres-
sure control valve spring (9) are regulated so
that they are in balance.
The difference in hydraulic pressure applied to
both sides of flow sensor valve spool (3) pushes
the spool to the right, and the fill signal continues
to be sent to the transmission controller.
10-48 D575A-3 SD
FILL SWITCH
1. Terminal Function
2. Case This switch is installed to the side face at the flow
3. Nut sensor valve end of the ECMV. When the clutch is
4. Connector engaged, the end face of the spool contacts the ter-
minal of the switch and turns the switch ON. The fill
completed signal is then sent to the shift controller.
PROPORTIONAL SOLENOID
1. Connector FUNCTION
2. Filter This solenoid is installed on the pressure control
3. Shaft valve side of the ECMV. Upon receiving the com-
4. Plunger mand current from the travel controller, it operates
5. Coil the spool of the pressure control valve.
6. Case
7. Base
D575A-3 SD 10-49
ECMV (For Forward , 2nd, 3rd clutch)
Unit: mm

Tolerance Standard
Clearance between flow sen- Standard size Clearance limit
Shaft Hole clearance
1 sor valve spool and valve
body –0.035 +0.013 0.035 –
Ø 19 0.064
–0.045 0 0.058
Clearance between pressure
–0.035 +0.011 0.035 –
2 control valve spool and valve Ø 14 0.062
–0.045 0 0.056
body
Clearance between pressure –0.035 +0.012 0.035 –
3 Ø 5.7 0.063
control valve spool and piston –0.045 0 0.057 Replace
Free length Installed le ngth Installed load Free length Installed load
4 Spring for fill switch
41.7 N 37.6 N
15 13 14.7
{4.25 kg} {3.83 kg}
Return spring of folw sensor 4.9 N 4.4 N
5 33.5 29.5 32.8
valve {0.5 kg} {0.45 kg}
Return spring of pressure con- 10.6 N 9.5 N
6 16.2 11.7 15.9
trol valve {1.08 kg} {0.97 kg}
10-50 D575A-3 SD
ECMV (For Reverse, 1st clutch)
Unit: mm

Tolerance Standard
body –0.035 +0.013 0.035 –
Ø 19 0.064
–0.045 0 0.058
–0.035 +0.011 0.035 –
–0.045 0 0.056
body
3 Ø 5.7 0.063
41.7 N 37.6 N
15 13 14.7
{4.25 kg} {3.83 kg}
5 33.5 29.5 32.8
valve {0.5 kg} {0.45 kg}
6 16.2 11.7 15.9
D575A-3 SD 10-51
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD LUBRICATION RELIEF VALVE
LUBRICATION RELIEF VALVE
1. Valve body FUNCTION

2. Lubrication relief spool • This valve is installed to the left side of the trans-
mission and prevents abnormal pressure in the
a. Lubrication pressure meaurement plug transmission lubrication circuit.
Cracking pressure: 0.26 MPa {2.7 kg/cm2}
10-52 D575A-3 SD
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD LUBRICATION RELIEF VALVE
Unit: mm

Tolerance Standard
Clearance between lubricating Standard size Clearance limit
1 oil relief valve spool and valve
body –0.035 +0.013 0.035 –
Ø 22 0.078
–0.045 0 0.058
Replace
Valve spring of lubricating oil Free length In stalled length Installed load Free length Installed load
2
relief valve
91.9 N 87.3 N
68.5 37 66.4
{9.37 kg} {8.9 kg}
D575A-3 SD 10-53
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD STEERING CLUTCH, BRAKE CONTROL
STEERING CLUTCH, BRAKE CONTROL
1. Joystick 5. Transmission controller

1A. Steering 6. Steering controller
2. Brake pedal 7. Steering control valve
3. Pitch angle sensor 8. Bevel gear speed sensor
4. Engine controller 9. Engine speed sensor
10-54 D575A-3 SD
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD STEERING CONTROL VALVE
STEERING CONTROL VALVE
1. Line filter 5. ECMV (R.H brake)

2. ECMV (L.H clutch) 6. Mechanical brake valve
3. ECMV (R.H clutch) 7. Valve assembly
4. ECMV (L.H brake)
D575A-3 SD 10-55
VALVE ASSEMBLY (REDUCING-SUDDEN STOP PREVENTION)
1. Solenoid valve
2. Reducing valve
3. Sudden stop prevention
valve
a. Left brake oil pressure

meaurement port
b. Right brake oil pressure
meaurement port
c. Reducing oil pressure
meaurement port
10-56 D575A-3 SD
• SUDDEN STOP PREVENTION VALVE
1. Solenoid valve
(see 10-59 page)
2. Pressure reducing valve
3. Spring
4. Changeover spool
5. Spring
A. From pump
B. From right brake ECMV
C. To right brake
D. From Left brake ECMV
E. To left brake
OUTLINE
The steering brake is filled with the oil from the
ECMV to release the brake. (Brake oil pressure: 25
kg/cm2)
If the electric system has a trouble under this condi-
tion, the oil in the steering brake is drained rapidly
(Brake oil pressure: 0 kg/cm 2 ) and the brake is
applied suddenly regardless of the operator’s will.
The sudden stop prevention valve is installed so that
the brake will not be applied suddenly but applied
gently when the electric system has a trouble.
OPERATION
The oil from the pump flows in port A and its pres-
sure is reduced to 14 kg/cm2 by pressure reducing
valve (2) and spring (3), then it flows in chamber F.
1. Operation under normal condition

The solenoid valve is turned ON (energized) and
the oil does not flow in chamber G. Accordingly,
spring (5) presses changeover spool (4) to the
right and ports B and D of right and left brake
chambers C and E and ECMV are opened.
The oil flowing out of the right brake ECMV flows
through ports B and C to the right brake clutch.
(The left brake passes through ports D and E.)
2. When electric system has a trouble

If the electric system has a trouble, solenoid
valve (1) is turned OFF (de-energized) and the
oil in chamber F flows through the solenoid valve
into chamber G and pushes spring (5) to move
changeover spool (4) to the left.
Then, ports B and D of right and left brake cham-
bers C and E and ECMV are closed. Instead,
pressure reducing chamber F and ports C and E
are opened and the pressure in each brake
chamber is kept at 14 kg/cm2 and the brake is
applied gently.
D575A-3 SD 10-57
ECMV
★ ECMV stands for Electronic Control Modulation Valve.
1. Connector 6. Proportion solenoid A. To clutch

4. Spring 9. Spring
meaurement port
10-58 D575A-3 SD
ECMV
Unit:mm

Tolerance Standard
body –0.035 +0.013 0.035 –
Ø 19 0.064
–0.045 0 0.058
–0.035 +0.011 0.035 –
–0.045 0 0.056
body
3 Ø 5.7 0.063
41.7 N 37.6 N
15 13 14.7
{4.25 kg} {3.83 kg}
5 33.5 29.5 32.8
valve {0.5 kg} {0.45 kg}
6 16.2 11.7 15.9
D575A-3 SD 10-59
SUDDEN STOP PREVENTION VALVE
Unit:mm

Tolerance Standard
Clearance between pressure Shaft Hole clearance
1
reducing valve spool and body
–0.02 +0.013 0.02 –
Ø 19 0.063
–0.03 0 0.043
Clearance between –0.035 +0.013 0.035 –
2 Ø 19 0.076
changeover spool and body –0.045 0 0.058
Replace
Free length Installed le ngth Installed load Free length Installed load
3 Pressure reducing spring
24.1 N 229.3 N
69.5 58.3 67.4
{24.6 kg} {23.4 kg}
30.4 N 28.9 N
4 Changeover spool spring 49.0 42.5 47.5
{3.10 kg} {2.95 kg}
10-60 D575A-3 SD
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD STEERING CLUTCH, STEERING BRAKE
STEERING CLUTCH, STEERING BRAKE

(1/3)
OUTLINE
• The steering clutches and steering brakes are • Both the left and right steering clutch and brake
installed at the left and right ends of the bevel can be operated independently.
gear, between the steering shaft and final drive. • Lubrication of the steering clutch and brake is
• The steering clutch engages and disengages the carried out by forced lubrication using the oil
transmission of motive force from the steering cooled in the oil cooler.
shaft to change the direction of travel of the
machine.
• The steering brake stops the transmission of
motive force from the steering clutch to the final
drive, and is used to carry out sharp turns or to
stop the machine.
D575A-3 SD 10-61
(2/3)
10-62 D575A-3 SD
(3/3)
1. Brake output shaft 11. Steering shaft

2. Brake flange 12. Clutch flange
3. Piston spring (Belleville spring) 13. Clutch disc
4. Brake piston 14. Clutch plate
5. Piston housing 15. Clutch piston
6. Wave spring 16. Piston spring (Belleville spring)
7. Brake disc 17. Drum
8. Brake plate 18. Oil filler
9. Stopper 19. Dipstick
10. Bevel gear 20. Bevel pinion
D575A-3 SD 10-63
OPERATION OF STEERING CLUTCH
1. L.H. steering clutch "ENGAGED"

• When the L.H. steering lever is not being
pulled, no oil is sent from the steering control
valve. The force of piston spring (3) makes
clutch piston (4) push clutch discs (7) and
clutch plates (8) against stopper (9), so the
discs and plates are brought into close con-
tact with each other.
• The rotation of steering shaft (11) is transmit-
ted from clutch hausing (12) through the
discs and plates and the drum (17) and out-
put shaft (1).
2. L.H. steering clutch "DISENGAGED"

• When the L.H. steering lever is pulled, oil is
sent from the steering control valve. This
pressure oil pushes clutch piston (4) and
compresses piston spring (3), so clutch pis-
ton (4) moves to the left. Clutch discs (7)
and clutch plates (8) are then freed from the
pressure keeping them in close contact with
each other.
• The rotation of steering shaft (11) is no
longer transmitted to drum (17), so the
machine turns left slowly.
• When the L.H. steering lever is released, the
drain circuit of the steering control valve is
connected, and clutch piston (4) is pushed
back to the right by the force of piston spring
(3). The oil is drained, and the steering
clutch returns to the condition described
above in "Steering clutch ENGAGED".
10-64 D575A-3 SD
OPERATION OF STEERING BRAKE
1. L.H. steering brake "RELEASED"

• When the L.H. steering lever and brake
pedal are not being operated, the oil from the
steering control valve pushes brake piston
(5). This compresses piston spring (3) and
moves brake piston (5) to the left.
• As a result, brake discs (13) and brake plates
(14) are not in close contact. The rotation of
clutch flange (12) is transmitted to output
shaft (1).
2. L.H. steering brake "APPLIED"

1) L.H. steering lever pulled fully
• When the L.H. steering clutch is DISEN-
GAGED, the rotation of steering shaft
(11) is not transmitted to drum (17) of the
clutch brake. In addition, the oil drain cir-
cuit of the steering brake is open, so
brake piston (5) is moved to the right by
the force of piston spring (3), and the oil
drained.
• As a result, the force of the piston spring
pushes brake discs (7) and brake plates
(8) into close contact with stopper (9).
Brake plates (8) are held to brake flange
by spline, so drum (17), which was rotat-
ing because of the inertia of the machine,
is immediately stopped. The machine
then turns sharply to the left.
And, the oil is drained from the quick
drain valve to the steering case.
2) Brake pedal depressed

The left and right steering clutches are
engaged, and the steering brakes are
applied, so the machine is stopped.
D575A-3 SD 10-65
STEERING CLUTCH, STEERING BRAKE

(1/2)
980±245 Nm 274.4±29.4 Nm
(100±25 kgm) 8 7 2 1 5 (28±3
3 kgm) 16 2 1 5 17 6
21
274.4±29.4 Nm
(28±3 kgm)
12
11
22
20
13 3 4 14 10 19 9 18 15
539±49 Nm 274.4±29.4 Nm 274.4±29.4 Nm
(55±5 kgm) (28±3 kgm) (28±3 kgm)
SAD00748
10-66 D575A-3 SD
Unit: mm
Thickness of brake, clutch Standard size Repair limit

Replace
plate 4.7 4.2
1
Tolerance Repair limit Correct or
Warping of brake, clutch plate
Max. 0.3 0.4 replace
Thickness of brake, clutch Standard size Repair limit

Replace
disc 6.1 5.6
2
Tolerance Repair limit Correct or
Warping of brake, clutch disc
Max. 0.3 0.4 replace
Thickness of total brake plate Standard size Repair limit

3
and disc assembly 97.2 93.2
Thickness of total brake plate

4 81.7 78.2 Replace
and disc assembly
Backlash of brake, clutch disc, Standard clearance Repair limit

5
and brake hub 0.4 – 0.8 1.0
Backlash between bevel gear Adjust or

6 0.36 – 0.46 0.36 – 0.46
and pinion replace
Clearance between seal ring

7 0.5 – 0.8 0.8
and piston seal ring groove
Replace
Clearance between seal ring
8 0.5 – 0.8 0.8
and cage seal ring groove
Tolerance Standard
Inside diameter of seal ring Standard size Clearance limit
9 contact surface of steering
clutch cage –0.5 +0.097
420 0.5 – 0.797 0.5 – 0.797
–0.7 0
Inside diameter of seal ring

–0.125 +0.057 0.125 – 0.125 –
10 contact surface of steering 325
–0.214 0 0.271 0.271
clutch piston
Inside diameter of seal ring –0.5 +0.089

11 400 0.5 – 0.789 0.5 – 0.789
contact surface of brake cage –0.7 0
Replace
Inside diameter of seal ring
–0.125 +0.057 0.125 – 0.125 –
12 contact surface of brake pis- 340
–0.214 0 0.271 0.271
ton
13 Brake belleville spring
52.92 kN 50.47 kN
20.2 13.7 19.5
{5,400 kg} {5,150 kg}
83.8 kN 79.38 kN
14 Clutch belleville spring 18.65 13.9 18.4
{8,500 kg} {8,100 kg}
D575A-3 SD 10-67
(2/2)
980±245 Nm 274.4±29.4 Nm
(100±25 kgm) 8 7 2 1 5 (28±3
3 kgm) 16 2 1 5 17 6
21
274.4±29.4 Nm
(28±3 kgm)
12
11
22
20
13 3 4 14 10 19 9 18 15
539±49 Nm 274.4±29.4 Nm 274.4±29.4 Nm
(55±5 kgm) (28±3 kgm) (28±3 kgm)
SAD00748
10-68 D575A-3 SD
Unit: mm

Tolerance Standard
Standard size Interference limit
Interference between bevel Shaft Hole interference
15
gear and reamer bolt
+0.023 +0.033 –0.031 – Replace
20 —
+0.002 0 0.023
Interference between drum +0.023 +0.033 –0.031 –
16 20 —
and reamer bolt +0.002 0 0.023
Runout of rear face of bevel Service limit: 0.08 Correct or
17
gear (measure after installing to bevel gear shaft) replace
Standard rotating torque: 5.0 – 6.9 Nm {0.51 – 0.71 kgm}
Preload of bevel gear shaft
18 (When bevel pinion and gear are not meshed, Adjust
taper roller bearing
at tip of bevel gear: 26.5 – 37.3 N {2.7 – 3.8 kg})
Standard shim thickness of
19 2.5 Adjust shim
bearing cage
Standard shim thickness for
20 3.0 Adjust shim
taper serration flange mount
Face runout, radial runout of Service limit: Face runout 0.2, radial runout 0.2 Correct or
21
gear (Measure as individual part after press fitting gear to shaft) replace
Stepped difference and press-
Press-fitting force: 343 ± 49 kN {35 ± 5 tons}
22 fitting force of shaft and gear Correct
Stepped difference: 3 ± 0.5
taper serration portion
D575A-3 SD 10-69
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
(1/3)
OUTLINE
• The final drive uses a 2-stage spur gear and 1- • The rotating and sliding parts of the sprocket are
stage planetary gear reduction system. fitted with floating seals to prevent sand and soil
• The lubrication consists of two systems: a splash from entering and prevent the lubrication oil from
type system in which the rotation of a gear in the leaking.
oil accumulated in the final drive case lubricates
all parts: and a forced lubrication system, which
is used particularly for the 1st stage and 2nd
stage bearings, and which is provided by a lubri-
cation pump driven by the steering output shaft.
10-70 D575A-3 SD
(2/3)
D575A-3 SD 10-71
(3/3)
1. Shaft
2. Sprocket hub
3. Sprocket teeth
4. Planetary gear
(No. of teeth: 21)
5. Cover
6. No. 2 pinion (No. of teeth: 18)
7. No. 1 pinion (No. of teeth: 14)
8. Gear coupling
9. No. 1 gear (No. of teeth: 43)
10. No. 1 hub
11. No. 2 gear (No. of teeth: 70)
12. No. 2 hub
13. Carrier
14. Sun gear (No. of teeth: 26)
15. Ring gear (No. of teeth: 110)
16. Wear guard
17. Floating seal
18. Cover
19. Plug
20. Holder
21. Element
22. Bypass valve
23. Lubrication pump
24. Filter
25. Valve
26. Strainer
10-72 D575A-3 SD
POWER TRAIN
OPERATION
• The motive power form the bevel gear shaft and • The rotation of carrier (13) passes through shaft
steering clutch is transmitted to No. 1 pinion (7) (1) and is transmitted to sprocket hub (2). The
through gear coupling (8). From No. 1 pinion (7), sprocket hub rotates in the same direction as
it passes through No. 1 gear (9) and No. 1 hub sun gear (14).
(10), and rotates No. 2 pinion (6). • The power transmitted to sprocket teeth (3)
• From No. 2 pinion (6), it passes through No. 2 through sprocket hub (2).
gear (11) and No. 2 hub (12), and rotates sun
gear (14).
• The rotation of sun gear (14) is transmitted to
planetary gear (4), but ring gear (15), which is
meshed with the planetary gear, is locked by
cover (5), so the planetary gear rotates around
the sun gear along the ring gear. Therefore, the
rotation of the sun gear rotates carrier (13).
D575A-3 SD 10-73
LUBRICATION PUMP
★ This illustration shows the left side.
1. Rear case OUTLINE

2. Front case • The lubrication pump is driven by the steering
3. Driven gear output shaft, and acts to carry out forced lubrica-
4. Drive gear tion of the final drive gears and bearings.
• This pump can rotate either clockwise or coun-
A. Oil outlet port terclockwise. (To deal with the forward and
B. Oil outlet port reverse travel of the machine.)
C. Discharge port (or suction port)
D. Suction port (or discharge port)
10-74 D575A-3 SD
LUBRICATION VALVE
1. Plug OUTLINE
2. Spring • The lubrication pump can rotate in either direc-
3. Ball tion, so the discharge and suction ports of the
4. Valve body pump differ according to the direction of rotation
of the pump (the direction of the pump depends
A. Port A (outlet port) on whether the machine is traveling forward or in
P1. Port P1 (from lubrication pump) reverse). For this reason, this valve fixes the
P2. Port P2 (from lubrication pump) flow of oil in a constant direction.
T. Port T2 (inlet port)
D575A-3 SD 10-75
10-76 D575A-3 SD
Unit: mm
Backlash between No. 1 pin- Standard size Repair limit

1
ion and No. 1 gear 0.32 – 0.82 1.5
Backlash between No. 2 pin-

2 0.40 – 0.97 1.5
ion and No. 2 gear
Backlash between sun gear

3 0.25 – 0.72 1.5
and planetary pinion
Backlash between planetary

4 0.32 – 1.00 1.5
pinion and ring gear
Replace
Outside diameter of No. 1 pin- Standard size Repair limit
5
ion oil seal contact surface 130.0 129.9
Tolerance Standard
Clearance between pinion Shaft Hole clearance
6
shaft and carrier (small end)
+0.064 +0.035 – 0.004 –
114.3 0
+0.039 0 0.064
IClearance between pinion +0.043 +0.040 – 0.043 –

7 150 0.1
shaft and carrier (big end) +0.003 0 0.037
Shim adjustment of holder

8 mount at end face of final Standard shim thickness: 1
drive cover Adjust
Shim adjustment of No. 1 pin-
9 Standard shim thickness: 3
ion shaft
Stepped difference and press-

fitting force of No. 1 pinion Press-fitting force: 343 ± 49 kN {35 ± 5 tons}
10 Correct
shaft and gear taper serration Stepped difference: Within ± 0.5
portion
Clearance at 2nd pinion shaft

11 Standard shim thickness: 2.8
bearing mount cage
Clearance between floating Adjust

12 seal cover and end face of 3
sprocket hub
13 Wear of wear plate When drain plug of final drive starts to wear
Tolerance Standard
Clearance between main Shaft Hole clearance
14
frame and final drive cage
–0.210 +0.089
375 0.21 – 0.388 0.4 Replace
–0.299 0
Clearance between main –0.020 +0.063

15 479 0.02 – 0.146 0.2
frame and final drive cage –0.083 0
Tightening torque for sprocket Initial torque: 980.7 ± 98.1 Nm {100 ± 10 kgm}
16
nut Additional tightening angle: 180 ± 5°
D575A-3 SD 10-77
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD TRACK FRAME
TRACK FRAME
OUTLINE
• The track roller uses an X-shape bogie mount to
increase the ground contact area between the
track shoe and ground surface on rough sur-
faces, thereby increasing the drawbar pull.
• The X-shape bogie is fitted with rubber pads to
absorb the shock from the ground surface.
10-78 D575A-3 SD
1. Idler
2. Idler yoke
3. Recoil spring assembly
4. Carrier roller
5. Frame
6. Guard
7. X-shape bogie
8. Rubber pad
9. Track roller (single flange)
10. Guard
11. Track roller (double flange)
12. Guard
13. Guide
14. Spring
15. Spacer
D575A-3 SD 10-79
Unit: mm

Item Repair limit
Deformation of outside cylin- Bending 7 (for each 3000 of length)

1 Twisting 3 (for each 300 of level length)
der of track frame
Dents (window at top of valve) 10 Correct or
Dents (others) 12 replace
Clearance between idler

2 thrust bearing plate and guide Clearance: 1 (Standard shim thickness: 10)
plate
Protrusion of idler guide wear

3 Protrusion: 2 (Standard shim thickness: 2) Adjust
plate from guide
10-80 D575A-3 SD
A
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD IDLER
IDLER
★ The dimension marked indicates the basic dimension for measuring the wear amount of the idler tread
surface by using the uruta - sonic.
10-82 D575A-3 SD
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD IDLER
Unit: mm

1 Outside diameter of protrusion 1,246

2 Outside diametr of tread
1,190 1,165
Rebuild or
3 Tread step 28 40.5
replace
4 Tread thickness 37.5 25
5 Overall width 358
6 Tread width 92
Tolerance
Standard size Standard clearance
Clearance between bushing Shaft Hole
7
and shaft
–0.350 +0.178
205 0.345 – 0.591
–0.440 +0.005 Replace
Tolerance bushing
Standard
Standard size
Interference between bushing Shaft Hole interference
8
and idler
–0.143 +0.046
215 0.058 – 0.187
–0.104 +0.044
9 Width of shaft flange 342 Replace
Tightening torque for oil filler

10 205.9 ± 49 Nm {21 ± 5 kgm} Retighten
plug
D575A-3 SD 10-83
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD CARRIER ROLLER
CARRIER ROLLER
10-84 D575A-3 SD
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD CARRIER ROLLER
Unit: mm

1 Outside diameter of flange 296

2 Outside diametr of tread
260 235
Rebuild or
3 Width of tread 88
replace
4 Thickness of tread
45 32.5
5 Flange width 27
Tolerance Standard
6 Standard size
Shaft Hole interference
Interference between bearing –0.006 +0.028 Replace

or bushing and roller 150 0.004 – 0.074 bushing
–0.024 +0.068
7
0 +0.005
100 0.027 – 0.025
–0.022 +0.025
8 Play of roller in axial direction 0.010 – 0.220 Replace

9 205.9 ± 49 Nm {21 ± 5 kgm} Retighten
plug
D575A-3 SD 10-85
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD TRACK ROLLER
TRACK ROLLER
10-86 D575A-3 SD
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD TRACK ROLLER
Unit: mm

1 Outside Outsite 381
diameter
2 of flange Inside 365

3 Outside diameter of tread
325 289
4 Thickness of tread 75 57
5 Overall width 436

Rebuild or
Single Duble replace
6 Inside width
174 117
7 Single flange 92
Tread width
8 Double flange 91
9 F lange outside 39.5

Flange width
10 Flange inside 38
11 Shaft flange width 370
Tolerance
Standard size Standard clearance
Clearance between bushing Shaft Hole
12
and shaft
–0.377 +0.138
165 0.358 – 0.578
–0.440 –0.019 Replace
Tolerance bushing
Standard
Standard size
13
and roller
–0.273 +0.040
175 0.170 – 0.273
–0.210 0

14 205.9 ± 49 Nm {21 ± 5 kgm} Retighten
plug
D575A-3 SD 10-87
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD TRACK SHOE
TRACK SHOE
• LUBRICATED TYPE TRACK LINK
★ Portion P shows the link on the side where the bushing is pressed fitted.
10-88 D575A-3 SD
Unit: mm

1 Link pitch
317.8 319.4
Turn or
When turned
Standard size replace
Normal load Impact load
2 Bushing outside diameter
126 117.5 120

Rebuild or
3 Link height
213 195 replace
Thickness of link metal (bush-

4 59.5
ing press-fitting portion)
321(Regular)
5
320(Master)
Replace
247(Regular)
6 Shoe bolt pitch
254(Master)
84(Regular)
7
92(Master)
8 Inside width 169
Rebuild or
9 Link Overall width 90.5
replace
10 Tread width 85
11 Protrusion of pin 3
12 Protrusion of regular bushing 2
13 Overall length of pin 440

Adjust or
replace
14 Overall length of bushing 271
15 Thickness of bushing metal 25.5
16 Thickness of spacer 10
17 Bushing 245 – 441 kN {25 – 45 ton}
Press-fitting
18 Regular pin 834 – 1,079 kN {85 – 110 ton} —
fotce
19 Mster pin —
Tightening torque (Nm {kgm}) Additional tightening angle (deg)

Regular link
2,060 ± 200 {210 ± 20} 120 ± 10
20a
Shoe bolt Tightening torque Additional tightening angle Lower limit torque Retighten
(Nm {kgm}) (deg) (Nm {kgm})
Master link
+20
1,961 ± 200 {200 ± 20} 120 0 —
20b
No. of shoes (each side) 49 —
★ The items matked are for dry type track
D575A-3 SD 10-89
Unit: mm

Tolerance Standard
Standard size
21
and link
+0.652 +0.087
115 0.465 – 0.652
+0.552 0
Interference between regular +0.496 –0.126

22 74 0.472 – 0.696
pin and link +0.346 –0.200
Tolerance Standard
Standard size
Clearance between regular Shaft Hole clearance
23
pin and bushing
+0.496 +1.236 Adjust or
74 0.240 – 0.890
+0.346 +0.736 replace
Tolerance Standard
Standard size
Interference between master Shaft Hole interference
24
pin and link
— — — —
Tolerance Standard
Standard size
Clearance between master Shaft Hole clearance
25
pin and bushing
— — — —
★ The items matked are for dry type track
10-90 D575A-3 SD
SINGLE SHOE
Unit: mm

1 Height
105 35
Repair by
2 Thickness 28 build-up
welding or
replace
3 Length of base 52
4 Length of tip 36
D575A-3 SD 10-91
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD RECOIL SPRING
RECOIL SPRING
1. Cylinder assembly OUTLINE

2. Adjustment valve • The recoil spring acts to adjust the tension of the
3. Piston track shoe and to absorb any shock.
4. Rod
5. Flange
6. Holder
7. Bushing
8. Pilot
9. Bolt
10. Recoil spring
11. Tube
12. Tube
13. Pilot
14. Track frame outer cylinder
15. Bracket
10-92 D575A-3 SD
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD RECOIL SPRING
Unit: mm

1 Recoil spring (each)
529.2 N
1,375 1.110
{54,000 kg}
Tolerance Standard Clearance

Standard size
Clearance between bushing Shaft Hole clearance limit
2
and cylinder
0 +0.240 – 0.190 –
250 —
–0.072 +0.190 – 0.312
Clearance between adjust- –0.1 +0.063 Replace

3 165 0.1 – 0.623 —
ment cylinder and bushing –0.56 0
Clearance between bushing –0.6 +0.057

4 361 – 0.6 – 1.0 —
and recoil spring case –0.943 0
Tolerance Standard Interference

Standard size
Inter-ference between bush- Shaft Hole interference limit
5
ing and flange
+0.240 +0.72 – 0.53
274 —
+0.190 0 – 0.24
Inter-ference between bush- 0 –0.244 – 0.187 –

6 329 —
ing and pilot flange –0.057 –0.319 – 0.319
Press-fitting force for inside

7 —
cylinder bushing
Press-fitting force for idler

8 784 ± 78.4 kN {80 ± 8 ton}
yoke
Adjustment
Press-fitting force for pilot
9 —
flange bushing
Clearance between recoil

10 5.0
spring bearing plate and nut
Clearance between recoil Standard size Repair limit

11 Repair
spring case and stopper 5
D575A-3 SD 10-93
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD TRACK ROLLER BOGIE
TRACK ROLLER BOGIE
1. Rubber pad 8. Retainer

2. Track roller 9. Drain plug
3. Flange 10. Inner bogie
4. Washer 11. Outer bogie
5. Collar 12. Floating seal
6. Washer 13. Shaft
7. Bushing 14. Oil filler plug
10-94 D575A-3 SD
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD TRACK ROLLER BOGIE
Unit: mm

Tolerance Standard Clearance
Standard size
Clearance between pin and Shaft Hole clearance limit
1 Replace
bushing
–0.036 +0.387
120 0.202 – 0.477 0.8
–0.090 +0.166
Standard shim thickness at

2 flange and track frame mount 2
surface
Clearance between inner

3 3 ± 1.9
bogie and outer bogie
Clearance between flange

4 3 ± 1.2
and cage Adjust
5 Press-fitting force for bushing 0 – 92.1 kN {0 – 9.4 ton}
6 Press-fitting force for cage 0 – 81.3 kN {0 – 8.3 ton}
7 Press-fitting force for spacer 2.9 – 11.8 kN {0.3 – 1.2 ton}
D575A-3 SD 10-95
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD SUSPENSION
SUSPENSION
OUTLINE
• The suspension consists of the pivot shaft and
equalizer bar that join the main frame and track
frame. When the machine sways, it transmits
the machine weight effectively to the ground.
• The equalizer bar joins the left and right track
frames at the front to the main frame.
Rubber bushings are installed at the side pin to
reduce external shock.
• The pivot shaft is supported by the rear part of
the main frame, and is joined to the track frame.
The track frame is designed so that when it oscil-
lates, it can rotate about the pivot shaft.
10-96 D575A-3 SD
1. Center pin 8. Pivot shaft

2. Bushing 9. Seal cage
3. Equalizer bar 10. Bushing
4. Spherical bushing 11. Cover
5. Side pin 12. Thrust washer
6. Spherical joint 13. Cover
7. Rubber bushing
D575A-3 SD 10-97
10-98 D575A-3 SD
Unit: mm

Tolerance Standard
Clearance between side pin Shaft Hole clearance
1
and bushing
–0.1 +0.3
140 0.1 – 0.6 1.0
–0.3 0
Clearance between side pin –0.043 +0.020

2 145 0.033 – 0.126 1.0
and ball joint –0.106 –0.010
Clearance between center –0.043 +0.221

3 175 0.142 – 0.327 0.5
shaft and bushing –0.106 +0.099
Clearance between pivot shaft –0.190 +0.114

4 305 0.205 – 0.385 1.0
and bushing –0.271 +0.015
Clearance between pivot shaft –0.170 +0.140

5 250 0.172 – 0.382 1.0
and bushing –0.242 +0.002
Replace
Tolerance Standard Interference
Standard size
Interference between cage Shaft Hole interference limit
6
and seal
+0.094 –0.243
386 0.280 – 0.394 —
+0.037 –0.300
Interference between pivot +0.200 –0.1

7 306 0.248 – 0.385 —
shaft and seal +0.148 –0.185
Interference between equal- +0.110 –0.033

8 245 0.123 – 0.189 —
izer bar and bushing +0.090 –0.079
Interference between equal- +0.168 +0.072

9 200 0.05 – 0.168 —
izer bar and bushing +0.122 0
Interference between equal- +0.260 +0.081

10 260 0.107 – 0.260 —
izer bar and ring +0.188 0
11 Press-fitting force for bushing 73.5 – 246.0 kN {7.5 – 25.1 ton}
Press-fitting force for outside

12 16.7 – 23.5 kN {1.7 – 2.4 ton}
ring of seal
Press-fitting force for inside

13 23.5 – 36.3 kN {2.4 – 3.7 ton}
ring of seal
Press-fitting force for bushing Replace

14 88.2 – 198.9 kN {9.0 – 20.3 ton}
(inside)
Press-fitting force for bushing

15 72.5 – 200.9 kN {7.4 – 20.5 ton}
(outside)
Press-fitting force for side

16 147 – 245 kN {15 – 25 ton}
bushing
D575A-3 SD 10-99
HYDRAULIC PIPING DIAGRAM
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD FOR WORK EQUIPMENT
HYDRAULIC PIPING DIAGRAM FOR WORK EQUIPMENT

OIL COOLER SYSTEM
1. Hydraulic oil cooler

2. Radiator
3. Pitch assist pump (SAR(4)-125+125+(1)-32)
4. Work equipment pump (SAL(4)-200+200)
5. Return filter
6. Hydraulic tank
7. PPC relief valve
8. Pitch assist control valve
10-100 D575A-3 SD
D575A-3 SD
BLADE SYSTEM
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
1. Blade pitch cylinder (R.H.)

2. Blade lift cylinder (R.H.)
3. Quick drop valve
4. Separation block
5. Blade valve
6. Blade valve
7. Pitch assist pump (SAR(4)-125+125+(1)-32)
8. Work equipment (SAL(4)-200+200)
9. Return filter
10. Hydraulic tank
11. Pitch assist control valve
12. Quick drop valve
13. Blade lift cylinder (L.H.)
14. Blade pitch cylinder (L.H.)
10-101
FOR WORK EQUIPMENT
WORK EQUIPMENT CONTROL SYSTEM
1. Lift merge solenoid valve 10. Pitch, tilt selector solenoid valve Lever position
2. Blade valve (front) 11. Return filter ➀ Blade lower
3. Blade valve (rear) 12. Hydraulic tank ➁ Blade raise
4. PPC relief valve 13. PPC lock valve ➂ Blade left tilt
5. Safety lock lever 14. Pitch priority solenoid valve ➃ Blade right tilt
6. Accumulator 15. Accumulator check valve ➄ Free
7. Pitch solenoid valve 16. Pitch assist solenoid valve ➅ Lock
8. Blade control lever 17. Control pump (SAR(1)-32)
9. Accumulator
10-102 D575A-3 SD
CENTRALIZED OIL PRESSURE DETECTION PIPING DIAGRAM
1. Hydraulic pump (SAR(4)-125+125+(1)-32) LBR. Pick-up port for steering brake pressure (L.H.)
(for pitch assist and pilot) LCL. Pick-up port for steering clutch pressure (L.H.)
2. Hydraulic pump (SAL(4)-200+200) LWP. Pick-up port for work equipment pump (For L.H.)
(for work equipment) PPC. Pick-up port for PPC pilot pressure
3. Torque converter valve RBR. Pick-up port for steering brake pressure (R.H.)
4. PPC relief valve RCL. Pick-up port for steering clutch pressure (R.H.)
5. Transmission control valve RWP. Pick-up port for work equipment pump (For R.H.)
6. Steering control valve TCI. Pick-up port for torque converter inlet pressure
TCL. Pick-up port for torque converter lock-up pressure
TCO. Pick-up port for torque converter outlet pressure
TCS. Pick-up port for torque converter stator clutch pressure
TM1. Pick-up port for 1st clutch pressure
TM2. Pick-up port for 2nd clutch pressure
TM3. Pick-up port for 3rd clutch pressure
TMF. Pick-up port for forward clutch pressure
TML. Pick-up port for transmission lubrication pressure
TMM. Pick-up port for transmission main pressure
TMR. Pick-up port for reverse clutch pressure
D575A-3 SD 10-103
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD HYDRAULIC TANK
HYDRAULIC TANK
1. Sight gauge
2. Tank
3. Strainer
4. Oil filler cap
5. Breather
6. Bypass valve
7. Filter
A. Hydraulic cooler circuit return

B. Work equipment circuit return
C. PPC drain
10-104 D575A-3 SD
PITCH, TILT SELECTOR SOLENOID
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD VALVE ASSEMBLY
PITCH, TILT SELECTOR SOLENOID VALVE ASSEMBLY
1. Pitch back solenoid valve ALO. To pitch selector solenoid A and L.H blade
2. Left tilt limit solenoid valve valve a22
3. Right tilt limit solenoid valve ARO. To pitch selector solenoid B and L.H blade
4. Pitch dump solenoid valve valve b22
5. Valve block P. From PPC pump
6. PPC valve P1. From PPC valve port P3
P2: From PPC valve port P4
PV. To PPC valve port P
T. To hydraulic tank
TV. From PPC valve port T
D575A-3 SD 10-105
PITCH BACK (PITCH DUMP) SOLENOID VALVE
1. Connector
2. Variable iron core
3. Coil
4. Cage
5. Spool
6. Block
7. Spring
OPERATION
When solenoid is de-energized (key ON)
• The signal current does not flow from the control-
ler, so coil (3) is de-energized.
For this reason, spool (5) is pushed fully to the
right by spring (7).
• As a result, pressurized oil from port P2 (P1) of
the PPC valve flows from port T to port A, and is
connected to port T of the left (right) tilt limit
solenoid.
Solenoid energized (key ON, switch ON)

• When the signal current flows from the controller
to coil (3) is excited.
For this reason, spool (5) is pushed to the left in
the direction of the arrow.
• As a result, port T closes and the flow of the
pressurized oil from port P2 (P1) of PPC valve is
shut off. At the same time, the pressurized oil
from the PPC pump flows from port P to port A,
and is connected to port P of the left (right) tilt
limit solenoid.
10-106 D575A-3 SD
LEFT (RIGHT) TILT LIMIT SOLENOID VALVE
1. Connector
2. Variable iron core
3. Coil
4. Cage
5. Spool
6. Block
7. Spring
OPERATION
When solenoid is de-energized (Tilt limit : OFF)
• The signal current does not flow from the control-
ler, so coil (3) is de-energized.
For this reason, spool (5) is pushed fully to the
right by spring (7).
• As a result, the flow of pressurized oil from port
A of the pitch back (dump) solenoid flows from
port T to port A. From fere it is connected to pitch
solenoid B (A) and the pitch back (dump) port of
the left pitch control spool of the blade valve.
Solenoid energized (Tilt limit : ON)

• When the signal current flows from the controller
to coil (3), coil (3) is excited.
For this reason, spool (5) is pushed to the left in
the direction of the arrow.
• As a result, the flow of pressurized oil from port
A of the pitch back (dump) solenoid is shut off at
port T. Pitch solenoid port B (A) and the pitch
back (dump) port of the left pitch control spool of
the blade valve are drained to the tank.
D575A-3 SD 10-107
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD PPC VALVE
PPC VALVE
FOR BLADE
P. From control pump

T. To tank
P1. For blade lower
P2. For blade raise
P3. For left tilt
P4. For right tilt
10-108 D575A-3 SD
1. Spool 6. Nut
2. Metering spring 7. Joint
3. Centering spring 8. Plate
4. Piston 9. Retainer
5. Disk 10. Body
Unit: mm

Free length Installa tion Installation Installation

Centering spring Free length
11 × O.D len gth load load Replace
(for P1, P2, P3, P4) spring if
107.9 N 86.3 N damaged or
48.57 × 15.5 32.5 —
{11 kg} {8.8 kg} deformed
16.6 N 13.2 N
12 Metering spring 26.7 × 8.14 24.9 —
{1.69kg} {1.35 kg}
D575A-3 SD 10-109
OPERATION
1. At neutral
Ports A and B of the control valve and ports P1,
P2, P3 and P4 of the PPC valve are connected
to drain chamber D at the bottom.
(Fig. 1)
2. Fine control (neutral → fine control)

When piston (4) starts to be pushed by disc (5),
retainer (9) is pushed. Spool (1) is also pushed
by metering spring (2) and moves down.
When this happens, port P1 is shut off from drain
chamber D. At almost the same time, it is con-
nected to pump pressure chamber PP, and the
pilot pressure of the control pump is sent from
port P1 to port A.
When the pressure at port P1 rises, spool (1) is
pushed back. Fine control hole f is shut off from
pump pressure chamber PP. At almost the same
time, it is connected to drain chamber D, so the
pressure at port P1 escapes.
As a result. spool (1) moves up and down until
the force of metering spool (2) is balanced with
the pressure of port P1.
The relationship of the positions of spool (1) and
body (10) does not change until retainer (9)
ontacts spool (1).
Therefore, metering spring (2) is compressed in
proportion to the travel of the control lever, so the
pressure at port P1 also rises in proportion to the
travel of the control lever. In this way, the spool
of the control valve moves to a position where
the pressure of chamber A (same as pressure at
port P1) and the force of the return spring of the
control valve spool are balanced. (Fig. 2)
10-110 D575A-3 SD
3. Fine control (control lever returned)

When disc (5) starts to be returned, spool (1) is
pushed up by the force of centering spring (3)
and the pressure at port P1.
Because of this, port P1 is connected to drain
chamber D, and the pressurized oil at port P1 is
released.
If the pressure at port P1 drops too much, spool
(1) is pushed down by metering spring (2), so
port P1 is shut off from drain chamber D. At
almost the same time, it is connected to pump
pressure chamber PP, so the pressure at port P1
supplies the pump pressure until the pressure
recovers to a pressure equivalent to the position
of the lever.
When the control valve returns, oil in drain cham-
ber D flows in from the valve on the side that is
not moving. It passes through port P2 and goes
to chamber B to charge the oil. (Fig. 3)
4. At full stroke
When disc (5) pushes down piston (4), and
retainer (9) pushes down spool (1), port P1 is
shut off from drain chamber D, and is connected
to pump pressure chamber PP.
Therefore, the pilot pressure oil from the control
pump flows to chamber A from port P1 to push
the control valve spool.
The return oil from chamber B passes from port
P2 and flows to drain chamber D. (Fig. 4)
D575A-3 SD 10-111
SAFETY LOCK VALVE,
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD PPC ACCUMULATOR
SAFETY LOCK VALVE
1. Lever
2. End cap
3. Seat
4. Ball
5. Body
PPC ACCUMULATOR
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
SPECIFCATIONS
Gas capacity: 500 cc
10-112 D575A-3 SD
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD PPC RELIEF VALVE
PPC RELIEF VALVE
1. Strainer OUTLINE
2. Relife valve • This valve adjusts the pressure in the PPC circuit
3. Body to a constant 3.14 MPa {32 kg/cm2}.
4. Oil cooler by-pass valve
C. To oil cooler
P. From PPC pump
P1. To pressure PPC
T. To tank
D575A-3 SD 10-113
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD MAIN CONTROL VALVE
MAIN CONTROL VALVE
1. Main relief valve Table 1

2. Blade lift spool return spring
3. Blade tilt spool return spring PPC valve Front valve Rear valve
(for left) (for right)
4. Blade pitch spool
5. Blade lift spool Right tilt P1 MA2 MB2
6. Body Dual
7. Safety valve (with suction) tilt
Left tilt P2 MB2 MA2
8. Suction valve
Pitch P2 MB2 MB2
a12,11. From P4 of PPC valve Pitch
a22,21. From P2 of PPC valve (See. Table 1) Pitch buck
MA2 MA2
b12,11. From P3 of PPC valve P1
b22,21. From P1 of PPC valve (See. Table 1)
A12,11. To bottom end of blade lift cylinder
A22,21. To bottom end of blade pitch cylinder
B12,11. To rod end of blade lift cylinder
B22,21. To rod end of blade pitch cylinder
P. Pump port
T. Tank port
10-114 D575A-3 SD
A
OUTLINE
• There are two blade valves. These two valves • Safety valve (with suction) (7) is installed to
control the operation of the blade lift and blade protect the circuit if any abnormal pressure
pitch in the hydraulic system, and are in the pri- should be generated in the blade pitch cir-
ority tandem circuit of the blade lift circuit. The cuit.
main control valve actuates each spool by the
hydraulic pressure from the PPC valve.
• The oil from the pump enters port P and is set to
the maximum pressure by the relief valve. The
oil passes through the bypass circuit of blade lift
spool (5) and blade pitch spool (4), then passes
through the filter and returns to the tank. If it
actuates the blade lift and blade pitch spools, it
flows to the blade lift and blade pitch cylinders.
10-116 D575A-3 SD
Unit: mm

9 Spool return spring
431.2 N 345.0 N
69.9 63.0 —
{44.0 kg} {35.2 kg}
61.5 N 49 N
10 Spool return spring 79.7 78.5 —
{6.28 kg} {5 kg}
18.8 N 14.7 N
11 Check vavle spring 78.2 52.0 —
{1.92 kg} {1.5 kg}
1.2 N 1.0 N Replace

12 Relief valve spring 20 14 —
{0.12 kg} {0.1 kg}
5.7 N 4.9 N
13 Relief valve spring 16 12 —
{0.58 kg} {0.5 kg}
380.2 N 303.8 N
14 Relief valve spring 27.7 25 —
{38.8 kg} {31 kg}
6.9 N 5.9 N
15 Suction valve spring 27.9 18.0 —
{0.70 kg} {0.6 kg}
Suction valve spring of safety 5.7 N 4.9 N

16 15.9 12 —
valve {0.58 kg} {0.5 kg}
D575A-3 SD 10-117
RELIEF VALVE
1. Main valve
2. Valve seat
3. Poppet
4. Spring
5. Adjustment screw
6. Lock nut
FUNCTION
• The relief valve is installed at the inlet of the
main control valve. When the oil goes above the
set pressure, the relief valve drains the oil to the
tank. In this way, it sets the maximum pressure
in the hydraulic circuit and protects the circuit.
SAFETY VALVE WITH SUCTION (DIFFERENTIAL TYPE)
1. Main valve
2. Suction valve
3. Sleeve
4. Valve seat
5. Plug
6. Lock nut
7. Adjustment screw
8. Spring
9. Poppet
10. Pilot piston
FUNCTION
• This valve is installed in the circuit between the
control valve and the cylinder. When the control
valve is at hold, and some impact causes the
generation of abnormal pressure, the pressure is
relieved from this valve to prevent damage to the
cylinder.
10-118 D575A-3 SD
SUCTION VALVE
1. Main poppet
2. Sleeve
3. Spring
OPERATION
• If negative pressure is generated in port A (lift
cylinder rod end) (if the pressure is lower than in
port B in the tank circuit), main poppet (1) opens
because of the difference in area of d1 and d2,
then flows from port B at the tank end to port A
at the cylinder port end.
D575A-3 SD 10-119
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD PITCH SELECTOR SOLENOID VALVE
PITCH SELECTOR SOLENOID VALVE
1. Connector OUTLINE
2. Solenoid (b) • The pitch switch solenoid valve is located
3. Valve between the PPC valve and the blade valve, and
4. Manual push pin at the downstream of the pitch tilt switch solenoid
valve, and its function is to switch the PPC pilot
A. A port pressure.
(from the left tilt limit solenoid ALO/ to the left • By operating the pitch back switch or the pitch
blade pitch spool a22) dump switch of the blade control lever, the pilot
B. B port pressure can be delivered to the left pitch cylin-
(from the right tilt limit solenoid ARO/ to the left der and the right pitch cylinder, and it enables to
blade pitch spool b22) switch from the tilt to the pitch.
P. P port (to the right blade pitch spool a21) • In addition, the pitch solenoid valve is operated
T. T port (to the right blade pitch spool b21) by the controller.
10-120 D575A-3 SD
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD PITCH PRIORITY SOLENOID VALVE
PITCH PRIORITY SOLENOID VALVE
1. Valve OUTLINE
2. Solenoid • The pitch priority solenoid valve is installed
3. Connector between the PPC valve and the blade lift spools
4. Manual push pin of the blade valve, and is shutting off the PPC
pilot pressure when pitch back switch or pitch
A. From PPC valve P2 (blade lift RAISE) dump switch is, operated.
B. From PPC valve port P1 (blade lift LOWER) • If the blade control lever is operated while the
P. To a12 of blade lift spools (blade lift RAISE) pitch dump or pitch back switch is depressed,
T. To b12 of blade lift spools (blade lift LOWER) the pitch priority solenoid, which is energized,
shuts off the PPC circuit from the PPC valve to
the blade lift spools.
As a result, blade lift spools can not be operated
and only pitch BACK or pitch DUMP will be car-
ried out."
D575A-3 SD 10-121
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD PITCH ASSIST SOLENOID VALVE
PITCH ASSIST SOLENOID VALVE
1. Valve OUTLINE
2. Solenoid • The pitch assist solenoid valve is installed
3. Connector between the ass ist hy draulic pump (S AR
4. Manual push pin 125+125) and the valve carries out the switching
of the pump flow.
A. Port A (to blade valve) • If the pitch dump switch on the blade control
B. Port B (to hydraulic tank) lever are operated, the oil from the assist
P. Port P (from pitch assist pump) hydraulic pump merges with the oil in the work
T. Port T (to hydraulic tank) equipment circuit.
X. Port X (from PPC pump) • When the pitch dump switch on the blade control
Y. Port Y (to hydraulic tank) lever are not being operated, the oil from the
assist hydraulic pump is drained to the hydraulic
tank.
10-122 D575A-3 SD
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD BLADE CONTROL KNOB
BLADE CONTROL KNOB
1. Switch (pitch dump) OUTLINE

2. Switch (pitch back) • The blade raise, lower, left tilt, and right tilt oper-
3. Cover ations are carried out by operating the blade
4. Connector (male) control knob to the front, rear, left, and right.
5. Connector (female) • While switch (1) is being pressed, the blade pitch
dump operation is carried out. (It is given priority
over the blade tilt operation.)
• While switch (2) is being pressed, the blade pitch
back operation is carried out. (It is given priority
over the blade tilt operation.)
• If switches (1) and (2) are pressed at the same
time, the blade pitch dump operation is carried
out. (The pitch dump operation is given priority.)
D575A-3 SD 10-123
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD PISTON VALVE
PISTON VALVE
• FOR BLADE LIFT CYLINDER
OUTLINE
• The piston valve is installed on the piston in the
blade lift cylinder. When the piston reaches its
stroke end, the vale 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 tor-
tional force from occurring. When one of the pis-
tons reaches its stroke end, its piston valve
opens to relieve the oil pressure.
In addition the piston valve relieves the shock
which occurs when the piston comes into contact
with the cylinder head or the bottom and serves
to reduce the subsequent surge pressure in the
cylinder by letting the oil escape from the cylin-
der before the piston reaches its stroke end.
OPERATION
1. Piston vale 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 pis-
ton (2) moves further.
When this happens, the oil at the cylinder head,
which was sealed by piston valve (3), escapes
from piston valve seats (4) and (5), and the pres-
sure inside the cylinder stops rising.
10-124 D575A-3 SD
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD QUICK DROP VALVE
QUICK DROP VALVE

• FOR BLADE LIFT CYLINDER
STRUCTURE
The quick drop valve consists of valve body (1),
spool (2), check valve (3), and spring (4).
The quick drop valve serves to increase the blade
lowering speed and to reduce the occurrence of vac-
uum when the blade is lowering, thereby shortening
the time lag before digging is started.
The blade lowering speed, which is generally deter-
mined by the pump discharge, can be made faster
with the quick drop valve.
1. Valve body
2. Spool
3. Check valve
4. Spring
OPERATION
1. Start of lowering
when the blade lever is operated to LOWER, the
oil from the control valve enters the cylinder bot-
tom through port A and pushes the piston. In the
meantime, the oil in the cylinder head is pushed
out into the piston, enters valve port B, and flows
into the tank from port C.
2. While lowering
Pressurized oil from the cylinder head flows into
port C through port B.
At this time, the oil flow is restricted by an orifice
a provided along the way, causing a differential
pressure before and after the orifice.
When the differential pressure becomes greater
than the force of spring (4), it compresses the
spring and moves spool (2) and check valve (3)
to the right.
When the spool and the check valve have
moved, part of the oil flowing from the cylinder
head to the tank enters the passage to the cylin-
der bottom together with the oil from the control
valve.
Thus, the blade lowering speed increases in
accordance with the amount of oil that flows to
the bottom of the cylinder and reduces the for-
mation of vacuum at the bottom of the cylinder.
D575A-3 SD 10-125
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD WORK EQUIPMENT CYLINDER
WORK EQUIPMENT CYLINDER

BLADE LIFT CYLINDER
BLADE PITCH CYLINDER
10-126 D575A-3 SD
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD WORK EQUIPMENT CYLINDER
Unit:mm

Tolerance Standard
Cylinder Standard size Clearance limit
Crearance
1 between piston –0.036 +0.256
Lift 120 0.076 – 0.346 0.376
rod and bushing –0.090 +0.040
–0.043 +0.216
Tilt 180 0.091 – 0.322 0.382
–0.106 +0.048
Crearance between piston rod
+0.3
2 spherical surface and blade 170 — — 10 Replace
0
ball bushing
Crearance between piston rod –0.3 0
3 120 0.28 – 0.50 1.0
support shaft and bushing –0.5 –0.020
Crearance between cylinder
–0.145 +0.040
4 support shaft bushing and 145 0.145 – 0.285 1.0
–0.245 0
yoke
Crearance between cylinder
–0.043 +0.395
5 bottom support shaft and 180 0.388 – 0.501 1.0
–0.106 +0.295
bushing
Standard shim thickness
6 between tip of piston rod and 8.0 Adjust
cap
D575A-3 SD 10-127
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD CYLINDER STAY, YOKE
CYLINDER STAY, YOKE
1. Support 5. Bushing 9. Yoke

2. Bushing 6. Shaft 10. Cap
3. Shaft 7. Bushing 11. Shim
4. Plate 8. Dust seal
10-128 D575A-3 SD
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD CYLINDER STAY, YOKE
Unit:mm

Tolerance Standard
Clearance between yoke Shaft Hole clearance
12
mounting pin and bushing
0 +0.339
210 0.203 – 0.454 0.5
–0.115 +0.203
Clearance between yoke 0 +0.332
13 160 0.195 – 0.432 0.5
mounting pin and bushing –0.100 +0.195
Clearance between yoke –0.274 +0.052
14 255 0.274 – 0.378 0.5 Replace
mounting boss and bushing –0.326 0
Clearance between blade lift
0 +0.040
15 cylinder support shaft and 145 0 – 0.140 0.5
–0.100 0
bushing
Clearance between cylinder 0 +0.040
16 160 0 – 0.140 0.5
stay and bushing –0.100 0
Clearance between cylinder 0 +0.178
17 210 0.076 – 0.293 0.5
stay and bushing –0.115 +0.076

Adjust
Standard shim thickness
20 between lock plate and blade 3.0
lift cylinder support bracket
D575A-3 SD 10-129
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD WORK EQUIPMENT
WORK EQUIPMENT
1. End bit 5. Pitch cylinder

2. Cutting edge 6. Straight frame
3. Blade 7. Center link
4. Center brace 8. Trunnion cap
OUTLINE
• The dozer can be divided into two parts: the blade, • The blade is raised and lowered by the blade lift
and the hydraulic control which operates the blade. cylinders, and is tilted to the left or right or
The following explanation is for the super dozer. pitched to the front and rear by the blade pitch
• Blade (3) uses a high-tension steel plate attached cylinders. The blade and straight frame are sup-
to the front of the blade to give it ample strength to ported on both the left and right by pitch cylin-
withstand even heavy-duty work. ders (5).
Cutting edge (2) and end bit (1) are made of Center link (7) and center brace (4) at the rear
wear-resistance steel, and a separable type is face of the blade prevent the blade from swaying
used to make it easy to carry out the turning to the side and also act as an escape mecha-
operation for the cutting edge. nism when the blade is tilted.
Straight frame (6) is given ample strength by the
tree-top shape of the high-tension steel plate.
The front is connected to the blade by a joint
block, and the rear is connected to the track
frame by the trunnion.
10-130 D575A-3 SD
10-132 D575A-3 SD
Unit:mm

Tolerance Standard
Clearance between pitch cyl- Shaft Hole clearance
1
inder bottom pin and bushing
–0.043 +0.395
180 0.338 – 0.501 2
–0.106 +0.295
Clearance between pitch cyl- –0.043 +0.5 Replace
2 180 0.343 – 0.605 2
inder bottom pin and bracket –0.106 +0.3
Clearance between pitch cyl- –0.3 +0.5
3 120 0.6 – 1.0 1
inder rod pin and bracket –0.5 +0.3
Clearance between pitch cyl- –0.3 +0.5
4 120 0.6 – 1.0 1
inder rod pin and joint bushing –0.5 +0.3
Clearance between arm and –0.2 +0.3 Adjust shim
5 215 0.2 – 0.6 1
cap –0.3 0 or replace
18
Clearance between joint and –0.2 +3
6 272 1.2 – 3.4 wear plate 9
bracket –0.4 +1 block 9
Clearance between bushing –0.3 +0.3
7 120 0.3 – 0.8 3
and blade bracket –0.5 0
Clearance between frame pin –0.3 +0.2
8 120 0.4 – 0.7 2
and bracket –0.5 +0.1
Clearance between bushing +0.072 +0.156
9 185 0.05 – 0.156 1
and blade bracket 0 +0.122 Replace
Clearance between trunnion –0.5 +0.5
10 280 0.5 – 1.5 8
and cap –1.0 0
Clearance between joint and –0.2 +0.3
11 240 0.3 – 0.7 3
bracket –0.4 +0.1
Clearance between blade pin –0.3 +0.3
12 120 0.3 – 0.8 3
and joint –0.5 0
Clearance between blade pin –0.3 +0.2
13 120 0.4 – 0.7 2
and bracket –0.5 +0.1
Clearance between center
–0.2 +0.3 Adjust shim
14 brace spherical surface and 215 0.2 – 0.6 1
–0.3 0 or replace
cap
Clearance between center link –0.043 +0.5
15 160 0.343 – 0.606 2
pin and center link –0.106 +0.3
16 160 0.343 – 0.606 2
pin and blade bracket –0.106 +0.3
17 450 1.2 – 2.1 5
and blade bracket –1.8 0 Replace
Clearance between blade ball –0.2 +0.5
18 180 0.5 – 0.8 2
shaft and bushing –0.3 +0.3
Clearance between piston rod
–0.2 +0.3
19 spherical surface and blade 170 0.2 – 0.6 10
–0.3 0
ball
D575A-3 SD 10-133
CUTTING EDGES AND END BITS
Unit: mm

1 Height of the outside of end bit
580 (585) 350 (410)
Replace
2 Width of end bit 770 (785) 620 (680)
3 Height of the inside of end bit 400 (450) 340 (345)
Turn or
4 Height of cutting edge 406 346 (up to 286 when turned)
Replace
★ The valves in ( ) are for heavy duty type end bits.
10-134 D575A-3 SD
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD COUNTERWEIGHT
COUNTERWEIGHT
1. Frame OUTLINE
2. Counterweight • To provide the optimum machine weight and
center of gravity for the work, the counterweight
is joined by four pins and installed to the rear of
the main frame.
★ Weight of counterweight: 5,800 kg
D575A-3 SD 10-135
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD COUNTERWEIGHT
Unit:mm

Tolerance Standard
Clearance between counter- Standard size Clearance limit
1 weight frame mounting pin
and frame –0.043 +0.6
125 0.443 – 0.706 1.5
–0.106 +0.4
Clearance between counter-
–0.043 +0.6
2 weight frame mounting pin 160 0.443 – 0.706 1.5
–0.106 +0.4
and frame
10-136 D575A-3 SD
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD AIR CONDITIONER
AIR CONDITIONER
AIR CONDITIONER PIPING
1. PTO case
2. V-belt
3. Air conditioner compressor
4. Vents
5. Air conditioner unit
6. Refrigerant piping
7. Reservoir
8. Condenser unit
9. Hot water pick-up piping
10. Hot water return piping
A. Fresh air
B. Recirculated air
D575A-3 SD 10-137
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD AIR CONDITIONER
AIR CONDITIONER SYSTEM DIAGRAM
1. Engine 11. Pressure switch A. Front glass

2. Valve (for cooling water) 12. Expansion valve B. L.H. door glass
3. Valve (for cooling water) 13. Evaporator C. Rear glass
4. Heater core 14. Thermistor D. Internal air of cab
5. Air conditioner compressor 15. Heat sensing tube E. External air of cab
6. Magnet clutch 16. FRESH/RECIRC selector
7. Coupler 17. Vent selector
8. Condenser 18. Blower
9. Receiver tank 19. Air conditioner unit
10. Coupler
10-138 D575A-3 SD
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD EMGINE CONTROL SYSTEM
ENGINE CONTROL SYSTEM
OUTLINE
The engine controller receives the manual signals Example:
from the No. 1 throttle and No.2 throttle, and the No. When the transmission is at neutral, even if the throt-
3 throttle, which is the control signal from the tle lever is set to the FULL position and the economy
machine. It selects the lowest engine speed from mode is selected, the engine speed is automatically
among these and controls the electronic governor. set to partial.
The control signal from the No. 3 throttle includes the
following.
(1) High idling speed control
(2) 3rd auto deceleration
D575A-3 SD 10-139
HIGH IDLING SPEED CONTROL
FUNCTION
• When waiting for work, if the transmission control
lever is placed at Neutral, the engine speed is
automatically reduced to the deceleration speed
to save fuel and reduce noise.
• When the lever is opereted, the engine speed
rises immediately to the speed set by the lever.
OPERATION
When control lever is at N
• If the engine speed is higher than the decelera-
tion speed and the transmission control lever is
returned to Neutral, the engine speed will imme-
diately be reduced to 100 rpm less than Hi speed
to the No. 1 deceleration speed.
• If 4 more seconds pass, the engine speed will be
reduced to the No. 2 deceleration speed (see
below) and will be held at this speed until the
lever is operated.
(No.2 deceleration speed: speed to match shoe
slip control selection mode)
• OFF
• Economy mode
• REVERSE slow
When lever is operated

• When the engine speed is being held at the No.2
deceleration speed, if any control lever is oper-
ated, the engine speed will rise immediately to
the speed set by the fuel contol dial.
NO. 3 DECELERATION SPEED
FUNCTION
• R3 → set to 1,400 rpm by auto-deceleration
when shifting.
10-140 D575A-3 SD
FUEL CONTROL DIAL
1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
6. Connector
FUNCTION
• The fuel control dial is installed side of the L.H
joystick. A potentiometer is installed under the
knob, and when the knob is turned, it rotates the
potentiometer shaft.
When the shaft rotates, the resistance of the
variable resistor inside the potentiometer
changes, and the desired throttle signal is sent to
the engine throttle • pump controller.
The shaded area in the graph on the right is the
abnormality detection area and the engine speed
is set at low idling
D575A-3 SD 10-141
THROTTLE POTENTIOMETER
1. Connector OUTLINE
2. Lever • The throttle potentiometer is installed under the
3. Body front of the operator’s cab and is interconnected
4. Potentiometer by a link with the decelerator pedal.
5. Coupling • When the decelerator pedal is operated, the link
6. Shaft rotates the shaft of the throttle potentiometer and
7. Stopper the resistance value changes. A constant volt-
age is applied between the No. 1 and No. 3 pins
of the potentiometer, and the voltage signal cor-
responding to the operating position of the decel-
erator pedal is sent from the No. 2 pin.
10-142 D575A-3 SD
ENGINE SPEED SENSOR
1. Magnet FUNCTION
2. Terminal • The engine speed sensor is installed to the ring
3. Case gear portion of the flywheel housing. A pulse
4. Boot voltage is generated by the rotation of the gear
5. Connector teeth, and a signal is sent to the controller.
D575A-3 SD 10-143
ENGINE CONTROLLER
10-144 D575A-3 SD
INPUT AND OUTPUT SIGNALS
D575A-3 SD 10-145
WITH ELECTRONIC ENGINE
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD THROTTLE CONTROLLER
ENGINE CONTROL SYSTEM WITH ELECTRONIC ENGINE

THROTTLE CONTROLLER
SYSTEM DRAWING
OUTLINE
• A fuel injection pump with electronic governor is • The network provides commonality of the data
used. and signals received from the engine controller
• The engine controller receives the signals from and the other controllers, and this contributes to
the sensor and switches, and transmits the con- ensuring optimum control between the engine
trol signal to the governor solenoid and pre- and the machine.
stroke solenoid (proportional solenoid).
10-146 D575A-3 SD
FUEL INJECTION PUMP WITH ELECTRONIC GOVERNOR
STRUCTURAL DIAGRAM
1. Delivery valve FUNCTION

2. Plunger barrel • After the governor actuation pressure is adjusted
3. Plunger by the hydraulic control valve in accordance with
4. Hydraulic piston the command from the engine controller, it acts
5. Hydraulic control valve on the piston at the rear of the rack and moves
(quantity adjustment) the control rack to adjust the fuel infection
6. Hydraulic control valve amount.
(injection timing adjustment) • The fuel injection timing is adjusted by changing
7. Gear pump (as seen from rear, left: oil, right: the length of the injection pump plunger. The
fuel) plunger is formed of two parts, and by sending
8. Center bearing electronically controlled hydraulic pressure
9. Cam shaft between these two parts, the length is changed
10. Roller to adjust the pre-stroke.
11. Tappet • The governor solenoid and pre-stroke solenoid
12. Pump housing are proportional solenoid, and they convert the
13. Tappet guide input current from the controller into propulsion.
14. Spring nut This propulsion controls the spool of the hydrau-
lic control valves (two valves: one for the gover-
nor and the other for the injection timing
adjustment), and converts the input current into
hydraulic power.
D575A-3 SD 10-147
GOVERNOR CUT RELAY
10-148 D575A-3 SD
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD MONITOR SYSTEM
MONITOR SYSTEM
• The machine monitor observes the condition of 3. Function to show error code.
the machine through the sensors installed to var- 4. Function to monitor current and voltage of
ious parts of the machine, and processes this sensors and solenoids.
information quickly. The syatem informs the • The monitor panel has the switch functions for
operator of the condition of the machine by dis- the monitor display functions.
playing the condition on the panel. It has a built-in CPU (Central Processing Unit),
The content of the panel displays can be broadly and processes the data and outputs the display.
divided into the following. The monitor display uses a liquid crystal display
1. Minitor portion that gives warnings when any (LCD). The switches are flat sheet switches.
abnormality occurs in the machine.
2. The gauge portion (coolant temperature,
torque converter oil temperature, fuel level)
that always informs the condeition of the
machine.
D575A-3 SD 10-149
Action by monitor panel (all models)
Monitor panel display
➀ Conditions and content of action ➁ Method ➂ Flow of signals
1) Direction, speed range display F. SW = ON Transmission speed sensor

F1, R3, etc. is informed by S-NET based on R. SW = ON – controller – monitor panel
value from transmission sensor. 1. SW = ON
2. SW = ON
3. SW = ON
S-NET communication
2) Engine speed gauge display S-NET communication Engine speed sensor –
Pulse from engine speed sensor is converted to controller – monitor panel
gauge valve and informed to monitor panel by
S-NET.
3) Troubleshooting display S-NET communication Sensors, solenoids –

When there is failure, appropriate error code is controller – monitor panel
infomed to monitor panel by S-NET. Depending
on nature of failure, information is also sento to
sound buzzer or light up caution lamp.
(1) When normal
User code
(2) When in trouble data display mode Service
code
Monitor panel displays code on hourmeter dis-
plya in turn with hourmeter value.
Monitor panel display
➀ Conditions and content of action ➁ Method ➂ Flow of signals
1) Display condition of S-NET communication, S-NET communication

sensors, and solenoids
Item number, condition of equipment informed Sensors – controller –
to monitor panel by S-NET. monitor panel
Monitor panel displays item on speed range dis-
play and applicable valve on hourmeter display.
2) REVERSE slow button on monitor panel used

to advance item
Buzzer cancel switch used to return to previous Monitor panel – controller –
item (26 items can be displayed.) monitor panel
10-150 D575A-3 SD
MONITOR PANEL
Monitor
1. Display (speed range) 8. Engine water temperature caution lamp

2. Power train oil temperature gauge 9. Transmission oil temperature caution lamp
3. Engine water temperature gauge 10. Hydraulic oil temperature caution lamp
4. Charge lamp 11. Radiator coolant level check lamp
5. Transmission lubricating oil pressure lamp 12. Engine oil level check lamp
6. Engine oil pressure caution lamp 13. Fuel gauge
7. Air cleaner clogging caution lamp 14. Service meter
OUTLINE 2. CHECK items

• The monitor panel consists of the monitor portion 1) After lighting up as explained in Section 1, if
that gives out warnig when any abnormality there is any abnormality in any CHECK item,
occurs in the machine, and the gauge portion that item flashes.
and service meter that always indicate the condi- 2) The CHECK item go out when the engine is
tion of the machine. started.
The monitor and gauge portions each have (The rise in the engine oil pressure is used to
microcomputers that process the signals from judge if the engine is running or not, or if the
each sensor and display the results. voltage from the alternator is more than 10V.)
A liquid crystal display is used.
For details of the items displayed on the monitor 3. CAUTION
and gauge portion, see the table on the next The caution items are checked from the time the
page. engine is started until the time the engine is
stopped.
OPERATION If there is any abnormality, the item flashes, and
1. Power switched on (starting switch ON) the warning lamp also flashes.
1) All items on the gauge and monitor light up If any item in CAUTION 2 flashes, the alarm
for 3 seconds. buzzer also sounds.
2) The warning lamps light up for 2 seconds ★ The monitor and warning lamps flash in an ON-
and the alarm buzzer sounds for 1 seconds. OFF cycle of approx. 0.8 sec.
★ The flashing cycle of the monitor may change
slightly if the ambient temperature is low (approx.
– 10°C or below), but this is not an abnormality.
D575A-3 SD 10-151
MONITOR PANEL DISPLA
Display
Symbol Display item Display range Display method
category
Displays when engine is

Radiator water level Below low level
stopped and starting
switch is ON
Display when normal:
OFF
Engine oil level Below low level Display when abnormal:
CHECK
Flashes
Display when normal:

When sensor is abnormal
OFF
Engine oil pressure or when wiring harness is
Display when abnormal:
disconnected
ON
Battery charge When charge is defective
Display when starting

switch is ON and engine
is running
C A U TIO N When clogged:
Air cleaner clogging Display when mormal:
1 Less then - 650 mmH2O
OFF
Flashes
CAUTION lamp flashes
Transmission lubricating Below 0.25 MPa
oil pressure {2.5 kg/cm2}
Below 49.03 kPa

Engine oil pressure
{0.5 kg/cm2}
Radiator water level Below low level

Display when starting
switch is ON and engine
is running
When at highest level
C A U TIO N Display when mormal:
Engine water tempera- (108°C or above) on
2 OFF
ture engine water tempera-
ture gauge
Flashes
When at highest level CAUTION lamp flashes
Torque converter oil (130°C or above) on Alarm buzzer sounds
temperature torque converter temper-
ature gauge
Hydraulic oil tempera-

105 ± 3°C or above
ture
10-152 D575A-3 SD
Display
Symbol Display item Display range Display method
category
Engine water tempera-

ture
One place lights up to

show applicable level
Torque converter oil tem-

Gauge
perature
All lamps light up below

Fuel level
applicable level
Actuated when alternator

S ervice
Hourmeter From 0 to 99999 is charged. Advances by
m eter
1 hour for every hour.
D575A-3 SD 10-153
SWITCHES
1. Lock-up mode switch

2. Economy mode switch
3. Reverse slow mode switch
OUTLINE Switch actuation table

• The mode selection panel has 3 mode selection
Item Actuation
switches. The selection mode changes each
time the switches are pressed. Lock-up mode ON ↔ OFF
The LED lights up to display the existing condi- Economy mode OFF ↔ 1 ↔ 2
tion. Reverse slow mode OFF ↔ ON
★ The bold letters indicate the default position of

the switch when the starting switch is turned ON.
10-154 D575A-3 SD
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD SENSOR
SENSOR
• The signals from the sensors are input directly to
the machine monitor panel.
Of the contact type sensors, the radiator water
level and hydraulic oil temperature sensors must
always be grounded on one side to the chassis.
When the points close and the signal wire is con-
nected to the chassis, the panel judges this as a
normal signal.
Type of sensor Sensor method When normal When abnormal
Engine oil level Contact ON OFF
Radiator water level Contact ON OFF
Hydraulic oil temperature Contact ON OFF
Transmission lubrication oil pressure Contact ON OFF
Engine oil pressure Contact OFF ON
Engine water temperature Resistance — —
Torque converter oil temperature Resistance — —
Fuel levelResistance Resistance — —
RADIATOR WATER LEVEL SENSOR
1. Ring FUNCTION
2. Float • The radiator water level sensor is installed to the
3. Switch radiator upper tank. When the cooling water
4. Bracket drops below the specified level, float (2) goes
5. Connector down and switch (3) goes OFF. The monitor
panel display and the alarm buzzer sounds.
D575A-3 SD 10-155
FUEL LEVEL SENSOR
1. Connector FUNCTION
2. Float • The fuel level sensor is installed at the inside of
3. Arm the fuel tank. Float (2) moves up and down
4. Body according to the amount of fuel remaining.
5. Spring The movement of the float actuates the variable
6. Contact resistance.
7. Spacer On the monitor panel, the signal is received and
if it is below the appropriate range for the gauge
display, all lamps light up.
10-156 D575A-3 SD
HYDRAULIC OIL TEMPERATURE SENSOR
1. Switch FUNCTION
2. Plug • The hydraulic oil temperature sensor is installed
3. Tube in the inlet tube of the hydraulic pump. It detects
4. Wire the temperature with switch (1), and when the
5. Connector temperature goes above the specified tempera-
ture, the switch goes OFF. The monitor panel
display and the alarm buzzer sounds.
ENGINE OIL PRESSURE SENSOR
1. Plug FUNCTION
2. Contact ring • This sensor is installed to the engine oil filter
3. Contact housing. The diaphragm detects the oil pres-
4. Diaphragm sure, and when it drops below the standard pres-
5. Spring sure, the switch is turned ON, and the lamp lights
6. Terminal up to warn of the abnormality.
Less than the specified pressure:
ON (the display lamp lights up)
More than the specified pressure:
OFF (the display lamp goes off)
D575A-3 SD 10-157
ENGINE WATER TEMPERATURE SENSOR

TORQUE CONVERTER OIL TEMPERATURE SENSOR
1. Thermistor FUNCTION
2. Body • The engine water temperature sensor is installed
3. Tube to the thermostat housing at the front top of the
4. Tube left side of the engine. Thermistor (1) detects the
5. Wire temperature and sends a signal to the monitor
6. Connector panel.
On the monitor panel, when this signal enters the
appropriate range for the gauge display, the
gauge lights up. If the temperature is above the
specified temperature, the monitor panel display
and warning lamp flash.
• The torque converter oil temperature sensor is
installed in the torque converter outlet tube on
the left side of the torque converter case, and it
acts in the same way as the engine water tem-
perature sensor.
ENGINE OIL LEVEL SENSOR
1. Float FUNCTION
2. Sensor • The engine oil level sensor is installed to the side
3. Tube face of the engine oil pan. When the engine oil
4. Wire level goes below the specified level, float (1)
5. Connector goes down and sensor (2) is turned OFF. A dis-
play appears on the monitor panel and the warn-
ing buzzer sounds.
10-158 D575A-3 SD
TRANSMISSION LUBRICATION OIL PRESSURE SENSOR
1. Body FUNCTION
2. Diaphragm • The transmission lubrication oil pressure sensor
3. Cap is installed to the transmission lubrication filter
4. Connector inlet tube. If the transmission lubrication oil pres-
sure goes below the set pressure, diaphragm (2)
rises and the contact is turned OFF.
When the contact goes OFF, the monitor panel
display lights up.
CAUTION BUZZER
1. Connector
2. Cable
3. Case
4. Ring
5. Grill
D575A-3 SD 10-159
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD MODE SELECTION SYSTEM
MODE SELECTION SYSTEM

SYSTEM DIAGRAM
OUTLINE • The lock-up control mode is the same as the con-

• The mode selection system automatically carries ventional lock-up function. It cannot be selected
out engine control to match the operating mode in combination with the economy mode,
selected by the operator, and acts to reduce fuel
consumption, extend the life of the track shoes.
• The engine control modes consist of the econ-
omy mode control used when dozing, and the
reverse slow mode control, whitch can be used
for either operation.
10-160 D575A-3 SD
FUNCTIONS OF MODE SELECTION

SYSTEM
• The mode selection system consists of the mode

selection panel (with built-in microcomputer) with
selects the operating mode, the machine control-
ler (with built-in microcomputer) which goberns
the engine control, the electronic engine throttle
controller (with built-in microcomputer) which
receives the command from the machine control-
ler and controls the fuel injection pump, the lock-
up controller which switches the lock-up of the
torque converter ON/OFF according to the
torque converter dividing pulse output by the
machine controller, and various sensors.
The following is an explanation of the functions
of each controller.
Functions of machine controller

1. It has a function which divides the bevel gear
shaft speed pulse and when the monitor panel
lock-up mode is input, it sends the divided torque
converter pulse signal to the lock-up controller.
2. The machine controller judges from the input
torque converter dividing pulse and the transmis-
sion oil pressure signal, and sends the lock-up to
the lock-up solenoid valve.
★ For details , see STRUCTURE AND FUNC-
TION, Operation of torque converter lock-up
control system.
Functions of engine controller

1. It follows the lower engine speed (higher voltage)
of the two signals (the manual command input
from the throttle potentiometer and the decelera-
tion potentiometer), and sends an electric cur-
rent signal to the governor solenoid to control the
engine.
★ For details , see STRUCTURE AND FUNC-
TION, Engine control system with electronic
engine throttle controller.
D575A-3 SD 10-161
OPERATION OF MODE SELECTION SYSTEM
• It is possible to select the three modes individually or in combination to carry out work under the optimum
conditions for the type of work.
Opera- Mode Indepen- Com-

tion
dent poundt
switch selection selection Mode actuation coditions Actuation, features of mode
• Automatically switches ON/OFF 1. When torque converter approaches stall range

according to the load or when gear is shifted, lock-up is turned OFF;
when there is light load, lock-up is turned ON.
ON OFF 2. Impossible to select combined operation with
Lock-up
Torque Between Max. economy mode.

! ! converter
1,260 rpm
1,230 rpm 3. Suitable for dozing operations where there is
output or
and comparatively little change in load.
shaft 1,870 rpm
Min.
speed 1,930 rpm
Speed F1, F2 F3, R3

rang R1, R2
When transmission is at F1 with econ- 1. Economy control is carried out when the trans-
Dozing
omy mode switch (1) or (2) ON mission is shifted to F1.

2. The engine output can be controlled to 2 lev-
Economy
els without operating the engine deceleration.

! !
Mode (1): 90% (at 1.5 km/h)
Mode (2): 65% (at 1.5 km/h)
3. At neutral, the engine speed is reduced to par-
tial speed.
When transmission is at R1, R2, R3 1. The engine output can be controlled to partial
Reverse slow
without operating the engine deceleration.

Engine speed when in traveling reverse: 1400
! ! !
– 1600 rpm
2. Set speed when traveling in reverse
R1, R2, R3: 70% of full throttle
★ When the above modes are set, it is possible to operate the fuel control lever and decelerator pedal. In
such cases, the engine output control is carried out according to the minimum value command from the con-
troller command, throttle command, and deceleration command.
10-162 D575A-3 SD
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD BLADE CONTROL SYSTEM
BLADE CONTROL SYSTEM
1. Blade control lever 8. Pitch selector solenoid

1A. Pitch back switch 9. Pitch priority solenoid
1B. Pitch dump switch 10. 1 pump cut solenoid
2. Blade raise switch 11. Pitch assist solenoid
3. Transmission controller 12. Blade valve
4. Pitch dump solenoid 13. Blade pitch cylinder
5. Pitch back solenoid 14. Blade lift cylinder
6. Right tilt limit solenoid 15. Hydraulic pump
7. Left tilt limit solenoid 16. Engine speed sensor
D575A-3 SD 10-163
OUTLINE Blade tilt limit control

• The difference from the average of the blade
Blade pitch control yoke angles is calculated according to the left
• When the pitch back switch on the blade control and right cylinder yoke angle sensor signals.
lever is pressed, the pitch solenoid, right tilt limit • The blade yoke angle average is used as the
solenoid, and pitch priority solenoid are turned parameter, and the blade yoke angle difference
ON. limit is calculated and the tilt limit is actuated
After 50 msec, the pitch back solenoid is turned according to the following conditions.
ON and PPC pressure acts on the pitch back 1) When the yoke angle difference is greater
end of the blade valve spool. than the (+) limit value, the left tilt limit sole-
• When the pitch dump switch on the blade control noid is turned ON.
lever is pressed, the pitch selector solenoid, left 2) When the yoke angle difference is smaller
tilt limit solenoid, and pitch priority solenoid are than the (–) limit value, the right tilt limit sole-
turned ON. noid is turned ON.
After 50 m.sec, the pitch dump solenoid is turned 3) If the above conditions are fulfilled when
ON and PPC pressure acts on the pitch dump operating the pitch, the tilt limit is actuated to
end of the right and left blade pitch spool. stop the pitch direction.
★ When the tilt limit is actuated, the tilt limit
Pitch assist pump control lamp lights up.
• The pitch assist solenoid is driven by the follow- (When the night lighting is ON, the lock-
ing logic. up lamp becomes dim.)
OFF conditions (when any of the following condi- Auto pitch back control
tions are fulfilled) • If the following condition is fulfilled, the blade can
1) When the pitch selector solenoid is OFF be reset automatically.
2) When the engine speed is below 700 rpm 1) When a traction force larger than 0.3 W is
3) When driving in F1 torque converter drive, generated while traveling forward in F1 or F2
with the travel speed below 1 km/h and the • If any of the following conditions is fulfilled, the
drawbar pull value more than 0.75 W blade cannot be reset automatically.
4) When driving in F2 with the travel speed less 1) When the neutral state continues for more
than 1.5 km/h than 30 seconds
2) When the transmission gear is shifted into
ON conditions (when all the following conditions neutral, then into a forward travel position
are fulfilled) • If any of the following conditions is fulfilled while
1) When none of the OFF conditions are ful- the blade can be reset automatically and the
filled (OFF conditions are given priority) machine is traveling in reverse, the blade is
2) When the engine speed is more than 800 pitched back automatically.
rpm 1) When the lift raise PPC oil pressure switch is
3) When more than 2 sec. has passed after turned ON
either 3) or 4) of the OFF conditions have 2) When the pitch back knob switch is turned
been canceled. ON
★ If any of the above conditions are not ful- • If any of the following conditions is fulfilled while
filled, the existing condition is main- the blade is pitched back automatically, the blade
tained. pitch back function is reset.
1) When time passes more than 0.5 seconds
after the reverse oil pressure switch is turned
off
2) When the pitch dump switch is turned ON
3) When the pitch back switch is kept turned
ON for more than 2 seconds
4) When the average yoke angle is reduced to
below 27 degrees.
10-164 D575A-3 SD
SENSOR
CYLINDER ANGLE SENSOR
1. Yoke
2. Rod
3. Angle sensor
Angle sensor
1. Potentiometer FUNCTION
2. Shaft • This is installed to the left and right lift cylinder
3. Connector yokes and detects the movement angle of the
left and right lift cylinders through a rod.
• When the blade moves, the potentiometer shaft
rotates and the resistance changes. A fixed volt-
age is applied to pins No. 1 – 3 of the potentiom-
eter, and a voltage signal corresponding to the
position of the blade is sent from No. 2 pin to the
blade controller.
D575A-3 SD 10-165
BLADE RAISE OIL PRESSURE SWITCH
1. Sensor FUNCTION
2. Connector • The oil pressure switchs are installed to the pitch
priority solenoid valve black and the signals are
sent to the controller.
10-166 D575A-3 SD
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD ACTUAL ELECTRICAL WIRING DIAGRAM
ACTUAL ELECTRICAL WIRING DIAGRAM

(1/2)
10-168 D575A-3 SD
D575A-3 SD 10-169
(2/2)
10-170 D575A-3 SD
1. Horn 58. Air conditioner wiring harness

2. Front lamp 59. Steering controller
3. Radiator water level sensor 60. Transmission controller
4. Right cylinder stay yoke angle sensor 61. Fuel control dial
5. Front lamp 62. Engine controller
6. Right side lamp 63. Fuse box
7. Right battery 64. Shift up-down switch
8. Right battery relay 65. Alarm buzzer
9. PPC lift RAISE oil pressure switch 66. Warning lamp
10. Torque converter oil temperature sensor 67. Shift mode pilot lamp
11. Engine oil pressure sensor
12. ROPS lamp
13. Rear lamp
14. ROPS lamp
15. Torque converter lock-up solenoid
16. Transmission lubricating oil pressure switch
17. Transmission modulating oil pressure switch
18. ROPS lamp
19. ROPS lamp
20. R.H clutch ECMV
21. L.H clutch ECMV
22. R.H brake ECMV
23. L.H brake ECMV
24. Working lamp
25. Bevel gear speed sensor
26. Backup alarm
27. Rear lamp
28. Transmission 1st clutch ECMV
29. Backup alarm switch
30. Transmission 2nd clutch ECMV
31. Transmission 3rd clutch ECMV
32. Transmission F clutch ECMV
33. Transmission R clutch ECMV
34. Air conditioner compressor
35. Alternator
36. Hydraulic oil temperature gauge
37. Hydraulic pump oil pressure sensor
38. Left battery
39. Left side lamp
40. Left battery relay
41. Pitch asist control valve solenoid
42. Starting motor
43. Left cylinder stay yoke angle sensor
44. Engine oil level sensor
45. Coolant temperature sensor
46. Knob switch (pitch control button)
47. Torque converter lock up pilot lamp
48. Horn switch
49. Monitor panel
50. Auto pitch back switch
51. Front lamp switch
52. Rear lamp, working lamp switch
53. Quick start switch
54. Auto shift down switch
55. Buzzer cancel switch
56. Starting switch
57. Cab wiring harness
D575A-3 SD 10-171
20 TESTING AND ADJUSTING
Standard value table for engine........................... 20-2

Standard value table for chassis ......................... 20-3
Standard value table for electrical related parts .. 20-9
Testing and adjusting ...................................... 20-101
Troubleshooting............................................... 20-201
★ Note the following when making judgements using the standard value tables for testing, adjusting, or trou-
bleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the machine from
the factory and is given for reference. It is used as a guideline for judging the progress of wear after the
machine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on the
results of various tests. It is used for reference together with the state of repair and the history of operation
to judge if there is a failure.
3. These standard values are not the standards used in dealing with claims.
When carrying out testing, adjusting or troubleshooting, park the machine on level ground, insert the
safety pins, and use blocks to prevent the machine from moving.
When carrying out work together with other workers, always use signals and do not let unauthorized peo-
ple near the machine.
When checking the water level, always wait for the water to cool down. If the radiator cap is removed
when the water is still hot, the water will spurt out and cause burns.
Be careful not to get caught in the fan, fan belt or other rotating parts.
D575A-3 SD 20-1
➀
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE
Engine SA12V170E-2
Item Measurement conditions Unit Standard value Service limit

for new machine value
High idling 1,980 ± 50 —
Engine Speed Low idling rpm 650 ± 50 —
At rated speed 1,800 —
Sudden acceleration Bosch Max. 6.0 8.0

Exhaust color At high idling index Max. 1.5 2.5
Exhaust gas temperature Whole speed range °C Max. 700 700

(At turbocharger inlet port) (Atmosphere temperature: 20°C)
Intake valve (20°C) 0.4 —

Valve clearance mm
Exhaust valve (20°C) 1.0 —
Compression pressure Oil temperature: 40 - 60°C MPa Min. 2.9 2.1

SAE30 oil {kg/cm2} {Min. 30} {21}
Engine speed: 160 - 200 rpm
(Water temperature inside operating

Blow-by pressure range) kPa Max. 5.88 11.77
At rated speed (SAE30 oil) {mmH2O} {Max. 600} {1,200}
(Water temperature inside operating

range)
At lhigh idling (SAE30) Max. 0.30 - 0.54 —

{Min. 3.0 - 5.4}
MPa Min. 0.10

Oil pressure At low idling (SAE30) {kg/cm2} {Min. 1.0} —
Min. 0.23 - 0.47

At lhigh idling (SAE10W) {Min. 2.3 - 4.7} —
At low idling (SAE10W) Min. 0.8 —

{Min. 8.0}
Oil temperature Whole speed range (inside oil pan) °C 80 - 110 120
Fuel injection timing Compression B.T.D.C. degree 17 ± 1 17 ± 1
Alternator drive belt tension Slack when pushed with finger force 13 - 17 —
of 98.1 N (10 kg}
mm
Air conditioner
compressor drive belt Slack when pushed with finger force 13 - 17 —
tension of 98.1 N (10 kg}
20-2 D575A-3 SD
➀
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR CHASSIS
Cate- Item Measurement conditions Unit Standard Permissible

gory value value
• Engine oil pressure:

Torque converter stall within operating range
speed 1,630 ± 50 Min. 1,550
• Engine oil temperature:
within operating range
• Power train oi temperature:
Engine speed
Torque converter stall 70-80°C

+
Work equipment • Hydraulic oil temperature: 1,440 ± 60 Min. 1,350
rpm
pump relief speed 45-55°C
• No. of speed range: F3
1st step 1,200 + 50 1,200 + 50

0 0
Decel slow idling
2nd step 950 ± 50 950 ± 50
1st step 38 ± 5 38 ± 5
• Engine stopped
Decelerator pedal mm
• Center of pedal
2nd step 48 ± 5 48 ± 5
N - FORWARD 30 ± 3 30 ± 3
• Engine stopped
Directional mm
• Center of lever knob
N - REVERSE 30 ± 3 30 ± 3
joystick
Full stroke
40 ± 5 40 ± 5
(N-Left, right)
• Engine at low idling
Operating effort of control lever, pedal
Steering mm
Until clutch is com- 10 ± 2 10 ± 2
pletely disengaged (Play:Max.3mm) (Play:Max.3mm)
Total travel 95 ± 5 95 ± 5
• Engine at low idling
Brake pedal Position until brake mm
• Center of pedal
oil pressure becomes 78 ± 5 78 ± 5
0 Mpa {0 kg/cm2}
• Engine at low idling HOLD - RAISE 70 ± 10 70 ± 10

• Hydraulic oil tempera-
Blade lever mm
ture: 45-55°C
• Center of lever knob HOLD - Left, right tilt 70 ± 10 70 ± 10
58.8 ± 4.9 58.8 ± 4.9

1st step {6.0 ± 0.5} {6.0 ± 0.5}
• Engine stopped
Decelerator pedal {kg}
• Center of pedal
2nd step 166.7 ± 4.9 166.7 ± 4.9
{17.0 ± 0.5} {17.0 ± 0.5}
FORWARD - N 44.1 ± 2 44.1 ± 2

{4.5 ± 0.2} {4.5 ± 0.2}
• Engine stopped
Directional {kg}
REVERSE - N 44.1 ± 2 44.1 ± 2
{4.5 ± 0.2} {4.5 ± 0.2}
D575A-3 SD 20-3
➀

gory value value
Until clutch is
completely 98± 1 98± 1
{1.0 ± 0.1} {1.0 ± 0.1}
disengaged
Left
Until machine turns
19.6 ± 4.9 19.6 ± 4.9
Operating effort of control lever, pedal
when brake is
{2.0 ± 0.5} {2.0 ± 0.5}
• Engine at low
joystick
applied
Steering idling N
{kg}
• Center of pedal Until clutch is
completely 11.8 ± 1 11.8 ± 1
{1.2 ± 0.1} {1.2 ± 0.1}
disengaged
Right
Until machine turns
when brake is 24.5 ± 4.9 24.5 ± 4.9
{2.5 ± 0.5} {2.5 ± 0.5}
applied
• Engine at low idling N 372.7 ± 52 Max. 490

Brake pedal
• Center of pedal {kg} {38 ± 5.3} {Max. 5.0}
• Engine at low idling HOLD - RAISE 25.5 ± 4.9 25.5 ± 4.9

{2.6 ± 0.5} {2.6 ± 0.5}
• Hydraulic oil tempera- N
Blade lever
ture: 45-55°C {kg}
25.5 ± 9.8 25.5 ± 9.8
• Center of lever knob HOLD - Left, right tilt
{2.6 ± 1.0} {2.6 ± 1.0}
20-4 D575A-3 SD
➀

gory value value
0.1 - 0.29 0.1 - 0.29

Engine at low idling
{1 - 3} {1 - 3}
Torque conveter relief
pressure (input)
0.74 - 0.93 0.74 - 0.93
Engine at high idling
{7.5 - 9.5} {7.5 - 9.5}
0.05 - 0.25 0.05 - 0.25

Engine at low idling
{0.5 - 2.5} {0.5 - 2.5}
Torque converter
outlet port pressure
0.59 - 0.78 0.59 - 0.78
{6 - 8} {6 - 8}
1.96 - 2.65
Engine at low idling —
{20 - 27}
Transmission main
relief pressure
2.26 - 2.75
Engine at high idling 2.26 {23}
{23 - 28}
1.96 - 2.65
Power train oil pressure
{20 - 27}
Transmission main MPa
actuation pressure {kg/cm2}
2.26 - 2.75
• Power train oil tempera- {23 - 28}
ture: 70-80°C
0.01 - 0.05
{0.1 - 0.5}
Transmission
lubrication pressure
0.05 - 0.15 0.05 - 0.15
{0.5 - 1.5} {0.5 - 1.5}
1.96 - 2.65
Engine at low idling 1.96 {20}
{20 - 27}
Steering clutch
actuating pressure
2.26 - 2.75
{23 - 28}
1.96 - 2.65
Engine at low idling 1.96 {20}
{20 - 27}
Brake actuating
pressure
2.26 - 2.75
{23 - 28}
Brake reducing Engine at high idling {kg/cm2} {11 ± 0.5} {11 ± 0.5}
pressure
Work eguipment oil pressure
Low idling 2.4 - 3.1 2.4 - 3.1

PPC inlet pressure
Full throttle 2.4 - 3.5 2.4 - 3.5
• Hydraulic oil tempera- MPa
ture: 45-55°C {kg/cm2} 17.6 - 20.6 Min. 16.7
Low idling
Blade pith back relief {180 - 210} {Min. 170}
pressure
(Front & rear pump) 19.6 - 21.6 18.6 - 21.6
Full throttle
{200 - 220} {190 - 220}
D575A-3 SD 20-5
➀

gory value value
Posture of work equipment

Engine
low 13 - 21 Max. 25
idling
RAISE
Full
throttle 4.5 - 6 Max. 7
Blade speed (lift)

Engine
low 1.5 - 2.0 1.5 - 2.0
idling
LOWER
• Hydraulic oil temperature:
45 - 55°C
• Blade: no load Full
• From ground to maximum throttle 1.5 - 2.0 1.5 - 2.0
height
Low
5 - 10 Max. 11
LEFT TILT idling
Full 2-3 Max. 5

throttle
Blade speed (tilt)
Low
• Hydraulic oil temperature: 7 - 12 Max. 14
RIGHT TILT
idling
Work equipment
45 - 55°C
• Blade: no load
• Left tilt - Right tilt Full sec.
3-4 Max. 6
throttle
Pitch 5.8 - 7 Max. 8

dump
Blade speed (pitch)

TAD00440

Pitch
45 - 55°C back 5.8 - 7 Max. 8
• Blade: no load
• Pitch dump – pitch back
• Engine at high idling

45 - 55°C Engine
• Lower the blade from the maxi- low Max. 10 Max. 12
idling
mum height, and measure the
Time lag (blade) time taken from the point when
the blade touches the ground
to the point where the idler is Engine
raised from the ground full Max. 1.8 Max. 1.5
throttle
20-6 D575A-3 SD
➀
Cate- Standard Permissible

gory Item Measurement conditions Unit value value
Hydraulic drift
(blade lift) Max. 150/5 Max. 200/5
• Hydraulic oil temperature: 45 - 55°C

• Engine stopped
• Center of blade cutting edge: from height of 800
mm to ground
mm/
Posture of work equipment min.
Hydraulic drift
TBD00441
(machine moves Max. 50/15 Max. 100/15
Work equipment
down)
• Hydraulic oil temperature: 45 - 55°C
• Engine stopped
• Blade pushed down, movement at center of
idler
LEFT TILT Max. 8 Max. 3
Hydraulic drift min.

(blade tilt)
45 - 55°C
• Set blade at max.
• tilt to raise machine.
• Measure time taken from RIGHT TILT Max. 8 Max. 3
immediately after stopping
engine to point where tracks
touche the ground.
D575A-3 SD 20-7
➀

gory value value
• On level surface 1st 19.5 (3.7) 19.5 (3.7)

• Engine at full throttle
• Engine water temperature:
F 2nd 10.6 (6.8) 10.6 (6.8)
Inside operating range
• Run-up distance:
Performance
• 10 - 30 m 3rd 6.0 (12.0) 6.0 (12.0)

• Measurement distance: 20 m sec.
Travel speed (km/h)
1st 16.0 (4.5) 16.0 (4.5)
R 2nd 9.0 (8.0) 9.0 (8.0)
3rd 5.2 (13.8) 5.2 (13.8)
20-8 D575A-3 SD
➀
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS
STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS
Inspec-
Sys- Name of component Connector tion Judgment table Measurement
tem No. methd conditions
If the condition is as shown in the table below, it 1) Turn starting
resistance
is normal swithc OFF.
Measure
2) Disconnect
Between (1) – (2) 500 – 1,000 Ω connector.
Between (1) – chassis Min. 1 MΩ
Measure with AC range 1) Start engine.
Measure
EG2
voltage
Engine speed sensor 2) Insert T-
(male) Between (1) – (2) 0.5 – 3.0 V adapter.
1) Screw in until speed sensor contacts ring gear,

Adjust
then turn back 3/4 turns.

2) Sensor should work normally when adjusted as
above.

resistance
is normal swithc OFF.

Measure
2) Disconnect
Between (1) – (2) 500 – 1,000 Ω connector.
Measure with AC range 1) While

Measure
Bevel gear speed TC1

voltage
traveling.
sensor (male) Between (1) – (2) 0.5 – 3.0 V 2) Insert T-
adapter.
Controller
1) Adjust with shims so that gap between bevel

Adjust
gear and speed sensor is 1 mm.

2) Sensor should work normally when adjusted as
above.

is normal switch OFF.
2) Disconnect
All resistances connector.
Measure resistance
Between CSL (3) – (1)

4 – 6 kΩ
Left yoke angle CSL Between CSR (1) – (3)
sensor (male) Signal
Right yoke angle CSR Between CSL (2) – (1)
sensor (male) 0.25 – 5.7 kΩ
Between CSR (2) – (3)
Signal
Between CSL (2) – (3)
0.25 – 5.7 kΩ
Between CSR (2) – (1)
If the condition is as shown in the table below, it 1) Start engine

is normal and operate
Measure resistance
lift lever to
Between Lever at neutral Min. 1 MΩ end of
(1) – (2) Lever operated Max. 1 Ω stroke.
PPC lift RAISE oil PP2 2) Disconnect
pressure switch (male) connector.
(lever at neutral)
D575A-3 SD 20-9
➀
Inspec-
If the condition is as shown in the table below, it 1) Engine
Measure resistance
Transmission pilot oil is normal stopped or
pressure switch started.
Between Engine stopped Max. 1 Ω 2) Disconnect
F TMF (male)
(1) – (2) Engine started Min. 1 MΩ connector.
R TMR (male)
1st TM1 (male)
2nd TM2 (male)
3rd TM3 (male) (engine started)
If the condition is as shown in the table below, it 1) Engine

Measure resistance
is normal stopped or
started.
Between Engine stopped Min. 1 MΩ 2) Disconnect
Transmission
(1) – (2) Engine started Max. 1 Ω connector.
modulating oil pressure TMM (male)
switch
Between (1) – chassis
(engine stopped) Min. 1 MΩ

resistance
Measure
Pitch selector solenoid P-1 (male) 2) Disconnect

Between (1) – (2) 10 – 40 Ω connector.
Pitch priority solenoid SL7 (male) Between (1), (2) – chassis Min. 1 MΩ
Controller

Pitch assist solenoid is normal switch OFF.
resistance
Measure
2) Disconnect
Left assist SL5 (male) Between (1) – (2) 10 – 40 Ω connector.
Between (1), (2) – chassis Min. 1 MΩ
Right assist SL6 (male)

resistance
Measure
2) Disconnect
Pitch assist solenoid Between (14) – (5) 260 – 360 Ω
358 (male) connector.
relay
Pitch/tilt selector If the condition is as shown in the table below, it 1) Turn starting
Measure resistance
solenoid is normal switch OFF.

2) Disconnect
Pitch back SL1 (male) Between (1) – (2) 30 – 80 Ω connector.
Pitch dump SL3 (male)
Left tilt limit SL2 (male)
Right tilt limit SL4 (male)

resistance
Measure
2) Disconnect
Torque converter lock- Between (1) – (2) 30 – 80 Ω connector.
LU2 (male)
up solenoid
20-10 D575A-3 SD
➀
Inspec-
1) Turn starting
Measure voltage
If the condition is as shown in the table below, it
is normal switch ON.
SE1 2) Insert
Power source Between SE1 (8), (16) – (7) 20 – 30 V T-adapter.
voltage SE4 Between SE4 (6) –(21) 20 – 30 V
1) Turn starting
Measure voltage
If the condition is as shown in the table below, it
Engine speed SE3 is normal switch ON.
sensor 2) Insert
Between (8) – (16) Max. 2.2 V T-adapter.
Bevel gear speed SE1 Between (17) –(3) Max. 2.7 V
sensor

2) Insert
Between (14) – (15) 4.75 – 5.25 V T-adapter.
Measure voltage
Right yoke angle (Power source)

sensor
potentiometer Between Max. pitch back
SE3 R.H. (1) – (15) (in contact with 3.5 ± 0.25 V
Left yoke angle ground)
sensor Max. pitch back
potentiometer Between
L.H. (2) – (15) (in contact with 1.5 ± 0.25 V
ground)
If it is not within this range, adjust the length of
the rod.
Controller
Controller

Measure voltage

2) Insert
Memory clear When switch T-adapter.
switch SE2 is ON Max. 1 V
Between (1)
(NVRAM clear) – chassis When switch
is OFF 20 – 30 V

is normal switch OFF
→ ON.
Within 2 sec. after 2) Insert
Measure voltage
turning starting T-adapter.

switch ON
Monitor caution (switches ON-OFF Max. 5 V
lamp input signal SE2 Between (2) every 2 sec. when
– chassis monitor caution
items flash)
Within 2 sec. after
turning starting 20 – 30 V
switch ON
If the condition is as shown in the table below, it 1) Start engine.

is normal 2) Insert
Measure voltage
T-adapter.
Between • Lift lever at
PPC lift oil pressure RAISE (3) – Max. 1 V
switch max. stroke
SE2 chassis
RAISE switch Between • Lift lever at
LOWER (16) neutral 20 – 30 V
– chassis
D575A-3 SD 20-11
➀
Sys- Connector Inspec- Measurement

tem Name of component No. tion Judgment table conditions
methd
Measure voltage
2) Insert
Buzzer cancel When switch T-adapter.
SE2 is ON Max. 1 V
switch Between (3)
– chassis When switch
is OFF 20 – 30 V

Measure voltage
2) Insert
Blade control • Pitch dump T-adapter.
between (5) When switch Max. 1 V
knob switch is OFF
SE2 – chassis
Pitch dump • Pitch back
Pitch back between (6) When switch 20 – 30 V
– chassis is ON

Measure voltage

2) Insert
When light 20 – 30 V T-adapter.
Lighting signal SE2 switch is ON
Between (7)
– chassis When light Max. 1 V
switch is OFF
Controller
Controller

2) Insert
Between 1st T-adapter.
Transmission pilot (11) – chassis
Measure voltage
oil pressure switch Between 2nd • When

(12) – chassis engine is Max. 1 V
1 st switch stopped
SE2 Between 3rd
2 nd switch
3 rd switch (13) – chassis
F switch • When
R switch Between F (9) engine is 20 – 30 V
– chassis started
Between R
(10)– chassis

Measure voltage

2) Insert
Transmission When engine
modulating oil SE2 20 – 30 V T-adapter.
Between (14) is stopped
pressure switch
– chassis When engine Max. 1 V
is started

Measure voltage

2) Insert
Torque converter When switch T-adapter.
SE2 is ON Max. 1 V
lock-up switch Between (15)
– chassis When switch
is OFF 20 – 30 V
20-12 D575A-3 SD
➀

methd
Measure voltage
2) Insert
When pitch T-adapter.
Pitch selector is actuated Max. 1 V
SE1 Between
solenoid
(4) – (7) When pitch is
not actuated 20 – 30 V

Measure voltage 2) Insert
Pitch/tilt selector Pitch dump T-adapter.
solenoid between When pitch Max. 1 V
(14) – (7) is actuated
SE1
Pitch dump
Pitch back
between When pitch is 20 – 30 V
Pitch back not actuated
(15) – (7)

Measure voltage
2) Insert
Pitch/tilt selector When tilt T-adapter.
solenoid Between R.H. limit is Max. 1 V
(6) – (7) actuated
SE1
Right tilt limit
When tilt
Between L.H. limit is not 20 – 30 V
Left tilt limit (5) – (7) actuated
Controller
Controller

Measure voltage

2) Insert
Between When normal Max. 1 V T-adapter.
Pitch priority (11) – (21)
solenoid SE4

Measure voltage

2) Insert
At pitch T-adapter.
Pitch assist dump Max. 1 V
SE4 Between
solenoid relay
(10) – (21) Other than
above 20 – 30 V

Measure voltage
2) Insert
When lock-up T-adapter.
is actuated Max. 1 V
Torque converter SE4 Between
lock-up solenoid (19) – (21) When lock-up
is not actu- 20 – 30 V
ated
D575A-3 SD 20-13
➀

methd

Measure voltage
2) Insert
Caution buzzer 2.5 – 3 sec. T-adapter.
Alarm buzzer between(9) – after switch Max. 1 V
SE4 (21) ON
Buzzer selector
relay Buzzer selector Other than
relay between above 20 – 30 V
(20) – (21)
Controller
Controller

Measure voltage
2) Insert
Caution T-adapter.
Caution lamp betwee When lamp is Max. 1 V
(3) – (21) ON
Torque converter SE4
lock-up lamp Lock-up
between When lamp is 10 – 30 V
(2) – (21) OFF
20-14 D575A-3 SD
➀
TESTING AND ADJUSTING
Tools for testing, adjusting and troubleshooting .......................................................................................... 20-102

Measuring engine speed............................................................................................................................. 20-104
Measuring air supply pressure (boost pressure)......................................................................................... 20-105
Measuring exhaust temperature ................................................................................................................. 20-106
Measuring exhaust color............................................................................................................................. 20-107
Adjusting valve clearance ........................................................................................................................... 20-108
Measuring compression pressure ............................................................................................................... 20-109
Measuring blow-by pressure ........................................................................................................................20-110
Measuring engine oil pressure .....................................................................................................................20-111
Testing and adjusting fuel injection timing....................................................................................................20-111
Testing and adjusting fan belt tension..........................................................................................................20-114
Testing and adjusting alternator belt tension................................................................................................20-114
Testing and adjusting belt tension for air conditioner compressor ...............................................................20-115
Adjusting engine speed sensor....................................................................................................................20-115
Measuring cooling fan speed .......................................................................................................................20-116
Adjusting fuel control dial and decelerator pedal .........................................................................................20-117
Measuring torque converter stall speed .......................................................................................................20-118
Measuring torque converter stall + hdraulic pump relief (full stall) speed ...................................................20-119
Measuring power train oil pressure ..............................................................................................................20-119
Procedure for releasing steering brake ....................................................................................................... 20-123
Simple procedure for testing brake performance ........................................................................................ 20-124
Adjustment of brake pedal linkage .............................................................................................................. 20-125
Adjusting clearance of idler......................................................................................................................... 20-126
Testing and adjusting track shoe tension .................................................................................................... 20-127
Testing and adjusting work equipment circuit pressure (main relief and PPC circuit) ................................ 20-127
Measuring PPC valve output pressure ....................................................................................................... 20-129
Adjusting PPC valve ................................................................................................................................... 20-130
Checking location of cause of hydraulic drift of blade ................................................................................. 20-130
Measuring leakage inside cylinder .............................................................................................................. 20-131
Releasing air remaining in hydraulic circuit on PPC valve .......................................................................... 20-132
Bleeding air from hydraulic cylinder ............................................................................................................ 20-132
Adjusting work equipment safety lever ....................................................................................................... 20-132
Procedure for adjusting blade tilt limit angle ............................................................................................... 20-133
D575A-3 SD 20-101
➀
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
Check or measure-
ment item Symbol Part No. Part Name Remarks
1 799-101-6000 Digital temperature –50 – 1,200°C (meter)

gauge
Water temperature, oil
temperature, exhaust B Exhaust temperature
2 6215-11-8180 –50 – 350°C (sensor)
temperature sensor
3 799-601-9020 Harness For exhaust temperature
799-101-5002 Hydraulic tester Pressure 2.5,5.9,39.2,58.8 MPa

gauge: {25,60,400,600 kg/cm2}
1
790-261-1203 Digital hydraulic tester Pressure 71.4 MPa {700 kg/cm2}
gauge:
2 799-401-2320 Hydraulic gauge 1.0 MPa {10 kg/cm2}
790-261-1311 Both male and female 14 x 1.5

Oil pressure C (female PT 1/8)
3 Adapter
790-261-1321 Both male and female 18 x 1.5
(female PT 1/8)
790-261-1360 Adapter Both male and female 14 x 1.5

(female PT 1/8)
4
790-261-1370 Nut 14 x 1.5 blind
07003-31419 Gasket For blind

1 795-502-1590 Compression gauge 0 – 6.9 MPa {0 – 70 kg/cm2}
(Kit Part No.: 795-502-1205)
795-502-1500 Adapter assembly
Compression pressure D
2 • 795-502-1510 • Adapter —
• 795-502-1520 • Plate —
1 799-201-1504 Blow-by checker Kit (gauge 0 – 4.9 kPa 0 – 500mmH2O}
2 799-201-1590 Gauge 0 – 9.81 kPa 0 – 1,000 mmH2O
Blow-by pressure E
799-201-1511 Nozzle 2 pcs
3
799-201-1450 Adapter 2 pcs
Valve clearance F Commercially Feeler gauge Intake 0.4 mm Exhaust 1.0 mm

available
1 799-201-9000 Handy Smoke Checker Discoloration 0 – 70%
Exhaust color G (with standard color)
2 Commercially Smoke meter (Discoloration x 1/10 Bosch index)
available
Air supply pressure H 799-401-2310 Pressure gauge 199.9 kPa {1,500 mmHg}
(boost pressure)
79A-264-0021 0 – 294 N {0 – 30 kg}

Operating effort I Push-pull scale
79A-264-0091 0 – 490 N {0 – 50 kg}
Stroke, hydraulic drift J Commercially Scale —

available
Work equipment K Commercially Stop watch —

Speed available
Voltage and resistance L 79A-264-0211 Tester —

values
20-102 D575A-3 SD
➀
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
Check or measure-
ment item Symbol Part No. Part Name Remarks
1 799-601-7100 T-adapter assembly —
799-601-7010 Fox x 1
799-601-7310 For SWP12P

Troubleshooting of
wiring harness and M 799-601-7070 For SWP14P
sensors 2 Adapter
799-601-7320 For SWP16P
799-601-7080 For M2
799-601-7360 For relay 5P
Measuring wear of P 791-827-1170 Wear gauge —

sprocket tooth
Blade tilt control angle Q 799-402-3800 Angle gauge —
D575A-3 SD 20-103
➀
TESTING AND ADJUSTING MEASURING ENGINE SPEED
MEASURING ENGINE SPEED

★ Measure the engine speed using the monitoring
mode and the adjustment mode of the monitor
panel.
For an overall explanation of the monitoring
mode and the adjustment mode, see MONITOR
PANEL DISPLAY AND SPECIAL FUNCTIONS.
1. Turn the starting switch ON.

2. Turn service switch (1) ON.
★ The service switch is installed inside the fuse
box.
2) Measuring engine high idling speed:
i) Turn economy mode switch (5) to 1, and
display [CH] on display (3) at the top of
the panel.
ii) Set the joystick and blade control lever to
the neutral position and set the fuel con-
trol dial to the MAX position.
3. Hold buzzer cancel switch (2) for at least 7 sec-

onds at the ON position and switch display (3) at
the top of the panel.
★ One of [99], [CH], [01], or [– –] is displayed
on the display at the top of the panel.
4. Start the engine, and measure the speed with
the number displayed on display (4) at the bot-
tom of the panel when the following conditions 5. After completing the measurement, turn starting
are set. switch (5) OFF and switch the panel to the nor-
★ The engine speed is shown in units of 1 rpm mal mode.
on the display at the bottom of the panel.
1) Measuring low idling speed: ★ For details of MEASURING TORQUE CON-
i) Turn economy mode switch (5) OFF, and VERTER STALL SPEED and MEASURING
display [99] on display (3) at the top of TORQUE CONVERTER STALL + HYDRAULIC
the panel. PUMP RELIEF SPEED, see the separate
ii) Set the joystick and blade control lever to respective items.
the neutral position and set the fuel con-
trol dial to the MIN position.
20-104 D575A-3 SD
➀
TESTING AND ADJUSTING MEASURING AIR SUPPLY PRESSURE
MEASURING AIR SUPPLY 3. Run the engine at high idling to stall the torque
converter, and read the air supply pressure
PRESSURE (boost pressure).
(BOOST PRESSURE) ★ For details of the procedure for stalling the
t o r q u e c o n v e r t e r, s e e M E A S U R I N G
Be careful not to touch any hot parts when TORQUE CONVERTER STALL SPEED.
removing or installing the measuring tools. ★ The air supply pressure (boost pressure)
★ Measure the air supply pressure separately for should be measured with rhe engine running
the left and right banks. at rated output. However, when measuring in
★ Measure the air supply pressure under the fol- the field, a similar value can be obtained at
lowing conditions. torque converter stall speed.
• Coolant temperature: Within operating range
• Power train oil temperature: Within operating
range
• Hydraulic temperature: 45 – 55°C
1. Fit hose of pressure gauge kit H1, then con-

nect boost gauge A.
2. Run the engine at a mid-range speed or above to

bleed the oil from the hose.
★ Insert the connection of the hose and pres-
sure gauge about half way, repeat the action
to open the self-seal portion at the hose end,
and bleed the oil.
★ If Pm kit A is available, the air bleed coupling
(790-261-1130) inside the kit can be used.
★ If there is oil inside the hose, the gauge will
not work, so always bleed the oil.
D575A-3 SD 20-105
➀
TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE
MEASURING EXHAUST Measurement procedure

1. When measuring in order to adjust the fuel
TEMPERATURE injection amount of the left and right banks
Measure the exhaust temperature in two ways:
★ Raise the coolant temperature to the operating with the engine at low idling, and with the engine
range before measuring. at high idling with the torque converter stalled.
• When measuring with the torque converter
1. Connect digital temperature gauge B1 to con- stalled, measure as follows.
nector (1) of the exhaust temperature sensor B2, 1) Raise the exhaust temperature by using
with wiring harness B3. torque converter stall + hydraulic pump relief
(relieved by using PITCH BACK).
★ Approx. 20 seconds
2) Stop relieving the hydraulic pump and con-
tinue the torque converter stall only.
3) The exhaust temperature will drop slightly
and become stable, so measure the temper-
ature at this point (left and right at the same
time).
★ If only the torque converter is stalled, even if
the torque converter overheats, the exhaust
temperature will rise but will not become sta-
ble.
For this reason, always use the above proce-
dure.
2. When measuring the maximum value for the

exhaust temperature
Carry out actual work and measure the maxi-
mum value during operation.
Note:
The exhaust temperature varies greatly according to
the ambient temperature (temperature of the engine
intake air), so if any abnormal value is obtained,
carry out temperature compensation.)
20-106 D575A-3 SD
➀
TESTING AND ADJUSTING MEASURING EXHAUST COLOR
MEASURING EXHAUST 2) Connect the air hose to tool G2.

★ Keep the pressure of the air supply below 1.5
COLOR MPa {15 kg/cm2}.
3) Connect the power cord to the power source
• When measuring in the field where there is no air socket.
or electric power supply, use G1; when recording ★ When connecting the cord, check that the
formal data, use G2. power switch of tool G2 is OFF.
★ Raise the coolant temperature to the operating 4) Loosen the cap nut of the suction pump, and fit
range before measuring. the filter paper.
★ Fit the filter paper securely so that the
When measuring the exhaust color, be exhaust gas cannot leak.
careful not to touch the exhaust pipe. 5) Turn the power switch of tool G2 ON.
6) Accelerate the engine suddenly, and depress the
accelerator pedal of tool G2 at the same time to
Measuring with G1 collect the exhaust gas color on the filter.
1) Install filter paper to tool G1. 7) Place the filter paper used to catch the exhaust
2) Insert the exhaust gas suction port into the gas color on top of at least 10 sheets of unused
exhaust pipe, accelerate the engine suddenly, flter paper inside the filter paper holder, and read
and operate the handle of tool G1 at the same the value shown.
time to collect the exhaust gas on the filter paper.
3) Remove the filter paper and compare it with the
scale supplied to judge the condition.
Measuring with G2
1) Insert probe into the outlet port of the exhaust
pipe, and tighten the clip to secure it to the
exhaust pipe.
D575A-3 SD 20-107
➀
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE 4. Tighten the locknut (6) to hold the adjustment

screw (5) in position.
CLEARANCE
Locknut: 67.7 ± 9.8 Nm {6.9 ± 1.0 kgm}
★ Adjust the clearance between the crosshead and
rocker arm as follows.
Unit:mm
Intake valve Exhaust valve
Both hot and cold 0.4 1.0
Method of adjusting valve clearance

1. Remove the cylinder head cover.
2. Rotate the crankshaft in the normal direction to

align the R1.6 TOP line on vibration damper (1)
with pointer (2) to set the right No. 1 cylinder at
compression top dead center. When rotating, 5. Following the firing order of the engine, rotate the
check the movement of the intake valve of right crankshaft, align the damper line with the pointer,
No. 6 cylinder. and adjust the clearance of each cylinder.
★ When the right No. 1 cylinder is near com- ★ Firing order
pression top dead center, the intake valve of R1 – L6 – R5 – L2 – R3 – L4 – R6 – L1 –
right No. 6 cylinder moves (opens). R2 – L5 – R4 – L3
3. Loosen locknut (6) of adjustment screw (5) for

right No. 1 cylinder, then insert feeler gauge F of
the specified thickness between crosshead (4)
and rocker arm (3), and adjust with the adjust-
ment screw until the clearance is a sliding fit.
20-108 D575A-3 SD
➀
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION 5. Place the fuel control lever in the NO INJEC-

TION position. Crank the engine with the start-
PRESSURE i ng moto r a nd mea su re th e co mp ressio n
pressure.
Be careful not to touch any hot places when ★ Measure the compression pressure at the
installing or removing the measuring tools. point where the pressure gauge indicator
remains steady.
★ Raise the temperature of the cooling water to the
operating range before measuring. If the fuel ocntrol lever is not placed at the
NO INJECTION position, fuel will spurt out.
1. Adjust the valve clearance.
★ For details, see ADJUSTING VALVE CLEAR- ★ If the adapter mount is coated with a small
ANCE. amount of oil, it will reduce the leakage.
★ For details of the standard values for the com-
2. Remove the nozzle holder assembly of the cylin- pression pressure, see TABLE OF STAN-
der to be measured. D A R D VA L U E S F O R T E S T I N G,
★ Be careful not to let dirt or dust get inside. ADJUSTING, AND TROUBLESHOOTING.
★ When measuring the compression pressure,
3. Install adapter D2 in the mount of the nozzle measure the engine speed to confirm that it
holder assembly. is within the specified range.
Adapter D2: ★ For details of installing the nozzle holder assem-

26.9 ± 2.5 Nm {2.75 ± 0.25 kgm} bly after measuring the compression pressure,
see INSTALLATION OF NOZZLE HOLDER
ASSEMBLY.
4. Connect compression gauge assembly D1 to the

adapter.
When measuring the compression pres-

sure, be careful not to touch any hot parts
or to get caught in the rotating parts.
D575A-3 SD 20-109
➀
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY 3. Run the engine at high idling with the torque con-
verter continuously stalled, and measure the
PRESSURE pressure indicated by the gauge E2.
★ Be careful not to overheat the torque con-
The measuring equipment is installed at a verter (the red range of the oil temperature
position that cannot be seen from the opera- gauge lights up).
tor's seat, so take steps to ensure that no one
starts the engine during the operation.
★ Raise the coolant temperature to the operating

range before measuring.
1. Install the nozzle E3 of blow-by checker E1 to

the tip of breather hose (3), then connect it to the
gauge with the hose.
2. Install nozzle E3 to the tip of the remaining

breather hoses (1) and (2).
★ Block the port used to connect the gauge.
When measuring, be careful not to touch

any hot parts or rotating parts. Reference:
Blow-by varies greatly according to the condition of
the engine. Therefore, if the blow-by value is consid-
ered abnormal, check for problems connected with
defective blow-by, such as excessive oil consump-
tion, defective exhaust gas color, and prematurely
dirty or deteriorated oil.
20-110 D575A-3 SD
➀
MEASURING ENGINE OIL PRESSURE,
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING
MEASURING ENGINE OIL TESTING AND ADJUSTING

PRESSURE FUEL INJECTION TIMING
★ Raise the coolant temperature to the operating Test and adjust the fuel injection timing of the injec-
range before measuring. tion pump as follows.
• If the injection pump has not been repaired, and
1. Connect the hose of oil pressure gauge to pres- it is assembled to the original engine, adjust by
sure measurement nipple (1), then install oil aligning the match marks.
pressure gauge C2 (1.0 MPa {10 kg/cm2}). • If the injection pump has been repaired or
replaced, use the delivery valve method to
adjust.
★ Set the No. 1 cylinder to the compression top
dead center before testing and adjusting.
★ For detials, see ADJUSTING VALVE CLEAR-
ANCE.
★ When using the DELIVERY VALVE method,
make preparations to replace the delivery valve
copper gasket and O-rig with new parts.
TESTING AND ADJUSTING BY ALIGN-

ING MATCH MARKS METHOD
1. Testing
2. Start the engine, and measure the oil pressure at Check that line a on the injection pump and line
low idling and high idling. b on the case are aligned.
D575A-3 SD 20-111
➀
2. Adjusting 3. Remove spring (6) and delivery valve (5) from

If the results of the inspection shows that the delivery valve holder (4), then assemble delivery
lines are not aligned, or if the injection pump has valve holder (4) again.
been repalced (or removed and installed), adjust ★ When doing this, assemble the same O-ring
the fuel injection timing as follows. and copper gasket that were removed.
1) Loosen 4 mounting bolts (1) and 4 mounting (Replace with new parts after adjusting.)
bolts (2) of the injection pump.
2) Align line a of injection pump with line b on
the case, then tighten mounting bolts (2) and
(1).
4. Set the fuel control lever at the FULL position.
5. Remove rack stopper bolt (7), then tighten rack

pusher bolt to move the rack.
★ For details of adjusting the fuel injection ★ Tighten the rack pusher bolt until it contacts
amount for the left and right banks, see the rack piston (8), then tighten it a further 8
ADJUSTING INJECTION PUMP RACK turns and tighten locknut .
LINKAGE. ★ Rack pusher bolt part number: 01016-30850
• Testing and adjusting with delivery valve

method
1. Disconnect fuel injection pope (3) fo right No. 1
cylinder.
★ Before disconnecting the pipe, wipe off all
the fuel at the top of the fuel injection pump
to prevent dust from entering.
2. Remove delivery valve holder (4).
20-112 D575A-3 SD
➀
6. Set with the right No. 1 cylinder at the TOP posi- ★ After adjusting, remove the delivery valve
tion, then rotate the crankshaft 35 – 40° in the holder (10), assemble the delivery valve (12)
opposite direction. and spring (11), then install the delivery valve
holder (10) again.
7. Operate the priming pump and rotate the crank- ★ Always replace the copper gasket (9) and O-
shaft slowly in the normal direction. Check the ring of the delivery valve with new parts. If
point where the fuel stops fowing from the the old parts are used, they may cause fuel
delively valve holder. leakage.
Be careful not to mistake the mounting posi-
8. Check that the fuel injection timing line on the tion of the copper gasket.
vibration damper and the pointer are aligned at ★ Replace rack pusher bolt and rack stop-
the point where the fuel stops flowing. per bolt (7). (If they are not replaced, there is
★ BEYOND injection timing line: danger that the engine may overrun.)
Timing RETARDED
★ BEFORE injection timing line:
Timing ADVANCED
• If the results of the test show that the fuel injec-

tion timing is incorrect, adjust the fuel injection
timing as follows.
1) Set with the right No. 1 cylinder at the TOP
position, then rotate the crankshaft 35 – 40°
in the opposite direction.
2) Rotate the crankshaft slowly in the normal
direction, and align the injection timing line
on damper and pointer correctly.
3) Loosen bolt (1) in the oblong hole of the
injection pump mounting flange, operate the
• Be careful to assemble the copper gasket (9)
priming pump, and turn the flange at the
in the correct mounting position (below the
pump end a little at a time. Stop at the point
seat).
where fuel stops flowing from the delivery
valve holder (10). Order for tightening delivery valve holder
4) Tighten the bolt in the oblong hole of the
injection pump mounting flange. Unit: Nm {kgm}
★ Check the injection timing again to con- 1st step 137.3 – 156.9 {14 – 16}
firm that the injection timing is correctly
2nd step Return to 0
adjusted.
5) Align with line a on the fuel injection pump, 3rd step 137.3 – 156.9 {14 – 16}
then make line b on the coupling. 4th step Return to 0
5th step 137.3 – 156.9 {14 – 16}
D575A-3 SD 20-113
➀
TESTING AND ADJUSTING FAN BELT TENSION,
TESTING AND ADJUSTING TESTING AND ADJUSTING ALTERNATOR BELT TENSION
TESTING AND ADJUSTING TESTING AND ADJUSTING

FAN BELT TENSION ALTERNATOR BELT TENSION
1. Testing and adjusting 1. Testing
An auto-tensioner is installed to maintain the cor- Push a point midway between the alternator pul-
rect tension regardless of the amount the V-belt ley and the drive pulley at a pressure of approx.
has stretched, so there is no need to adjust the 98.1 N {10 kg} and check deflection a of the belt.
belt until it breaks. However, check that dimen- For details, see STANDARD VALUE TABLE.
sion A is 36 ± 3 mm, and if it is not within the
that range, loosen locknut (2) and adjust with
adjustment bolt (3).
2. Replacing
1) Loosen locknut (2) and make the spring free.
2) Loosen adjustment bolt (3) and make tension
pulley (1) free.
Loosen until dimension A is 210 mm.
3) Push the tension pulley in the direction of the
arrow to a point where the V-belt comes off,
then replace the V-belt.
★ Replace all 6 V-belts at the same time.
2. Adjusting
1) Loosen bolt (1) and nuts (2), (3).
2) Turn the turnbuckle (4) so that the belt ten-
sion is in standard value.
3) After adjusting, tighten bolt and nuts securely.
20-114 D575A-3 SD
➀
TESTING AND ADJUSTING BELT TENSION
FOR AIR CONDITIONER COMPRESSOR,
TESTING AND ADJUSTING ADJUSTING ENGINE SPEED SENSOR
TESTING AND ADJUSTING ADJUSTING ENGINE SPEED

BELT TENSION FOR AIR SENSOR
CONDITIONER COMPRESSOR
★ Adjust both left bank speed sensor (1) and right
Testing bank speed sensor (2) in the same way.
• Measure deflection a of the belt when it is
pushed with a finger force of approx. 58.8 N
{approx. 6 kg} at a point midway between the
compressor pulley and the engine drive pulley.
• Deflection a of belt:
See STANDARD VALUE TABLE
Adjusting
★ If the belt tension is not correct, adjust as follows.
1. Loosen 4 mounting bolts (1) and locknut (2).
2. Turn the adjustment bolt (3) and move air condi-

tioner compressor (4) together with the bracket
to adjust the tension of the belt.
3. Tighten locknut (2) and 4 mounting bolts (1).
D575A-3 SD 20-115
➀
ADJUSTING ENGINE SPEED SENSOR,
TESTING AND ADJUSTING MEASURING COOLING FAN SPEED
1. Screw in sensor body (3) so that the tip contacts MEASURING COOLING FAN
ring gear (2).
★ Be careful not to damage the sensor tip or let SPEED
iron particles stick to it.
When measuring, be careful not to touch the
Sensor thread: Gasket sealant (LG-6) fan.
2. After sensor body (3) contacts ring gear (4), turn This position cannot be seen from the opera-
it back 3/4 – 1 turn to adjust clearance a. tor's seat, so take action to prevent anyone
• Clearance a: 1.2 – 1.5 mm from starting the engine by mistake when the
tools are being installed.
3. Tighten locknut (5).
1. Open the grill and set the adapter of tachometer
Locknut: A facing the fan.
49.0 – 68.6 Nm {5.0 – 7.0 kgm}
2. Stick reflecting tape to the fan.
★ When fixing the wiring in position, be careful that
no excessive force is brought to bear on the sen- 3. Install tachometer A to the engine.
sor wiring. For details, see MEASURING ENGINE SPEED.
4. Measure the fan speed when the engine speed

is set to 1,800 rpm.
20-116 D575A-3 SD
➀
TESTING AND ADJUSTING ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL
ADJUSTING FUEL CONTROL (2) When the engine speed is below 1,980
rpm
DIAL AND DECELERATOR Move decelerator pedal stopper (2)
PEDAL toward the higher speed side to set the
engine speed to the full level.
1. Outline of fuel control system ★ Full engine speed: 1,980 ± 50 rpm
• The speed signals from the fuel control dial 9) Press the decelerator pedal to the position
and the decelerator pedal potentiometers are where the pressing effort changes and adjust
each input to the engine controller. stopper screw (3) so that the engine speed
The engine controller gives priority to the will be at the first deceleration speed.
lower speed of the two input signals and ★ First deceleration speed: 1,200 ± 50 rpm
sends a command to the electronic governor.
• Adjustment of the engine speed is all carried
out by the decelerator pedal linkage.
2. Adjusting
1) Turn the starting switch on and set the moni-
tor panel to monitoring code [99].
★ For details, see MEASURING ENGINE
SPEED.
2) Connect the wiring harness and turn the fuel
control dial to the FULL position.
3) Check that the engine speed is above 1,200
rpm w hile the decelerator pedal is not
pressed.
4) If the engine speed is below 1,200 rpm, turn
decelerator pedal rod (1) to lengthen it and
heighten the engine speed to above 1,200
rpm.
(If the engine speed cannot be heightened to
above 1,200 rpm by the above operation, the
wires are connected wrongly or the controller
has a trouble.)
5) Press the decelerator pedal to the stopper
and adjust rod (1) so that the engine speed
will be at the second deceleration speed,
then lock the rod.
★ Second deceleration speed:
1,000 ± 50 rpm
6) Release the decelerator pedal.
7) Check again that the fuel control dial is set to
the FULL position.
8) Checking and adjusting full engine speed
(1) When the engine speed is above 1,980
rpm
Move decelerator pedal stopper (2)
toward the lower speed side to lower the
engine speed to below 1,900 rpm. Then,
move decelerator pedal stopper (2)
toward the higher speed side to set the
engine speed to the full level. (Adjust the
engine speed by this method to eliminate
the play of the decelerator pedal.)
★ Full engine speed: 1,980 ± 50 rpm
D575A-3 SD 20-117
➀
TESTING AND ADJUSTING MEASURING TORQUE CONVERTER STALL SPEED
MEASURING TORQUE 6. Depress the decelerator pedal and set the fuel
control dial to high idling.
CONVERTER STALL SPEED
Make sure that the area around the machine is
safe before starting the operation.
★ Measure the torque converter stall speed under

the following coditions.
• Power train oil temperature: 70 – 90 °C
• Hydraulic oil temperature: 45 – 55 °C
1. Make sure that AUTO SHFT DOWN SWITCH is

turned OFF.
7. Let the decelerator pedal back slowly, run the

engine at high idling, and stall the torque con-
verter.
Depress the brake pedal firmly during

operation.
For safety reasons, always keep your right
foot on the full decelerator pedal until the
completi on of the measurement operation.
8. When the power train oil temperature gauge

enters the red gauge, immediately return the joy-
stick to neutral.
2. Turn the starting switch ON and set the monitor
panel to morning code [99]. 9. Repeat Steps 5 – 8 three times.
★ For details, see MEASURING ENGINE SPEED.
10. Repeat Steps 5 – 7 again and measure the
3. Start the engine and set the fael control dial to engine speed immediately the power train oil
low idling. temperature gauge enters red range.
★ After completion of the measurement, return
4. Unlock the parking lever. the joystick swiftly to neutral, and run the
engine at high idling to lower the power train
oil temperature.
5. Depress the steering brake firmly, move the

directional lever to FORWARD and push the shift
up buttom to 3. Display [F3] on display at the
panel.
20-118 D575A-3 SD
➀
MEASURING TORQUE CONVERTER STALL
+ HIDRAULIC PUMP RELIEF (FULL STALL) SPEED,
TESTING AND ADJUSTING MEASURING POWER TRAIN OIL PRESSURE
MEASURING TORQUE MEASURING POWER TRAIN

CONVERTER STALL + OIL PRESSURE
HIDRAULIC PUMP RELIEF
(FULL STALL) SPEED Stop the machine on level ground, lower the
work equipment to the ground and apply the
parking brake.
Make sure that the area around the machine is
safe before starting the operation. ★ When measuring the hydraulic pressure, remove
all the sand and dirt from around the nipple and
★ Measure the torque converter stall speed under plug.
the following coditions. ★ Raise the power train oil temperature to at least
• Coolant temperature: Within operating range 70°C before measuring.
• Power train oil temperature: 70 – 90 °C
• Hydraulic oil temperature: 45 – 55 °C • Refer to the diagram and table below to install oil
pressure gauge C to the nipple for the circuit to
1. Make sure that AUTO SHFT DOWN SWITCH is be measured.
turned OFF.
Table of centralized pressure pick-up port positions
2. Turn the starting switch ON and set the monitor and gauges to use when measuring hydraulic pres-
panel to morning code [99]. sure
★ For details, see MEASURING ENGINE SPEED.
No. Measurement location Gauge
3. Start the engine and set the fuel control dial to (MPa {kg/cm2})
low idling, then operate the blade pitch cylinder LBR. Steering brake pressure (L.H.) 5.9 {60}
to the end of the pitch BACK stroke. LCL. Steering clutch pressure (L.H.) 5.9 {60}
PPC. PPC pilot pressure 5.9 {60}
4. Unlock the parking lever.
RBR. Steering brake pressure (R.H.) 5.9 {60}
5. Depress the steering brake firmly, move the direc- RCL. Steering clutch pressure (R.H.) 5.9 {60}
tional lever to FORWARD and push the shift up TCI. Torque convertr inlet pressure 2.5 {25}
buttom to 3. Display [F3] on display at the panel.
TCL. Torque convertr lock-up pressure 5.9 {60}
6. Depress the decelerator pedal and set the fuel TCO. Torque convertr outlet pressure 1.0 {10}
control dial to high idling. TCS. Torque converter stator clutch 5.9 {60}
pressure
7. Let the decelerator pedal back slowly, run the TM1. 1st clutch pressure 5.9 {60}
engine at high idling, and stall the torque con- TM2. 2nd clutch pressure 5.9 {60}
verter.
TM3. 3rd clutch pressure 5.9 {60}
Depress the brake pedal firmly during TMF. Forward clutch pressure 5.9 {60}
operation. TML. Transmission lubrication pressure 1.0 {10}
For safety reasons, always keep your right TMM. Transmission main pressure 5.9 {60}
foot on the full decelerator pedal until the
TMR. Reverse clutch pressure 5.9 {60}
completi on of the measurement operation.
8. When the power train oil temperature gauge

enters the red gauge, immediately return the joy-
stick to neutral.
9. Repeat Steps 5 – 8 three times.
10. Repeat Steps 5 – 7 again and measure the

engine speed immediately the power train oil
temperature gauge enters red range.
★ After completion of the measurement, return
the joystick swiftly to neutral, and run the
engine at high idling to lower the power train
oil temperature.
D575A-3 SD 20-119
➀
1. Measuring torque converter oil pressure 2) Start the engine and turn the lock-up mode
1) Measuring torque converter inlet port and switch ON.
outlet pressure 3) Drive the vehicle in F1 at full throttle and
i) Install oil pressure gauges C1 and C2 to measure the oil pressure when the LOCK-
torque converter inlet pressure measure- UP lamp on the monitor panel lights up.
ment nipple TCI and outlet pressure
measurement nipple TCO. Perform the above operation in a suffi-
ii) Set the gearshift lever at neutral, and ciently wide place for driving the vehi-
measure the torque converter inlet port cle. Before measuring the pressure,
pressure and outlet port pressure with check that there are no workers around
the engine at low idling and high idling. the vehicle.
3. Measuring torque converter stator clutch

pressure
1) Fit hose of oil pressure gauge C1 to pressure
measurement nipple TCS, then connect oil
pressure gauge C1 (5.9 MPa {60 kg/cm2}).
2) Start the engine and set all the functions of
the full monolever to neutral.
★ Any position can be used for the speed
range.
3) Measure the oil pressure at engine high
idling.
4. Measuring transmission oil pressure

2. Measuring torque converter lock-up clutch 1) Measuring transmission main relief pressure.
pressure i) Install oil pressure gauge C1 to pilot
1) Fit hose of oil pressure gauge C1 to pressure reducing pressure measurement nipple
measurement nipple TCL, then connect oil TMM.
pressure gauge C1 (5.9 MPa {60 kg/cm2}). ii) Set the gearshift lever at neutral, and
measure the pressure with the engine at
low idling and high idling.
20-120 D575A-3 SD
➀
2) Measuring transmission clutch actuating (4) When directional lever is in F and

pressure. (clutch circuit pressure). GEAR Shift is in 3
i) Positions of measuring nipples Measure the forward clutch and 3rd
Install oil pressure gauge hoses to the clutch actuating pressure.
following oil pressure measuring nipples (5) When directional lever is in R and
according to their measurement items. GEAR Shift is in 1
Forward clutch actuating pressure TMF Measure the reverse clutch and 1st
Reverse clutch actuating pressure TMR clutch actuating pressure.
1st clutch actuating pressure TM1
2nd clutch actuating pressure TM2 Combination of speed range and
3rd clutch actuating pressure TM3 clutches (No. 5 (1st) is the rotating
clutch)
Clutch No.1 No.2 No.3 No.4 No.5

No. (R) (F) (3rd) (2nd) (1st)
N !
F1 ! !
F2 ! !
F3 ! !
R1 ! !
R2 ! !
R3 ! !
Do not run the engine at high idling.
3) Measuring transmission lubrication oil pres-

sure.
i) Install oil pressure gauge C2 to lubrica-
tion oil pressure measurement nipple
TML.
ii) Set the gearshift lever at neutral, and
measure the pressure with the engine at
ii) Condition of vehicle

Release the parking brake and turn ON
the brake pedal and run the engine at
low idling, then change the gear speed
and measure the pressure according to
the following measurement items.
iii) Measurement items

(1) When directional lever is in neutral
Measure the 1st clutch actuating
pressure.
(2) When directional lever is in F and Note:
GEAR Shift is in 1 The oil pressure differs greatly between high
Measure the forward clutch and 1st temperature and low temperature, so warm
clutch actuating pressure. up the oil thoroughly before measruing.
(3) When directional lever is in F and For details, see MEASURING ENGINE
GEAR Shift is in 2 SPEED AT TORQUE CONVERTER STALL.
Measure the forward clutch and 2nd
clutch actuating pressure.
D575A-3 SD 20-121
➀
5. Measuring left steering clutch pressure 3) Measure the oil pressure with the engine at
1) Fit hose of oil pressure gauge C1 to pressure low idling and high idling.
measurement nipple LCL, then connect oil
pressure gauge C1 (5.9 MPa {60 kg/cm2}) If the brake pedal is pressed, the oil
pressure cannot be measured accu-
rately. Accordingly, when measuring
the oil pressure, park the vehicle on a
level place and lower the blade and
check around the vehicle.
7. Measuring right steering clutch pressure

measurement nipple RCL, then connect oil
pressure gauge C1 (5.9 MPa {60 kg/cm2})
2) Start the engine, unlock the parking lower

and operate the full monolever steering fully
to the left.
★ Set the directional lever to the neutral
position any position can be used for the
speed range.
3) Measure the oil pressure with the engine at
If the brake pedal is pressed, the oil

pressure cannot be measured accu- 2) Start the engine, unlock the parking lever
rately. Accordingly, when measuring and operate monolever steeiring fully to the
the oil pressure, park the vehicle on a right.
level place and lower the blade and ★ Set the directional lever to the neutral
check around the vehicle. position any position can be used for the
speed range.
6. Measuring left steering brake pressure 3) Measure the oil pressure with the engine at
1) Fit hose of oil pressure gauge C1 to pressure low idling and high idling.
measurement nipple LBR, then connect oil
pressure gauge C1 (5.9 MPa {60 kg/cm2}) If the brake pedal is pressed, the oil
pressure cannot be measured accu-
rately. Accordingly, when measuring
the oil pressure, park the vehicle on a
level place and lower the blade and
check around the vehicle.
2) Start the engine, unlock the parking leverr

and set all the functions of the full monolever
to neutral.
★ Any position can be used for the speed
range.
20-122 D575A-3 SD
➀
MEASURING POWER TRAIN OIL PRESSURE,
TESTING AND ADJUSTING PROCEDURE FOR RELEASING STEERING BRAKE
8. Measuring right steering brake pressure PROCEDURE FOR

measurement nipple RBR, then connect oil RELEASING STEERING
pressure gauge C1 (5.9 MPa {60 kg/cm2}) BRAKE
2) Start the engine, unlock the parking lever
and operate the full monolever steering fully ★ If it is necessary to release the steering brake,
to the right. such as when installing the gear coupling,
★ Any position can be used for the speed release the brake as follows.
range.
3) Measure the oil pressure with the engine at 1. Remove the cover on top of the bevel gear shaft
low idling and high idling. case.
2. Remove plug (1) from the brake case.
3. Screw in 4 bolts of tool until the tip contacts,

then turn them back one turn.
4. Tighten 4 nuts uniformly to pull brake piston

(2) and release the brake.
D575A-3 SD 20-123
➀
TESTING AND ADJUSTING SIMPLE PROCEDURE FOR TESTING BRAKE PERFORMANCE
SIMPLE PROCEDURE FOR

TESTING BRAKE
PERFORMANCE
★ Carry out the simple test of the brake perfor-
mance under the following conditions.
• Power train oil temperature: Within operating
range
1. Stop the machine on a level surface and set the

blade to the travel posture.
2. Set the full monolever speed range to 2.
If it is set to 1, there will be excess load on

the brakes, so always carry out this test in
position 2.
3. Run the engine at low idling, unlock the parking

lever, depress the brake pedal securely, then set
the monolever direction to F.
★ Set the steering to the neutral position.
4. Depress the decelerator pedal and set the fuel

control dial to high idling.
5. Release the decelerator pedal gradually and

raise the engine speed to high idling. Check that
the machine does not start to move.
The torque converter is stalled, so depress

the brake pedal firmly during operation. For
safety reasons, always keep your right foot
on the decelerator pedal until the comple-
tion of the measurement operation.
20-124 D575A-3 SD
➀
TESTING AND ADJUSTING ADJUSTMENT OF BRAKE PEDAL LINKAGE
ADJUSTMENT OF BRAKE PEDAL LINKAGE

★ If the travel of the brake pedal is not within the 3) Connect the all rods, then press brake pedal
standard value, adjust the linkage as follows. (1) and check again that its stroke is 95 ± 5
1. Adjustment of brake pedal linkage mm. (The pedal must stop at spring box (6).)
When floor frame is in sub-assembly state Check that the stroke of the brake valve
(When rod (4) is not connected) spool is in the range shown at right when
1) Press brake pedal (1) to the end and check brake pedal (1) is operated in the above
that pedal stroke A is 95 ± 5 mm. stroke.
After floor frame assembly is mounted 4) Connect the all rods, then press and lock
2) Install rods (4) and (5) and set pedal (1) free, brake pedal (1) and check that the oil pres-
then adjust turnbuckle (5) so that the valve sure of both brakes is 0 MPa {0 kg/cm2}.
spool will be in neutral (the valve spool does 5) Lock the brake pedal and check that the
not move). clearance between the lever, rod and the
other parts.
2. Assembly and adjustment of parking brake

1) Assemble and adjust the link on the brake 4) On the brake valve side, adjust the position
pedal side. of the hole so that yoke (9) at the cable end
2) Assemble the lever mechanism sub-assem- will pull lever (10) in the OFF position of the
bly and check the operation of limit switch brake when the cable is pulled, then install
(7). the cable.
Raising lever → Switch is turned OFF.
Lowering lever → Switch is turned ON.
3) Install the lever mechanism sub-assembly to
the floor frame and install control cable (8).
D575A-3 SD 20-125
➀
ADJUSTMENT OF BRAKE PEDAL LINKAGE,
TESTING AND ADJUSTING ADJUSTING CLEARANCE OF IDLER
5) Adjust and install the cable on the floor frame ADJUSTING CLEARANCE OF
side so that the lever will be raised under the
condition of 4 above. IDLER
6) After installing the cable, check that the
brake valve is drained and the brake is actu- The idler moves forward and backward under exter-
ated when the lever is lowered. Then, check nal pressure. When this happens, side guide (1) and
that the brake oil pressure is maintained and guide plate (2) become worn. As they become worn,
the brake is released when the lever is there is side play in the idler, or the idler turns at an
raised. angle, causing the track to come off or resulting in
7) Check again that the signal of the limit switch uneven wear, so adjust as follows.
is normal.
Adjustment
1. Drive the machine for 1 – 2 m on flat ground,
then measure clearance a (4 places: left, right,
inside, outside) between the track frame and
side guide (1).
2. If clearance a is more than 3 mm, remove bolt

(3), then take out shim (4), and adjust so that the
clearance on one side is less than 0.5 mm.
★ There are two types of shim (thickness: 0.5

mm and 1.0 mm).
20-126 D575A-3 SD
➀
TESTING AND ADJUSTING TRACK SHOE TENSION,
TESTING AND ADJUSTING WORK EQUIPMENT CIRCUIT PRESSURE
TESTING AND ADJUSTING (MAIN RELIEF AND PPC CIRCUIT)
TESTING AND ADJUSTING TESTING AND ADJUSTING

TRACK SHOE TENSION WORK EQUIPMENT CIRCUIT
PRESSURE (MAIN RELIEF
Testing
1. Drive the machine forward and stop on a hori- AND PPC CIRCUIT)
zontal surface.
★ Stop the machine without using the brake. Stop the machine on level ground, lower the
work equipment to the ground and apply the
2. Pull steel rod between the idler and carrier roller, parking brake.
and measure clearance a from the bottom of the
rod to the track shoe grouser. ★ When installing the oil pressure gauge, remove
• Standard clearance a: 20 – 30 mm all the sand and dirt from around the plug.
★ Raise the temperature of the hydraulic oil to 45 –

55°C before measuring.
• Refer to the diagram and table below to install oil

pressure gauge C1 to the nipple for the circuit to
be measured.
Table of centralized pressure pick-up port positions

and gauges to use when measuring hydraulic pres-
sure
Gauge
No. Measurement location (MPa{kg/cm2})
PPC PPC relief pressure 5.9 {60}
Adjusting LWP Hydraulic pump (front) relief pressure 39.2 {400}
★ If the track shoe tension is not normal, adjust as
RWP Hydraulic pump (rear) relief pressure 39.2 {400}
follows.
1. Remove cover .
2. If tension is too high:
Loosen plug (1) and release some of the grease.
There is danger that the plug may fly out
under the high internal pressure of the
grease, so never loosen the plug more
than 1 turn.
3. If tension is too low:
Pump in grease through grease fitting (2).
★ If the track tension is poor, move the
machine backwards or forwards slowly.
★ After complection of the adjustment, repeat
the above procedure to check the tension
again.
D575A-3 SD 20-127
➀
TESTING AND ADJUSTING (MAIN RELIEF AND PPC CIRCUIT)
WORK EQUIPMENT CIRCUIT 2) Turn adjustment screw (2) as follows to

adjust.
1. Measuring work equipment circuit pressure • To RAISE pressure, turn CLOCKWISE
1) Install oil pressure gauge C1 to nipples LWP • To LOWER pressure, turn CONTER-
(for front pump) and RWP (for rear pump) for CLOCKWISE
measuring work equipment main relief pres- ★ One turn of the adjustment screw adjusts
sure. the pressure by 12.5 MPa {128 kg/cm2}.
2) Measure the relief pressure when the balde
pitch cylinder is operated for the pitch back Locknut: 68.6 ± 9.8 Nm {7 ± 1 kgm}
with the engine at high idling and low idling.
★ The front pump forms an independent
circuit for the left pitch cylinder, and the
rear pump forms an independent circuit
for the right pitch cylinder.
PPC CIRCUIT
1. Measuring PPC circuit pressure (relief pressure)

1) Install oil pressure gauge C1 to oil pressure
2. Adjusting work equipment circuit main relief measurement nipple PPC.
valve 2) Measure the relief pressure with the engine
1) Loosen locknut (1). at low idling and high idling.
20-128 D575A-3 SD
➀
(MAIN RELIEF AND PPC CIRCUIT),
TESTING AND ADJUSTING MEASURING PPC VALVE OUTPUT PRESSURE
2. Adjusting PPC pump relief valve MEASURING PPC VALVE

1) Remove cap (3).
2) Loosen locknut (4). OUTPUT PRESSURE
3) Turn adjustment screw (5) to adjust.
★ Turn the adjustment screw as follows. Lower the blade completely to the ground.
• To INCREASE pressure, turn CLOCK-
WISE ★ Raise the hydraulic oil temperature to 45 – 55 °C
• To DECREASE pressure, turn COUN- before measuring.
TERCLOCKWISE
Operate the blade control levers to release
Locknut: 9.8 Nm {1.0 kgm} the remaining pressure in the PPC circuit.
★ After complection of the adjustment, repeat the
above procedure to check the oil pressure again. 1. Disconnect hose (1) of the circuit to be mea-
sured.
2. Fit adapter inside hydraulic tester C1, and

connect the hose.
★ Adapter Part No.: 790-261-1321
3. Install the oil pressure gauge 5.9 MPa {60 kg/

cm2}.
4. Measure the hydraulic pressure with the engine

at low idling and high idling.
D575A-3 SD 20-129
➀
ADJUSTING PPC VALVE,
TESTING AND ADJUSTING CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF BLADE
ADJUSTING PPC VALVE CHECKING LOCATION OF

★ If there is excessive play at the tip of the blade
CAUSE OF HYDRAULIC DRIFT
lever and ripper lever, adjust the PPC valve as OF BLADE
follows.
• Standard play dimension a: ★ If hydraulic drift occurs in the blade and ripper
1 – 5 mm at point 250 mm from center of lever (cylinder), check as follows to see if the cause is
(both front-to-rear and left-right) in the cylinder packing or in the control valve.
★ The diagram shows the ripper PPC valve.
1. Inspection posture
1. Remove boot (1). 1) Blade lift cylinder
• Push the blade against the ground to
2. Loosen locknut (2), then turn disc (3) to adjust raise the chassis.
the play. ★ The piston has a valve so do not operate
★ When doing this, do not move the piston. to the end of the stroke.
3. Secure disc (3) in position and tighten locknut

(2).
Locknut:
98.07 – 127.49 Nm {10 – 13 kgm}
4. Install boot (1).
2) Blade pitch cylinder

• Extend the pitch cylinder rod fully (maxi-
mum tilt), then push the blade against the
ground to raise the chassis.
20-130 D575A-3 SD
➀
CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF BLADE,
TESTING AND ADJUSTING MEASURING LEAKAGE INSIDE CYLINDER
2. Inspection MEASURING LEAKAGE

1) Set the cylinder of the circuit to be checked
in the inspection posture, then stop the INSIDE CYLINDER
engine.
★ For details of the inspection posture, see • If the hydraulic drift exceeds the standard value,
Items 1) – 2). check if the cause of the hydraulic drift is in the
2) Operate the control lever in the direction to cylinder or in the control valve.
extend the cylinder rod. ★ Oil temperature when measuring: 45 – 55 °C
★ For details of the inspection posture, see
Items 1) – 2). 1. Measurement posture
3) Operate the control lever in the direction to 1) Blade tilt cylinder
extend the cylinder rod. • Fully extend the rod of the cylinder to be
• If the downward movement becomes measured, and lower the end of the
faster, the packing is defective. blade to the ground.
• If there is no change, the control valve is ★ The blade lift cylinder has a built-in
defective. piston valve, so measurement is
★ If there is no more pressure in the accu- impossible.
mulator, run the engine for approx. 10
seconds to charge the accumulator 2. Measuring
before carrying out the operation. 1) Disconnect the head piping, and block the
piping at the chassis end with a blind plug.
Reference:
If the cause of the hydraulic drift is in the packing, Be careful not to disconnect the piping
the speed of downward movement in the above at the bottom end.
operation will become faster for the following rea-
sons. 2) Start the engine, run the engine at high
1) With the work equipment in the posture given idling, and apply the relief pressure to the
above, (holding pressure applied to the bottom bottom end of the cylinder.
end), the oil will leak from the bottom end to the 3) Wait for 30 seconds, then measure the
head end. However, the volume at the head end amount of leakage over the next 1 minute.
is smaller than at the bottom end (by an amount
proportional to the area of the rod), so if the oil
flows in from the bottom end, the internal pres-
sure at the head end will rise.
2) If the internal pressure at the head end rises, a
balance will be made in proportion to this at a
certain pressure (this differs according to the
amount of leakage).
3) When the pressure becomes balanced, the
speed of downward movement becomes slower.
In this condition, if the lever is operated as
shown above, the circuit at the head end is con-
nected to the drain circuit (the bottom end is
closed by a check valve), and the oil at the head
end flows to the drain circuit to increase the
speed of downward movement.
D575A-3 SD 20-131
➀
RELEASING AIR REMAINING IN HYDRAULIC CIRCUIT ON PPC VALVE,
BLEEDING AIR FROM HYDRAULIC CYLINDER,
TESTING AND ADJUSTING ADJUSTING WORK EQUIPMENT SAFETY LEVER
RELEASING AIR REMAINING ADJUSTING WORK

IN HYDRAULIC CIRCUIT ON EQUIPMENT SAFETY LEVER
PPC VALVE
1. Adjust dimension a between the pins of rod (1),
★ When disconnecting the piping between the then connect to safety lever (2) and PPC lock
hydraulic cylinder and control valve, release the valve (3).
remaining pressure inside the circuit as follows. • Dimension a between pins: 347 mm
1) Lower the work equipment to the

ground and stop the engine.
2) Loosen the oil filler cap slowly to
release the pressure inside the hydrau-
lic tank.
3) Operate the control levers several
times to release the remaining pres-
sure in the hydraulic piping and accu-
mulator.
★ If the control lever is operated 3 – 4
times, the pressure accumulated in
the accumulator is removed.
4) Start the engine, run the engine at low
idling for approx. 10 seconds, then stop
the engine and operate the control
lever suddenly.
★ Repeat the above operation 2 – 3
times.
BLEEDING AIR FROM

HYDRAULIC CYLINDER
★ When operating the hydraulic cylinders for the
first time after replacing or reassembling the cyl-
inders or piping, always bleed the air from the
hydraulic cylinder as follows:
1) Start engine and run at low idling for approx.

5 minutes.
2) Run the engine at low idling, and raise and

lower the blade 4 – 5 times.
★ When operating the hydraulic cylinder,
stop the piston rod 100 mm from the end
of its stroke. Do not relieve the circuit
under any circumstances.
3) Run the engine at high idling and repeat Step

2), then run the engine at low idling and
operate the piston rod to the end of its stroke
to relieve the circuit.
20-132 D575A-3 SD
➀
TESTING AND ADJUSTING PROCEDURE FOR ADJUSTING BLADE TILT LIMIT ANGLE
PROCEDURE FOR ADJUSTING 4. Press PITCH BACK button (7) on the blade lever
to save the blade horizontal condition to the sys-
BLADE TILT LIMIT ANGLE tem.
★ When the buzzer sounds once, the saving is
★ If the blade and blade cylinder potentiometer completed.
have been removed and installed again, or the
machine controller has been replaced, adjust the
blade tilt limit angle as follows.
★ If this adjustment is not carried out, the amount
of tilt will be reduced, or will become too large
and will interfere with the track, so always carry
out this adjustment.
★ Carry out the adjustment on a level ground sur-
face.
5. Turn service switch (4) OFF.

★ To set the blade to the adjustment posture,
switch the monitor panel to the normal mode.
1. Start the engine, run at low idling, and set the

blade at the following basic posture.
1) Set the tilt angle to horizontal (0°).
2) Set the pitch angle to the maximum pitch
back.
3) Lower the blade to the ground.
2. Adjust installation dimension a of rod (1), and

connect to potentiometer lever (2) and yoke (3).
• Installation dimension a: 570 mm 6. Operate the blade as follows as preparation to
make it possible to operate the tilt.
1) Raise the tip 200 – 300 mm from the ground.
2) Set the angle of the edge to 55°.
★ Use angle gauge Q to adjust the angle of
the edge correctly.
3) Raise the tip of the blade approx. a further 1
m above the ground surface.
3. Turn service switch (4) ON, turn economy mode

switch (5) to 1, and display [20] on display (6) at
the panel.
★ The service switch is installed inside the fuse
box.
D575A-3 SD 20-133
➀
TESTING AND ADJUSTING PROCEDURE FOR ADJUSTING BLADE TILT LIMIT ANGLE
7. Turn service switch (4) ON again and display 10. Operate the blade lever to right tilt and set the
[20] on display (6) at the panel. right tilt angle to 7°.
★ The tilt limit function will not work, so operate
slowly and be careful not to let the tilt angle
become too large.
★ Use angle gauge Q to adjust the tilt angle
correctly.
8. Operate the blade lever to left tilt and set the left
tilt angle to 7°.
★ The tilt limit function will not work, so operate
slowly and be careful not to let the tilt angle
become too large.
★ Use angle gauge J to adjust the tilt angle 11. Press PITCH DUMP button (8) on the blade
correctly. lever to save the right tilt limit value to the sys-
tem.
9. Press PITCH DUMP button (8) on the blade ★ When the buzzer sounds once, the saving is
lever to save the left tilt limit value to the system. completed.
★ When the buzzer sounds once, the saving is
completed. 12. Turn service switch (4) OFF and stop the engine.
13. Start the engine again, operate the left and right
tilt, and check that the blade does not interfere
with the track when the blade is raised to any
height.
• Automatic stop angle for tilt: 7 ± 1°
20-134 D575A-3 SD
➀
TROUBLESHOOTING
Points to remember when troubleshooting ................................................................................................. 20-202

Sequence of events in troubleshooting ....................................................................................................... 20-203
Points to remember when carrying out maintenance.................................................................................. 20-204
Checks before troubleshooting .................................................................................................................. 20-212
Type of connector and position of installation ............................................................................................. 20-213
Location of connector, sensor ..................................................................................................................... 20-218
Connection table for connector pin numbers .............................................................................................. 20-221
Explanation of functions of control mechanism of electrical system ........................................................... 20-239
Display method and special functions of monitor panel .............................................................................. 20-245
Method of using troubleshooting charts ..................................................................................................... 20-267
Troubleshooting of network system (N mode) ............................................................................................ 20-301
Troubleshooting of engine controller system (E mode)............................................................................... 20-401
Troubleshooting of steering controller system (ST mode) .......................................................................... 20-501
Troubleshooting of transmission controller system (T mode) ..................................................................... 20-601
Troubleshooting of hydraulic and mechanical systems (H mode)............................................................... 20-701
Troubleshooting of monitor panel and electrical system (M mode)............................................................ 20-801
D575A-3 SD 20-201
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

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

disassemble the components. 5) Other maintenance items can be checked
If components are disassembled immediately any externally, so check any item that is consid-
failure occurs: ered to be necessary.
4. Confirming failure
• Parts that have no connection with the failure or
Confirm the extent of the failure yourself, and
other unnecessary parts will be disassembled. judge whether to handle it as a real failure or as
• It will become impossible to find the cause of a problem with the method of operation, etc.
the failure. ★ When operating the machine to reenact the
It will also cause a waste of manhours, parts, or oil troubleshooting symptoms, do not carry out
or grease, and at the same time, will also lose the any investigation or measurement that may
confidence of the user or operator. make the problem worse.
For this reason, when carrying out troubleshooting, 5. Troubleshooting
it is necessary to carry out thorough prior investiga- Use the results of the investigation and inspec-
tion and to carry out troubleshooting in accordance tion in Items 2 – 4 to narrow down the causes of
with the fixed procedure. failure, then use the troubleshooting flowchart to
2. Points to ask user or operator locate the position of the failure exactly.
1) Have any other problems occurred apart from ★ The basic procedure for troubleshooting is
the problem that has been reported? as follows.
2) Was there anything strange about the machine 1) Start from the simple points.
before the failure occurred? 2) Start from the most likely points.
3) Did the failure occur suddenly, or were there 3) Investigate other related parts or infor-
problems with the machine condition before mation.
this? 6. Measures to remove root cause of failure
4) Under what conditions did the failure occur? Even if the failure is repaired, if the root cause of
5) Had any repairs been carried out before the fail- the failure is not repaired, the same failure will
ure? occur again.
When were these repairs carried out? To prevent this, always investigate why the prob-
6) Has the same kind of failure occurred before? lem occurred. Then, remove the root cause.
3. Check before troubleshooting
1) Check the oil level
2) Check for any external leakage of oil from the
piping or hydraulic equipment.
3) Check the travel of the control levers.
4) Check the stroke of the control valve spool.
20-202 D575A-3 SD
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTNG
SEQUENCE OF EVENTS IN TROUBLESHOOTNG
Office, shop Jobsite

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

ask the following points.
Name of customer
Type, serial number of machine
Details of jobsite, etc.
2) Ask questions to gain an outline of the
problem.
Condition of failure
TEW00182
Work being carried out at the time of the
failure
Operating environment
Past history, details of maintenance, etc.
TEW00183
Step 2
Determining probable location of cause
1) Look at the troubleshooting section of the

shop manual to find locations of possible
causes.
TEW00184
Step 3
Preparation of troubleshooting tools
1) Look at the troubleshooting section of the Step 7

shop manual to find locations of possible Pinpoint locations of failure (carry out
causes. troubleshooting)
T-adapter Decide action to take
Hydraulic pressure gauge kit, etc.
2) Look in the parts book and prepare the 1) Before starting troubleshooting, locate and
necessary replacement parts. TEW00186 repair simple failures.
Check before starting items
Other check items
2) See the Troubleshooting Section of the shop
manual, select a troubleshooting flowchart
that matches the symptoms, and carry out
troubleshooting. TEW00187
Step 6
Re-enacting failure
Drive and operate the machine to confirm the

condition and judge if there is really a failure.
TEW00188
Step 4 Step 5
Go to jobsite Ask operator questions to confirm details of
failure.
Was there anything strange about the ma-

chine before the failure occurred?
Did the failure occur suddenly?
TEW00189
Had any repairs been carried out before the TEW00190
failure?
D575A-3 SD 20-203
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

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

tric 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 deforma-
tion or damage. For this reason, it is necessary to
be extremely careful when handling wiring har-
nesses.
Main failures occurring in wiring harness

➀ Defective contact of connectors (defective con-
tact between male and female)
Problems with defective contact are likely to
occur because the male connector is not prop-
erly 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 oxi-
dization of the contact surfaces.
➁ 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 break-
age.
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 break-
age.
20-204 D575A-3 SD
➂ 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 con-
nector may separate, or the soldering may be
damaged, or the wiring may be broken.
➃ 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 con-
nector, water may enter the connector, depend-
ing on the direction of the water jet.
As already said, the connector is designed to
prevent water from entering, but at the same
time, if water does enter, it is difficult for it to be
drained. Therefore, if water should get into the
connector, the pins will be short-circuited by the
water, so if any water gets in, immediately dry
the connector or take other appropriate action
before passing electricity through it.
➄ 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.
★ When wiping the mating portion of the con-
nector, be careful not to use excessive
force or deform the pins.
★ If there is oil or water in the compressed air,
the contacts will become even dirtier, so
remove the oil and water from the com-
pressed air completely before cleaning with
compressed air.
D575A-3 SD 20-205
2) Removing, installing, and drying connectors

and wiring harnesses
• Disconnecting connectors
➀ Hold the connectors when disconnecting.
When disconnecting the connectors, hold the
connectors and not the wires. For connectors
held by a screw, loosen the screw fully, then hold
the male and female connectors in each hand
and pull apart. For connectors which have a lock
stopper, press down the stopper with your thumb
and pull the connectors apart.
★ Never pull with one hand.
➁ When removing from clips

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

After removing any connector, cover it with a vinyl
bag to prevent any dust, dirt, oil, or water from
getting in the connector portion.
★ If the machine is left disassembled for a long
time, it is particularly easy for improper con-
tact to occur, so always cover the connector.
20-206 D575A-3 SD
• Connecting connectors
➀ Check the connector visually.
1) Check that there is no oil, dirt, or water stuck
to the connector pins (mating portion).
2) Check that there is no deformation, defective
contact, corrosion, or damage to the connec-
tor pins.
3) Check that there is no damage or breakage to
the outside of the connector.
★ If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry cloth.
If any water has got inside the connector,
warm the inside of the wiring with a dryer,
but be careful not to make it too hot as
this will cause short circuits.
★ If there is any damage or breakage,
replace the connector.
➁ Fix the connector securely.

Align the position of the connector correctly, then
insert it securely.
For connectors with lock stopper, push in the con-
nector until the stopper clicks into position.
➂ Correct any protrusion of the boot and any mis-

alignment of the wiring harness
For connectors fitted with boots, correct any pro-
trusion of the boot. In addition, if the wiring har-
ness is misaligned, or the clamp is out of position,
adjust it to its correct position.
★ If the connector cannot be corrected easily,
remove the clamp and adjust the position.
➃ If the connector clamp has been removed, be

sure to return it to its original position. Check also
that there are no loose clamps.
D575A-3 SD 20-207
• 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.

➀ Disconnect the connector and wipe off the water
with a dry cloth.
★ If the connector is blown dry with com-
pressed air, there is the risk that oil in the air
may cause defective contact, so remove all
oil and water from the compressed air
before blowing with air.
➁ Dry the inside of the connector with a dryer.

If water gets inside the connector, use a dryer to
dry the connector.
★ Hot air from the dryer can be used, but regu-
late 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.
➂ Carry out a continuity test on the connector.

After drying, leave the wiring harness discon-
nected and carry out a continuity test to check
for any short circuits between pins caused by
water.
★ After completely drying the connector, blow
it with contact restorer and reassemble.
20-208 D575A-3 SD
3) Handling control box

➀ The control box contains a microcomputer and
electronic control circuits. These control all of
the electronic circuits on the machine, so be
extremely careful when handling the control
box.
➁ Do not open the cover of the control box unless
necessary.
➂ Do not place objects on top of the control box.

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

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

1) Always turn the power OFF before disconnecting or connect connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
★ Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
★ If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays
will be generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current),
move the related wiring and connectors several times and check that there is no change in the reading
of the tester.
★ If there is any change, there is probably defective contact in that circuit.
D575A-3 SD 20-209
3. POINTS TO REMEMBER WHEN HAN-

DLING HYDRAULIC EQUIPMENT
With the increase in pressure and precision of hydraulic

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

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

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

operations.
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil filler
and the area around it clean, and also use clean
pumps and oil containers. If an oil cleaning device is
used, it is possible to filter out the dirt that has col-
lected during storage, so this is an even more effec-
tive method.
20-210 D575A-3 SD
5) Change hydraulic oil when the temperature is

high.
When hydraulic oil or other oil is warm, it flows eas-
ily. 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 flush-
ing 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, con-
trol valve, etc.) or when running the machine, carry
out oil cleaning to remove the sludge or contami-
nants in the hydraulic oil circuit.
The oil cleaning equipment is used to remove the
ultrafine (about 3µ) particles that the filter built into
the hydraulic equipment cannot remove, so it is an
extremely effective device.
D575A-3 SD 20-211
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING

Judgment
Item value Action
1. Check fuel level, type of fuel — Add fuel
2. Check for impurities in fuel — Clean, drain
Lubricating oil, coolant
3. Check hydraulic oil level — Add oil

4. Check hydraulic strainer — Clean, drain
5. Check power train oil level — Add oil
6. Check engine oil level (oil pan oil level), type of oil — Add oil
7. Check coolant level — Add water
8. Check dust indicator for clogging — Clean or replace
9. Check hydraulic filter — Replace
1. Check for looseness, corrosion of battery terminal, wiring — Tighten or replace

equipment
Electrical
2. Check for looseness, corrosion of alternator terminal, wiring — Tighten or replace

3. Check for looseness, corrosion of starting motor terminal, wiring — Tighten or replace
1. Check for abnormal noise, smell — Repair

mechanical
equipment
Hydraulic,
2. Check for oil leakage — Repair

3. Carry out air bleeding — Bleed air
1. Check battery voltage (engine stopped) 24 – 26V Replace

2. Check battery electrolyte level — Add or replace
Electrics, electrical equipment
3. Check for discolored, burnt, exposed wiring — Replace

4. Check for missing wiring clamps, hanging wiring — Repair
5. Check for water leaking on wiring (be particularly careful attention — Disconnect
to water leaking on connectors or terminals) connector and dry
6. Check for blown, corroded fuses — Replace
7. Check alternator voltage (engine running at 1/2 throttle or above) After running
for several
minutes:
27.5 – 29.5 V
8. Check operating sound of battery (when switch is turned ON/OFF) — Replace
20-212 D575A-3 SD
TROUBLESHOOTING TYPE OF CONNECTOR AND POSITION OF INSTALLATION
TYPE OF CONNECTOR AND POSITION OF INSTALLATION
D575A-3 SD 20-213
20-214 D575A-3 SD
D575A-3 SD 20-215
20-216 D575A-3 SD
TROUBLESHOOTING LOCATION OF CONNECTOR, SENSOR
LOCATION OF CONNECTOR, SENSOR

★ For details of this page, see page 90-201
20-218 D575A-3 SD
D575A-3 SD 20-219
20-220 D575A-3 SD
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

★ The terms male and female refer to the pins, while the terms male housing and female housing refer to the
mating portion of the housing.
No. X type connector

of
pins Male (female housing) Female (male housing)
1
1
2 2
TEW00221
TEW00222
1 3 3 1
2 2
TEW00223 TEW00224
1 3
3 1
2 4 4 2
TEW00225 TEW00226
D575A-3 SD 20-221
No. SWP type connector

of
1 4 4 1
3 6
6 3 BLP00033
TEW00235
1 5 5 1
4 8 8 4
TEW00237 TEW00238
4 1 1 4
12 8 5 5 8
12 9 9 12
BLP00035
BLP00034
1 4 8 11 11 8 4 1
14
3 7 10 14
14 10 7 3
TEW00239 TEW00240
4 1
1 4
8 5
5 8
16
12 9
9 12
16 13
BLP00036 13 16 BLP00037
20-222 D575A-3 SD
No. M type connector

of
2 2
1 BLP00038 1 BLP00039
2 3 3 2
1 1
TEW00243 TEW00244
1 3 3 1
2 4 4 2
TEW00245 TEW00246
1 4 4 1
3 6 6 3
TEW00247 TEW00248
4 1 1 4
8 5
BLP00040
5 8 BLP00041
D575A-3 SD 20-223
No. S type connector

of
1 5 5 1
4 8 TEW00249
8 4 TEW00250
6 1
1 6
10
5 10 10
TEW00251 5 BLP00042
1 6 6 1
12
5 12
BLP00043 12 5 TEW00254
1 8 8 1
16
7 16 BLP00044 16 7 TEW00256
20-224 D575A-3 SD
No. MIC connector

of
1 3 3 1
4 5 4
5
5
BLP00045
BLP00046
1 5 1
5
6 9 9 6
9
BLP00047 BLP00048
1 7 7 1
13
8 13 8
13
BLP00049 BLP00050
1 9 9 1
10 17
17 10
17
BLP00051 BLP00052
1 11
11 1
12 21
21 21 12
TEW00259 TEW00260
D575A-3 SD 20-225
No. AMP040 type connectorr

of
4 8
8 4
1 5
5 1 BLP00054
BLP00053
6 12 12 6
12
1 7
BLP00055
7 1 BLP00056
8 16
16 8
16
9 1
1 9 TEW00232
BLP00057
10 20
20 10
20
11 1
1 11 TEW00234
BLP00058
20-226 D575A-3 SD
No. AMP070 type connector

of
1 7 7 1
6 14
BLP00059 14 6 BLP00060
1 9 9 1
12
8 18
BLP00061 18 8 BLP00062
D575A-3 SD 20-227
No. L type connector

of
1 1
2
2
2
TEW00258
TEW00257
20-228 D575A-3 SD
No. Automobile connector

of
2 2
1
1 BLP00063 BLP00064
1 1
3 2
2 3 BLP00065
BLP00066
1 2 2 1
4 3
3 4 BLP00067 BLP00068
3 1 1 3
4 6
6 4 BLP00069
BLP00070
4 1 1 4
5 8
8 5 BLP00071 BLP00072
D575A-3 SD 20-229
No. Relay connector

of
2 5 2 1
1 3 6 5 6 3
BLP00073 BLP00074
6 4 3 6 5
4 3 1 2
5 2 1
BLP00075 BLP00076
20-230 D575A-3 SD
(Pin No. is printed on connector (wire insertion side), too.)

Type HD30 series connector
(Shell
size Part No. of
code) Body (Plug) Body (Receptacle)
T-adapter
Pin (male terminal) Pin (female terminal)
799-601-9210
Part No.: 08191-11201, 08191-11202, Part No.: 08191-14101, 08191-14102,

18-8 08191-11205, 08191-11206 08191-14105, 08191-14106
(1) Pin (female terminal) Pin (male terminal)
799-601-9210
Part No.: 08191-12201, 08191-12202, Part No.: 08191-13101, 08191-13102,

08191-12205, 08191-12206 08191-13105, 01891-13106
799-601-9220
Part No.: 08191-21201, 08191-12202, Part No.: 08191-24101, 08191-24102,

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
799-601-9220
Part No.: 08191-22201, 08191-22202, Part No.: 08191-23101, 08191-23102,

08191-22205, 08191-22206 08191-23105, 08191-23106
D575A-3 SD 20-231

(Shell
size Part No. of
T-adapter
799-601-9230
Part No.: 08191-31201, 08191-31202 Part No.: 08191-34101, 08191-34102

18-20
799-601-9230
Part No.: 08191-32201, 08191-32202 Part No.: 08191-33101, 08191-33102
799-601-9240
Part No.: 08191-41201, 08191-42202 Part No.: 08191-44101, 08191-44102

18-21
799-601-9240
Part No.: 08191-42201, 08191-42202 Part No.: 08191-43101, 08191-43102
20-232 D575A-3 SD

(Shell
size Part No. of
T-adapter
799-601-9250
Part No.: 08191-51201, 08191-51202 Part No.: 08191-54101, 08191-54102

24-9
799-601-9250
Part No.: 08191-52201, 08191-52202 Part No.: 08191-53101, 08191-53102
799-601-9260
Part No.: 08191-61201, 08191-62202, Part No.: 08191-64101, 08191-64102,

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
799-601-9260
Part No.: 08191-62201, 08191-62202, Part No.: 08191-63101, 08191-63102,

08191-62205, 08191-62206 08191-63105, 08191-63106
D575A-3 SD 20-233

(Shell
size Part No. of
T-adapter
799-601-9270
Part No.: 08191-71201, 08191-71202, Part No.: 08191-74101, 08191-74102,

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
799-601-9270
Part No.: 08191-72201, 08191-72202, Part No.: 08191-73101, 08191-73102

08191-72205, 08191-72206 08191-73105, 18191-73106
799-601-9280
P a rt N o.:08 191-81 201,0819 1-8120 2,08 191 -8 1203 , P art N o.: 08 191-84 101,0819 1-8410 2,08 191-84 103 ,
24-22 08 191-81 204,0819 1-8120 5,08 191 -8 0206 08 191-84 104,0819 1-8410 5,08 191-84 106
799-601-9280
P a rt N o.:08 191-82 201,0819 1-822 02,08 191 -8 2203 , P art N o.:0 819 1-8 310 1,08 191-83 102,0819 1-8310 3,
08 191-82 204,0819 1-822 05,08 191 -8 2206 0 819 1-8 310 4,08 191-83 105,0819 1-8310 6
20-234 D575A-3 SD

(Shell
size Part No. of
code) Body (Plug) Body (Receptacle) T-adapter
799-601-9290
Part No.: 08191-91203, 08191-91204, Part No.: 08191-94103, 08191-94104,

24-31 08191-91205, 08191-91206 08191-84105, 08191-94106
799-601-9290
Part No.: 08191-92203, 08191-92204, Part No.: 08191-93103, 08191-93104,

08191-92205, 08191-92206 08191-93105, 08191-93106
D575A-3 SD 20-235

Type
(Shell DT series connector
size
code) Body (Plug) Body (Receptacle) v
2 799-601-9020
Part No.: 08192-12200 (Normal type) Part No.: 08192-12100 (Normal type)
08192-22200 (Fine wire type) 08192-22100 (Fine wire type)
3 799-601-9030
4 799-601-9040
6 799-601-9050
20-236 D575A-3 SD
DT series connector
c
Body (Plug) Body (Receptacle) Part No. of T-adapter
8GR :799-601-9060
8B :799-601-9070
8
8G :799-601-9080
8BR :799-601-9080
12GR :799-601-9110
12B :799-601-9120
10 12G :799-601-9130
12BR :799-601-9140
D575A-3 SD 20-237

Type
(Shell DTM series connector
size
code) Body (Piug) Body (Receptacle) Part No. of T-adapter
2 799-601-9010
Part No.: 08192-02200 Part No.: 08192-02100

Type
(Shell DTHD series connector
size
code) Body (Piug) Body (Receptacle) Part No. of T-adapter
2 —
Part No.: 08192-03120 (Contact size #12) Part No.: 08192-31100 (Contact size #12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
20-238 D575A-3 SD
EXPLANATION OF FUNCTIONS OF CONTROL
TROUBLESHOOTING MECHANISM OF ELECTRICAL SYSTEM
EXPLANATION OF FUNCTIONS OF CONTROL MECHANISM OF

ELECTRICAL SYSTEM
D575A-3 SD 20-239
20-240 D575A-3 SD
D575A-3 SD 20-241
Functions of machine monitor system Functions of engine throttle, pump controller

• Monitor panel (1) receives the signals from each control system
switch and sensor and the S-NET data from the • Engine controller (15) receives the signals from
engine controller, steering controller and trans- the sensors, the S-NET data from the monitor
mission controller. It then calculates these and panel, the S-NET data from the steering control-
drives or displays the lamps, gauges, tachome- ler and transmission controller, and the SSC
ter, and service meter, displays codes when an throttle command and neutral signal. It then cal-
abnormality occurs, and also carries out monitor- culates these and sends signals to the solenoid
ing of the functions and machine condition. valves or relays to control the engine.
• The voltage generated by alternator (2) is input • Fuel control dial (16) detects the amount of
to the monitor panel. opening of the throttle and inputs an analog sig-
• Radiator water level sensor (3) detects the water nal to the engine controller.
level in the radiator sub tank and inputs an ON/ • Deceleration potentiometer (17) detects when
OFF signal to the monitor panel. the decelerator pedal is depressed and inputs an
• Engine oil level sensor (4) detects the level of the analog signal to the engine controller.
oil in the engine oil pan and inputs an ON/OFF • Engine speed sensors (18) and (19) detect the
signal to the monitor panel. speed of the engine flywheel and input a pulse
• Engine oil pressure sensor (5) detects the signal to the engine controller.
engine oil pressure when the engine is running The signal from left bank engine speed sensor
and inputs an ON/OFF signal to the monitor (19) is also input to the steering controller and
panel. transmission controller.
• Hydraulic oil level sensor (6) detects the level of • Governor cut relays (20) and (21) receive the
the oil in the hydraulic tank and inputs an ON/ ON/OFF signals output from the engine control-
OFF signal to the monitor panel. ler and supply or stop the power for the sole-
• Air cleaner clogging sensor (7) detects clogging noids.
of the air cleaner from negative intake air pres- • Buzzer cancel switch (22) inputs the ON/OFF
sure between the air cleaner and turbocharger, signal to the engine controller and steering con-
and inputs an ON/OFF signal to the monitor troller to stop the buzzer when an abnormality
panel. occurs.
• Torque converter oil temperature sensor (8) • Rack sensors (23) and (24) detect the position of
detects the temperature of the oil in the power the fuel injection pump rack and input an analog
train and inputs an analog signal to the monitor signal to the engine controller
panel. • Pre-stroke solenoids (25) and (26) receive the
• Fuel level sensor (9) detects the level of the fuel analog signal output from the engine controller,
in the fuel tank and inputs an analog signal to the and control the pre-stroke of the fuel injection
monitor panel. pump.
• Engine water temperature sensor (10) detects • Governor solenoids (27) and (28) receive the
the temperature of the engine cooling water and analog signal output from the engine controller
sends an analog signal to the monitor panel and and control the functions of the fuel injection
engine controller. pump governor.
• SSC initial setting connector (11) inputs an ON/
OFF signal to the monitor panel to switch the ini-
tial setting of the SSC switch on the panel.
• Service switch (12) inputs an ON/OFF signal to
the monitor panel to switch the display on the
monitor panel and engine controller.
• Caution lamp (13) receives the ON/OFF signal
output from the monitor panel and turns the lamp
on or off.
• Alarm buzzer (14) receives the ON/OFF signal
output from the monitor panel and turns the
buzzer on or off.
20-242 D575A-3 SD
Functions of steering control system • Transmission lubricating oil pressure sensor (38)
• Steering controller (29) receives the signals from detects the transmission lubricating oil pressure
each switch and sensor, the switch signals from and input an ON/OFF signal to the steering con-
the monitor panel, and the S-NET data from the troller.
monitor panel, engine controller and transmis- • Bevel gear speed sensor (39) detects the rotat-
sion controller. It then calculates these and out- ing speed of the bevel gear and inputs a pulse
puts signals to the steering solenoid valves, or signal to the steering controller and transmission
engine controller to control the movement of the controller.
machine. • Parking lever switch (40) detects the condition of
• Brake pedal potentiometer (30) detects when the the parking lever and inputs an ON/OFF signal to
brake pedal is depressed and inputs an analog the steering controller and transmission control-
signal to the steering controller. ler.
• Steering lever potentiometer (31) and (32) detect • Emergency stop prevention valve solenoid (41)
when the steering lever is open and input an receives the ON/OFF signal output from the
analog signal to steering controller. steering controller and switches the emergency
• Pitch angel sensor (33) detects the angle of the stop prevention valve solenoid.
machine and inputs an analog signal to steering • Left steering brake solenoid (42) and right steer-
controller and transmission controller. ing brake solenoid (43) receive the analog signal
• Fill switches (34), (35), (36) and (37) of the steer- output from the steering controller and control
ing detect the steering condition and input an the steering brake ECMV.
ON/OFF signal to the steering controller. • Left steering clutch solenoid (44) and right steer-
ing clutch solenoid (45) receive the analog signal
output from the steering controller and control
the steering clutch ECMV.
D575A-3 SD 20-243
Functions of transmission and pump controller • Pitch selection solenoid (67) receive the ON/
control system OFF signal output from the transmission control-
• Transmission controller (46) receives the signals ler and switch the pitch PPC circuit.
from each switch and sensor, the switch signals • Pitch dump solenoid (69) and pitch back sole-
from the monitor panel, and the S-NET data from noid (70) receive the ON/OFF signal output from
the monitor panel and engine controller and the transmission controller and switch the pitch
steering controller. It then calculates these and PPC circuit.
outputs signals to the solenoid valves, relays, or • Left tilt limit solenoid (71) and right tilt limit sole-
engine controller to control the movement of the noid (72) receive the ON/OFF signal output from
machine. the transmission controller and switch the tilt
• Directorial lever potentiometer (47) and (48) PPC circuit.
detect when directional lever is operated and • Blade lift 1 pump cut solenoid (73) receive the
input an analog signal to the transmission con- ON/OFF signal output from the transmission
troller. controller and switch the blade lift PPC circuit.
• Gear shift up switch (49) and gear shift down • Backup alarm relay (74) receives the ON/OFF
switch (50) detect when gear shift is pushed and signal output from the transmission controller
input an ON/OFF signal to the transmission con- and switches the backup alarm circuit.
troller. • Gear shift mode lamp (75) and (76) receive the
• Oil pressure switches (51) and (52) of the blade ON/OFF signal output from the transmission
lever detect the operating condition of the blade controller and turn the lamp on or off.
lever and input an ON/OFF signal to the trans- • Transmission solenoid (77), (78), (79), (80 and
mission controller. (81) receive an analog signal output from the
• Fill switches (53), (54), (55), (56), and (57) of the transmission controller and control transmission
transmission detect the gearshifting condition of clutch ECMV.
the transmission and input an ON/OFF signal to • Neutral safety relay (82) reserves the ON/OFF
the transmission controller. signal output from the transmission controller
• Blade lever switches (58) and (59) detect the and switches the engine start circuit.
operating condition of the switches and input an • Pitch dump assist pump relay (83) reserves the
ON/OFF signal to the transmission controller. ON/OFF signal output from the transmission
• Work equipment oil pressure sensor [200] (60) controller and switch the pitch dump assist sole-
detects the discharge pressure of the main pump noid circuit.
for the work equipment and inputs an analog sig-
nal to the transmission controller.
• Work equipment oil pressure sensor [200] (61)
detects the discharge pressure of the work
equipment main pump 2 and inputs an analog
signal to the transmission controller.
• Auto pitch back switch (62) input an ON/OFF sig-
nal to the transmission controller to select the
auto pitch bake function.
• Auto gear shift down switch (63) inputs an ON/
OFF signal to the transmission controller to
select the auto gear shift down function.
• Left cylinder angle sensor (64) and right cylinder
angle sensor (65) defect the blade lift cylinder
angle and input an analog signal to the transmis-
sion controller.
• Torque converter lock-up solenoid (66) receives
the ON/OFF signal output from the transmission
controller and engages or disengages the lock-
up clutch and stator clutch.
20-244 D575A-3 SD
TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR

PANEL
1. Economy mode switch 6. Rear light switch

2. Display 1 7. Fther motor switch
3. Display 2 8. Auto shift down switch
4. Auto pitch back switch 9. Key switch
5. Front light switch 10. Buzzer cancel switch
*1: Monitoring mode

To go to next item. press reverse slow mode switch : to go back to previous item. press buzzer cancel switch
*2: Adjustment mode
To go to next item. press reverse slow mode switch : to go back to previous item (not available)
*3: Service code display mode
E : Code for existing problem, P : Code for problem that occurred in past : Code and time of occurrence dis-
played in turn on service meter
To go to next item, press reverse slow mode switch : to go back to previous item (not available) : to clear
code, press buzzer cancel switch (P only)
D575A-3 SD 20-245
Procedure for switching to each mode
20-246 D575A-3 SD
1. Normal display functions

During normal operations, the speed range is shown
on the top panel and the service meter is displayed
on the bottom panel.
2. User code display function when abnormality

occurs
If an abnormality occurs during operations and it is
necessary to inform the operator, the user code and
service meter are displayed in turn on the bottom
panel.
In the case of user codes with a high emergency
level, the caution lamp flashes and the alarm buzzer
sounds at the same time.
<Reference>
The user codes are displayed only when an abnor-
mality with a high emergency level occurs.
This means that an abnormality may have occurred
even when there is no user code display. If any prob-
lem is felt, always use the service code display mode
to check if there is any service code.
D575A-3 SD 20-247
User codes and type of abnormality
User codes Type of abnormality Action taken by machine

• Torque converter lock-up does not come ON • Stops automatic stop function
• Blade is not automatically reset • When automatic stop function is not
• Pitch actuation stops actuated, work is possible, but be
E01 • Pitch dump speed is slow careful
• Abnormality in engine water temperature monitor
• Abnormality in power train oil temperature monitor
• Abnormality in hydraulic oil temperature monitor
• Tilt limit has no effect • Flashes caution lamp, sounds alarm

• Gear shift actuation stops buzzer
• Stops tilt limit function
E02 • If engine is stopped and then started
again, tilt limit function, automatic
stop function are not actuated, so
work is possible, but be careful
• Pitch is actuated when tilt is operated • Flashes caution lamp, sounds alarm
• Pitch actuation stops buzzer
• Torque converter lock-up is not switched ON or is • It is only possible to move machine
CALL03 not switched OFF to a safe place
• Engine runs on one bank (output is reduced)
• Engine speed cannot be controlled
• Abnormality in engine water temperature monitor
• Engine cannot be controlled • Flashes caution lamp, sounds alarm

• Machine cannot run. buzzer
CALL
• Engine must be stopped immedi-
ately
20-248 D575A-3 SD
3. Monitoring mode display function

The condition of all parts of the machine can be
checked on the monitor panel through the signals
from the sensors installed to various parts of the
machine.
The method for displaying the monitoring data con-
sists of values such as the engine speed, voltage,
and current that are displayed as numerals, and the
operating condition of the oil pressure switches and
solenoid valves that are displayed as bits.
D575A-3 SD 20-249
4. Operating method in monitoring mode

• Explanation of display
The monitored items are displayed in display
unit 1 by figures and alphabet letters.
The monitored items are displayed in display
unit 2 by figures and bits.
• Item selecting method

The items are selected in the normal order with
reverse slow mode selector switch (1) and in the
reverse order with the caution buzzer cancel
switch (2).
20-250 D575A-3 SD
• Measurement of normal operation in monitoring

mode
The normal operation can be started with the
monitored item (engine speed) displayed.
1) Display of item to be monitored

Example: Engine speed
2) Starting normal operation with monitored

value displayed
• Turn the auto shift-down switch (3) to
the position opposite to the current posi-
tion (If it is at the ON position, turn it to
the OFF position).
• Turn the travel lock lever to the FREE
position.
3) Returning to monitoring mode

i) Turn the travel lock lever to the LOCK
position.
ii) Turn on caution buzzer cancel switch (2)
for 1 second or longer.
• Function of holding monitored value

The currently monitored value (engine speed)
can be held with auto shift-down switch (3).
With this function, you can read a fluctuating
value and a momentary value.
Method of turning off holding function
Turn the auto shift-down switch to the position
opposite to the current position. Turn the travel
lock lever to the LOCK position.
D575A-3 SD 20-251
Monitoring code No. and display item
Code No. Monitoring item Display unit Component

99 Engine speed rpm Steering controller
91 Engine speed sensor voltage mV Steering controller
bo Bevel gear speed rpm Steering controller
97 Bevel gear speed sensor voltage mV Steering controller
7R Not used — —
95 Not used — —
bA Battery voltage mV Steering controller
L1 Steering potentiometer 1 voltage mV Steering controller
L2 Steering potentiometer 2 voltage mV Steering controller
L7 Brake potentiometer voltage mV Steering controller
A6 Pitch angle sensor ±0.001° Steering controller
A8 Pitch angle sensor voltage mV Steering controller
F5 Fuel control dial command value rpm Steering controller
F6 Not used — —
d5 Decelerator potentiometer command value rpm Steering controller
d6 Not used — —
A5 Not used — —
5U Shoe controller command value rpm Steering controller
5d Engine command voltage mV Steering controller
L9 Switch input 1 bit Steering controller
LE Not used — —
LL Not used — —
CE Not used — —
LF Switch input 5 bit Steering controller
LJ Switch input 6 bit Steering controller
7b Fill switch input bit Steering controller
P1 Left brake ECMV current command value mA Steering controller
c1 Left brake ECMV output current (F/B) mA Steering controller
P2 Right brake ECMV current command value mA Steering controller
c2 Right brake ECMV output current (F/B) mA Steering controller
P3 Left clutch ECMV current command value mA Steering controller
c3 Left clutch ECMV output current (F/B) mA Steering controller
P4 Right clutch ECMV current command value mA Steering controller
c4 Right clutch ECMV output current (F/B) mA Steering controller
58 On/Off output bit Steering controller
d7 Emergency stop prevention solenoid voltage mV Steering controller
d8 Engine drive command mV Steering controller
dA Battery controller relay drive voltage mV Steering controller
3E Engine speed rpm Transmission controller
92 Engine speed sensor voltage mV Transmission controller
7P Transmission speed rpm Transmission controller
94 Transmission speed sensor voltage mV Transmission controller
A7 Pitch angle sensor ±0.001° Transmission controller
A9 Pitch angle sensor voltage mV Transmission controller
L3 FR potentiometer 1 voltage mV Transmission controller
L4 FR potentiometer 2 voltage mV Transmission controller
20-252 D575A-3 SD

L5 Switch input 1 bit Transmission controller
L8 Switch input 2 bit Transmission controller
7H Fill switch input bit Transmission controller
P5 Forward clutch ECMV current command value mA Transmission controller
c5 Forward ECMV output current (F/B) mA Transmission controller
P6 Reverse clutch ECMV current command value mA Transmission controller
c6 Reverse ECMV output current (F/B) mA Transmission controller
P7 1st clutch ECMV current command value mA Transmission controller
c7 1st ECMV output current (F/B) mA Transmission controller
P8 2nd clutch ECMV current command value mA Transmission controller
c8 2nd ECMV output current (F/B) mA Transmission controller
P9 3rd clutch ECMV current command value mA Transmission controller
c9 3rd ECMV output current (F/B) mA Transmission controller
Ld ON/OFF output bit Transmission controller
dL Lockup solenoid voltage mV Transmission controller
db Backup alarm relay voltage mV Transmission controller
dN Neutral safety relay voltage mV Transmission controller
d1 N signal 1 voltage mV Transmission controller
d2 N signal 2 voltage mV Transmission controller
bd Blade knob switch input bit Transmission controller
bH Blade hydraulic switch input bit Transmission controller
57 Not used — —
HF Work equipment hydraulic F kg/cm2 Transmission controller
4F Work equipment hydraulic F sensor voltage mV Transmission controller
HR Work equipment hydraulic small, R kg/cm 2 Transmission controller
4R Work equipment hydraulic R sensor voltage mV Transmission controller
Lb Left yoke angle sensor voltage mV Transmission controller
Rb Right yoke angle sensor voltage mV Transmission controller
LA Blade lift angle 0.1° Transmission controller
7d Blade tilt angle 0.1° Transmission controller
55 Super solenoid state bit Transmission controller
59 Super solenoid state 2 bit Transmission controller
6L Left tilt limit solenoid voltage mV Transmission controller
6R Right tilt limit solenoid voltage mV Transmission controller
6P Pitch solenoid voltage mV Transmission controller
6E Pitch superiority solenoid voltage mV Transmission controller
6d Pitch dump solenoid voltage mV Transmission controller
6b Pitch back solenoid voltage mV Transmission controller
6c Lift 1 pump solenoid voltage (Optional) mV Transmission controller
6A Dump assist relay voltage mV Transmission controller
d3 Not used — —
d4 Not used — —
8L Not used — —
87 Not used — —
8c Not used — —
RR Regulation command value rpm Engine controller
D575A-3 SD 20-253

FO Fuel control command value rpm Engine controller
Fd Accelerator voltage mV Engine controller
dd Decelerator command value rpm Engine controller
dU Decelerator voltage mV Engine controller
5R Shoe controller command value rpm Engine controller
5E Shoe controller voltage mV Engine controller
1R Right rack sensor voltage mV Engine controller
2R Left rack sensor voltage mV Engine controller
15 Right governor solenoid current mA Engine controller
25 Left governor solenoid current mA Engine controller
1P Right pre-stroke solenoid current mA Engine controller
2P Left pre-stroke solenoid current mA Engine controller
1E Engine speed A rpm Engine controller
2E Engine speed B rpm Engine controller
75 Engine water temperature high °C Engine controller
HE Transmission N signal 2bits Engine controller
E5 Specification selection state — Engine controller
U1 Engine controller program No. — Engine controller
U2 Tachometer module program No. — Monitro panel
U3 Transmission controller program No. — Transmission controller
U4 Caution module program No. — Monitro panel
U5 Steering controller program No. — Steering controller
5N S-net connection state 6bit Steering controller
78 Engine water temperature °C Steering controller
77 Torque converter oil temperature sensor °C Steering controller
FL Fuel level sensor mV Steering controller
bU Theoretical travel speed m/h Steering controller
FR Theoretical drawbar pull m(F/W) Steering controller
C5 Not used — —
CF Not used — —
Cb Not used — —
Cc Not used — —
5F Not used — —
20-254 D575A-3 SD
Details of bit display items

★ The diagram on the right is an example of the bit dis-
play
➀, ➂, and ➄ display OFF condition
➁, ➃, and ➅ display ON condition
L9: Actuation status of parking lever switch

➀: (Not used)
➁: (Not used)
➂: (Not used)
➃: (Not used)
➄: Parking lever switch (N.C.)
➅: Parking lever switch (N.O.)
The figure at right shows that the parking lever switch
(N.C.) is turned on and the parking lever switch
(N.O.) is turned off.
In the normal state,
When the parking lever is at the LOCK position:
____0_
When the parking lever is at the FREE position:
_______0
LJ: Actuation status of lamp signal

➀: (Not used)
➁: (Not used)
➂: (Not used)
➃: Lighting signal
➄: (Not used)
➅: (Not used)
The figure at right shows that the lighting signal is
turned on.
7b: Actuation status of steering fill switch

➀: Left steering brake fill switch
➁: Left steering clutch fill switch
➂: (Not used)
➃: (Not used)
➄: Right steering clutch fill switch
➅: Right steering brake fill switch
This display shows the state of the steering ECMV fill
switch.
"_" shows that ECMV is draining (the clutch is
engaged completely = oil pressure is 0 kg/cm2), and
"0" shows that ECMV is applying pressure.
The figure at right shows that the left steering clutch
and right steering brake are engaged (Oil pressure is
0 kg/cm2).
D575A-3 SD 20-255
58: Actuation status of ON/OFF input

➀: (Not used)
➁: (Not used)
➂: (Not used)
➃: Engine controller drive relay
➄: Battery relay drive signal
➅: Emergency stop prevention solenoid
The figure at right shows that the emergency stop
prevention solenoid is turned on.
L5: Actuation status of gear shift switch and parking

lever switch
➀: Gear shift up switch (N. C.)
➁: Gear shift up switch (N. C.)
➂: Gear shift down switch (N. C.)
➃: Gear shift down switch (N. C.)
➄: Parking lever switch (N. C.)
➅: Parking lever switch (N. C.)
When the shift-up switch is turned OFF: 0_****
When the shift-up switch is turned ON: _0****
When the shift-down switch is turned OFF: * * 0 _ * *
When the shift-down switch is turned ON: * * _ 0 * *
When the parking lever lock switch is at LOCK position:
****0_
When the parking lever lock switch is at FREE position:
****_0
The figure at right shows that the shift-up switch is
turned off, shift-down switch is turned on, and the
parking lock lever is at the FREE position.
L8: Actuation status of gear shift down switch and auto

pitch back switch
➀: Auto gear shift down switch
➁: (Not used)
➂: (Not used)
➃: (Not used)
➄: (Not used)
➅: Auto pitch back switch
The figure at right shows that both auto shift-down
switch and auto pitch back switch are turned on.
7H: Actuation status of transmission fill switch

➀: Transmisson forward clutch fill switch
➁: Transmission reverse clutch fill switch
➂: Transmission 1st clutch fill switch
➃: Transmission 2nd clutch fill switch
➄: Transmission 3rd clutch fill switch
➅: (Not used)
This display shows the state of the transmission
ECMV fill switch.
The figure at right shows that the switches of the
transmission F clutch and 3rd clutch are turned on.
20-256 D575A-3 SD
Ld: Actuation status of ON/OFF output

➀: Neutral signal 1
➁: Neutral signal 2
➂: (Not used)
➃: Back alarm relay
➄: Neutral satety relay
➅: Lock up solenoid
This display shows if the transmission is in neutral.
When the transmission is in neutral: 00____
When the transmission is not in neutral: _ _ _ _ _ _
The figure at right shows that the transmission is in
neutral.
bd: Actuation status of blade lever knob switch

➀: Blade pitch back switch (N. C.)
➁: Blade pitch back switch (N. O.)
➂: Blade pitch dump switch (N. C.)
➃: Blade pitch dump switch (N. O.)
➄: (Not used)
➅: (Not used)
When the pitch back switch is turned OFF: 0 _ * * * *
When the pitch back switch is turned ON: _ 0 * * * *
When the pitch dump switch is turned OFF: * * 0 _ * *
When the pitch dump switch is turned ON: * * _ 0 * *
The figure at right shows that the pitch back switch
and pitch dump switch are turned off.
bH: Actuation status of blade lever oil pressure switch

➀: RAISE oil pressure switch (Full)
➁: RAISE oil pressure switch
➂: (Not used)
➃: (Not used)
➄: (Not used)
➅: (Not used)
When the blade lever is at UP position (at full stroke):
00____
When the blade lever is at UP position (not at full stroke):
_0____
The figure at right shows that the blade lever is at the
full stroke.
55: Actuation status of super solenoid

➀: Left tilt limit solenoid
➁: Right tilt limit solenoid
➂: Pitch selection solenoid
➃: Pitch priority solenoid
➄: Pitch dump solenoid
➅: Pitch back solenoid
The figure at right shows that the left tilt limit solenoid
is turned on.
D575A-3 SD 20-257
59: Actuation status 2 of super solenoid

➀: (Not used)
➁: (Not used)
➂: (Not used)
➃: (Not used)
➄: Pitch dump assist pump relay
➅: Blade lift 1 pump cut solenoid (OPT)
The figure at right shows that the pitch dump assist
pump relay is turned on.
HE: Actuation status transmission neutral signal

➀: Neutral signal 1
➁: Neutral signal 2
➂: (Not used)
➃: (Not used)
➄: (Not used)
➅: (Not used)
This display shows if the transmission is in neutral.
When the transmission is in neutral: 00____
When the transmission is not in neutral: _ _ _ _ _ _
The figure at right shows that the transmission is in
neutral.
E5: Machine specification

➀: Machine specification
➁: Machine specification
➂: Machine specification
➃: Machine specification
➄: (Not used)
➅: (Not used)
In the normal state, the following is displayed.
5N: S-NET connection status

➀: Engine controller
➁: Monitor panel (tachometer module)
➂: Transmission controller
➃: Monitor panel (caution module)
➄: Steering controller
➅: Monitro panel (switch module)
This display shows the connection of S-NET.
The figure at right shows that the front devices of (1) -
(6) are connected. In the normal state, the connec-
tion is made as shown in this figure.
20-258 D575A-3 SD
5. Adjustment mode display and function

This is used to check or change the model selection,
etc.
D575A-3 SD 20-259
Adjustment mode items list for large-sized bulldozer
Code Item Contents

Compensation value (Initialization) of 1st clutch Check and initialization of compensation value of 1st clutch
1*
trigger trigger
Compensation value (Initialization) of 2nd clutch Check and initialization of compensation value of 2nd clutch
2*
trigger trigger
20 Tilt limit Tilt limit setting mode
Compensation value (Initialization) of 3rd clutch Check and initialization of compensation value of 3rd clutch
3*
trigger trigger
5A Model code check steering controller Specification check and initial setting of steering controller
5C Specification code check (Set) Specification check and setting of model
7A Model code check transmission controller Specification check and initial setting of transmission controller
Transmission manual mode (Display: Travel
AF Mode for start at 2nd/3rd gear speed
speed)
bP Brake potentiometer adjustment mode Correction and check of neutral value of brake potentiometer
This mode is for the exclusive use of the factory, so it must not
CH Exclusive mode for factory
be touched.
Number of rewriting times of trigger compensa- Check and initialization of number of rewriting times of trigger
CN
tion value (Initialization) compensation value
Both clutch release mode (Display: Transmission
Co Mode for releasing both steering clutches
speed)
F clutch trigger compensation value (Initializa-
F* Check and initialization of F clutch trigger compensation value
tion)
Check and setting of compensation value of left brake oil pres-
N1 Left brake oil pressure offset (Setting)
sure
Check and setting of compensation value of right brake oil
N2 Right brake oil pressure offset (Setting)
pressure
Check and setting of compensation value of left clutch oil pres-
N3 Left clutch oil pressure offset (Setting)
sure
Check and setting of compensation value of right clutch oil
N4 Right clutch oil pressure offset (Setting)
pressure
Check and setting of compensation value of neutral value of
NA Standard value of inclination sensor
inclination sensor
Check and setting of compensation value of left full stroke
NL Left max. value of swing lever 1 (Setting)
value of swing lever
Check and setting of compensation value of neutral value of
No Neutral max. value of swing lever 1 (Setting)
swing lever
Check and setting of compensation value of right full stroke
NR Right max. value of swing lever 1 (Setting)
value of swing lever
PA Brake auto adjustment mode Auto correction mode of steering brake oil pressure
Pb Brake i-p mode I-P characteristics measurement mode of steering brake
Pc Clutch i-p mode I-P characteristics measurement mode of steering clutch
I-P characteristics measurement mode of transmission F
Pd F, R clutch i-p mode
clutch, R clutch
PE Clutch auto adjustment mode Auto correction mode of steering clutch oil pressure
I-P characteristics measurement mode of transmission 1st
PF 1st, 3rd clutch i-p mode
clutch, 3rd clutch
I-P characteristics measurement mode of transmission 2nd
PH 2nd clutch i-p mode
clutch
R clutch trigger compensation value (Initializa-
R* Check and initialization of R clutch trigger compensation value
tion)
20-260 D575A-3 SD
6. Service code display mode display and function

If any abnormality is detected in the electrical system
of the engine controller, steering controller, transmis-
sion controller, or monitor panel, the nature of the
abnormality and the time of occurrence are saved to
memory inside the monitor panel in the order of
occurrence.
When this mode is selected, the service codes
saved to memory and the time of occurrence of the
codes are displayed in turn on the service meter.
The letter at the left side indicates the following:
E: Problem still existing
P: Problem that has returned to normal
A maximum of 20 service codes can be saved in
memory.
If there is no service code saved in memory, [– –] is
displayed on the top panel.
D575A-3 SD 20-261
Service codes and abnormal system

Ser- Method of Troubleshooting User code
vice Abnormal system
re-enaction
E0101 Abnormality in network system (Engine controller system) ST N mode CALL03
E0104 Abnormality in network system (Monitor panel system) ST N mode CALL03
E0105 Abnormality in network system (Steering controller system) ST N mode CALL03
E0111 Abnormality in steering controller power source voltage ST ST mode CALL
E0112 Abnormality in transmission controller power source voltage ST T mode CALL
E0120 Short circuit in monitor caution lamp system ST M mode CALL03
E0121 Short circuit in monitor caution buzzer system ST M mode CALL03
E0142 Abnormality in transmission controller 5V power source ST T mode CALL03
E0143 Abnormality in steering controller 5V power source ST ST mode CALL03
E0145 Abnormality in steering controller sensor power source ST ST mode CALL03
E0146 Abnormality in transmission controller sensor power source ST T mode E01
E0151 Abnormality in specification selection of steering controller ST ST mode CALL
E0152 Abnormality in network system ST N mode CALL03
E0160 Abnormality in transmission controller E2PROM ST T mode E01
E0161 Abnormality in steering controller E2PROM ST ST mode E02
E0178 Disconnection in neutral safety relay system ST+ T mode E02
E0179 Short circuit in neutral safety relay system ST T mode E02
E0211 Abnormality in power train (torque converter) oil temperature E M mode —
E0212 Short circuit in torque converter lock-up solenoid system E+ T mode E01
E0213 Short circuit in torque converter lock-up solenoid system E+ T mode E01
E0221 Abnormality in pitch angle sensor system ST T mode E01
E0222 Short circuit in torque converter speed sensor system E T mode —
E0225 Slip in P/L clutch E+ T mode E02
E0230 Abnormality in travel lever forward-reverse system ST T mode CALL
E0231 Abnormality in travel lever forward-reverse system ST+ T mode CALL
E0232 Abnormality in travel lever forward-reverse system ST+ T mode CALL
E0233 Abnormality in forward-reverse potentiometer 1 system ST T mode CALL03
E0234 Abnormality in forward-reverse potentiometer 2 system ST T mode CALL03
E0235 Lag of forward-reverse signal ST T mode CALL03
E0236 Abnormality in shift-up switch system ST T mode E02
E0237 Abnormality in shift-down switch system ST T mode E02
E0238 Abnormality in travel lock switch system ST T mode CALL03
E0239 Disagreement in travel lock ST T mode CALL03
E0250 Disconnection in forward clutch ECMV system ST+ T mode CALL03
E0251 Short circuit in forward clutch ECMV system ST T mode CALL03
E0252 Disconnection in reverse clutch ECMV system ST+ T mode CALL03
E0253 Short circuit in reverse clutch ECMV system ST T mode CALL03
E0254 Disconnection in 1st clutch ECMV system ST+ T mode CALL03
E0255 Short circuit in 1st clutch ECMV system ST T mode CALL03
E0256 Disconnection in 2nd clutch ECMV system ST+ T mode CALL03
E0257 Short circuit in 2nd clutch ECMV system ST T mode CALL03
E0258 Disconnection in 3rd clutch ECMV system ST+ T mode CALL03
20-262 D575A-3 SD
Service Abnormal system Method of Troubleshooting User code

code re-enaction
E0259 Short circuit in 3rd clutch ECMV system ST T mode CALL03
Abnormality in forward clutch oil pressure system (Clutch is not
E0260 E+ T mode CALL03
engaged)
Abnormality in forward clutch oil pressure system (Clutch is not
disengaged)
Abnormality in reverse clutch oil pressure system (Clutch is not
engaged)
Abnormality in reverse clutch oil pressure system (Clutch is not
disengaged)
Abnormality in 1st clutch oil pressure system (Clutch is not
engaged)
Abnormality in 1st clutch oil pressure system (Clutch is not disen-
gaged)
Abnormality in 2nd clutch oil pressure system (Clutch is not
engaged)
Abnormality in 2nd clutch oil pressure system (Clutch is not disen-
gaged)
Abnormality in 3rd clutch oil pressure system (Clutch is not
engaged)
Abnormality in 3rd clutch oil pressure system (Clutch is not disen-
gaged)
E0270 Double failure in transmission clutch (Clutch is not engaged) ST+ T mode CALL03
E0271 Double failure in transmission clutch (Clutch is not disengaged) E+ T mode CALL
E0273 Abnormality in neutral signal system ST+ E mode, T mode E01
E0301 Disconnection in left yoke angle sensor system ST T mode E02
E0302 Short circuit in left yoke angle sensor system ST T mode E02
E0303 Disconnection in right yoke angle sensor system ST T mode E02
E0304 Short circuit in right yoke angle sensor system ST T mode E02
E0305 Short circuit in PPC lift RAISE oil pressure switch system E+ T mode —
E0311 Abnormality in knob switch DOWN (Pitch dump knob) system ST T mode E01
E0312 Abnormality in knob switch UP (Pitch back knob) system ST T mode E01
E0313 Disconnection in pitch back solenoid system ST+ T mode CALL03
E0314 Short circuit in pitch back solenoid system ST T mode CALL03
E0315 Disconnection in pitch dump solenoid system ST+ T mode CALL03
E0316 Short circuit in pitch dump solenoid system ST T mode CALL03
E0317 Disconnection in left tilt limit solenoid system E+ T mode E02
E0318 Short circuit in left tilt limit solenoid system ST T mode E02
E0319 Disconnection in right tilt limit solenoid system E+ T mode E02
E0320 Short circuit in right tilt limit solenoid system ST T mode E02
E0329 Abnormality in hydraulic oil temperature E M mode —
E0341 Disconnection in lift 1 pump solenoid system ST+ T mode —
E0342 Short circuit in lift 1 pump solenoid system ST T mode —
E0343 Disconnection in pitch dump assist relay system ST+ T mode E01
E0344 Short circuit in pitch dump assist relay system ST T mode E01
E0345 Disconnection in pitch selection solenoid system ST+ T mode CALL03
E0346 Short circuit in pitch selection solenoid system ST T mode CALL03
E0347 Disconnection in pitch priority solenoid ST+ T mode E01
D575A-3 SD 20-263

code re-enaction
E0348 Short circuit in pitch priority solenoid ST T mode E01
Disconnection in work equipment oil pressure sensor 1 (Pump
E0364 E T mode —
200) system
Short circuit in work equipment oil pressure sensor 1 (Pump 200)
E0365 E T mode —
system
Disconnection in work equipment oil pressure sensor 2 (Pump
E0366 E T mode —
200) system
Short circuit in work equipment oil pressure sensor 2 (Pump 200)
E0367 E T mode —
system
E0372 Short circuit in PPC lift RAISE FULL oil pressure switch system E+ T mode —
E0401 Abnormality in engine controller power source ST E mode CALL
E0402 Abnormality in engine controller ST E mode CALL
E0403 Wrong connection in engine controller ST E mode CALL
E0405 Abnormality in fuel control dial system ST E mode CALL03
E0406 Abnormality in decelerator potentiometer system ST E mode CALL03
E0407 Abnormality in shoe slip control command value ST E mode CALL03
E0409 Abnormality in engine speed sensor A system E E mode CALL03
E0410 Abnormality in engine speed sensor B system E E mode CALL03
E0411 Abnormality in right rack sensor system ST E mode CALL03
E0412 Abnormality in left rack sensor system ST E mode CALL03
E0413 Abnormality in rack sensor power source system ST E mode CALL03
E0421 Short circuit in right governor solenoid system ST E mode CALL
E0422 Disconnection in right governor solenoid system ST E mode CALL
E0423 Short circuit in left governor solenoid system ST E mode CALL
E0424 Disconnection in left governor solenoid system ST E mode CALL
E0425 Short circuit in right governor cut relay system ST E mode E01
E0426 Disconnection in right governor cut relay system ST E mode E01
E0427 Short circuit in left governor cut relay system ST E mode E01
E0428 Disconnection in left governor cut relay system ST E mode E01
E0430 Abnormality in engine oil pressure E M mode CALL
E0431 Abnormality in radiator water level ST M mode CALL
E0432 Abnormality in engine water temperature E M mode E01
E0433 Short circuit in left pre-stroke solenoid system ST E mode CALL03
E0434 Disconnection in left pre-stroke solenoid system ST E mode CALL03
E0435 Abnormality in engine water temperature sensor E E mode CALL03
E0437 Abnormality in right governor servo ST E mode CALL
E0438 Abnormality in left governor servo ST E mode CALL
E0440 Short circuit in solenoid power supply 1 system ST E mode CALL
E0441 Disconnection in solenoid power supply 2 system ST E mode CALL
E0442 Abnormality in engine controller backup power supply system ST E mode CALL03
E0443 Abnormality in engine controller switch power supply system ST E mode CALL03
E0455 Engine overheat E E mode —
E0456 Short circuit in right pre-stroke solenoid system ST E mode CALL03
E0457 Disconnection in right pre-stroke solenoid system ST E mode CALL03
20-264 D575A-3 SD

code re-enaction
E0486 Abnormality in transmission controller specification selection ST T mode CALL
E0492 Abnormality in engine controller specification selection ST E mode CALL03
E0610 Disconnection in backup alarm relay system ST+ T mode E01
E0611 Short circuit in backup alarm relay system ST T mode E01
E0660 Disconnection in ACC signal drive relay system ST+ ST mode —
E0661 Short circuit in ACC signal drive relay system ST ST mode —
E0721 Abnormality in pitch angle sensor system ST ST mode CALL03
E0730 Abnormality in travel lever swing system ST ST mode CALL
E0731 Abnormality in travel lever swing system ST+ ST mode CALL
E0732 Abnormality in travel lever swing system ST+ ST mode CALL
E0733 Abnormality in swing potentiometer 1 system ST ST mode CALL03
E0734 Abnormality in swing potentiometer 2 system ST ST mode CALL03
E0735 Lag of swing signal ST ST mode CALL03
E0736 Abnormality in brake potentiometer system ST ST mode CALL03
E0750 Disconnection in right steering clutch ECMV system ST+ ST mode CALL03
E0751 Short circuit in right steering clutch ECMV system ST ST mode CALL03
E0752 Disconnection in left steering clutch ECMV system ST+ ST mode CALL03
E0753 Short circuit in left steering clutch ECMV system ST ST mode CALL03
E0754 Disconnection in right steering brake ECMV system ST+ ST mode CALL
E0755 Short circuit in right steering brake ECMV system ST ST mode CALL
E0756 Disconnection in left steering brake ECMV system ST+ ST mode CALL
E0757 Short circuit in left steering brake ECMV system ST ST mode CALL
Abnormality in right steering clutch oil pressure system (Clutch is
E0760 E+ ST mode CALL
not engaged)
Abnormality in right steering clutch oil pressure system (Clutch is
not disengaged)
Abnormality in left steering clutch oil pressure system (Clutch is
not engaged)
Abnormality in left steering clutch oil pressure system (Clutch is
not disengaged)
Abnormality in right steering brake oil pressure system (Brake is
not engaged)
Abnormality in right steering brake oil pressure system (Brake is
not disengaged)
Abnormality in left steering brake oil pressure system (Brake is not
engaged)
Abnormality in left steering brake oil pressure system (Brake is not
disengaged)
E0779 Disconnection in emergency stop prevention solenoid system ST+ ST mode CALL
E0780 Short circuit in emergency stop prevention solenoid system ST ST mode CALL
E0781 Abnormality in travel lock switch system ST ST mode CALL
E0782 Disagreement in travel lock ST ST mode CALL03
E0930 Disconnection in engine speed sensor system E ST mode E01
E0931 Disconnection in engine speed sensor system E T mode E01
E0932 Disconnection in transmission speed sensor system E+ T mode E01
E0933 Disconnection in transmission speed sensor system E+ ST mode E01
D575A-3 SD 20-265
★ Method of re-enaction
S: Service code that can be re-enacted when starting switch is turned ON
S+: Service code that can be re-enacted when starting switch is turned ON and applicable switch or lever is
operated
E: Service code that can be re-enacted when engine is started
E+: Service code that can be re-enacted when engine is started and applicable switch or lever is operated
★ Troubleshooting mode
N mode: Troubleshooting of network system
E mode: Troubleshooting of engine controller system
ST mode:Troubleshooting of steering controller system
T mode: Troubleshooting of transmission controller system
M mode: Troubleshooting of monitor panel and electrical equipment system
★ Re-enaction of service code and method of confirming return to normal
The procedure for re-enacting the service code and checking that the condition has returned to normal after
repair is as follows.
1) Switch to the service code display mode and check the service code that is displayed.
★ Make a note of all the service codes.
2) Delete the service codes.
3) Carry out the re-enaction of all the service codes that were displayed.
★ For details of the method of re-enaction, see the above table or the section on troubleshooting.
4) Check if the service codes on the service code display are displayed or not displayed.
20-266 D575A-3 SD
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS

1. Category of troubleshooting code number
Troubleshooting Code No. Contents

N- Troubleshooting of network system
E- Troubleshooting of engine controller system
ST- C- Troubleshooting of steering controller system
T- T- Troubleshooting of transmission controller system
H- H- Troubleshooting of hydraulic, mechanical system
M- M- Troubleshooting of monitor panel and electrical system
2. Method of using troubleshooting table for each troubleshooting mode

1) Troubleshooting code number and problem
The title of the troubleshooting chart gives the troubleshooting code, and problem with the machine.
2) General precautions
When carrying out troubleshooting for the problem, precautions that apply to all items are given at the
top of the page and marked with ★.
The precautions marked ★ are not given in the , but must always be followed when carrying out the
check inside the .
3) Distinguishing conditions
Even with the same problem, the method of troubleshooting may differ according to the model, compo-
nent, or problem. In such cases, the problem is further divided into sections marked with small letters
(for example, a)), so go to the appropriate section to carry out troubleshooting.
If the troubleshooting table is not divided into sections, start troubleshooting from the first check item in
the failure mode.
4) Method of following troubleshooting chart (See Example ③)
• Check or measure the item inside , and according to the answer follow either the YES line or
the NO line to go to the next . (Note: The number written at the top right corner of the is an
index number; it does not indicate the order to follow.)
• Following the YES or NO lines according to the results of the check or measurement will lead finally
to the Cause column. Check the cause and take the action given in the Remedy column on the
right.
• Below the there are the methods for inspection or measurement, and the judgement values. If
the judgement values below the are correct or the answer to the question inside the is
YES, follow the YES line; if the judgement value is not correct, or the answer to the question is NO,
follow the NO line.
• Below the is given the preparatory work needed for inspection and measurement, and the
judgement values. If this preparatory work is neglected, or the method of operation or handling is
mistaken, there is danger that it may cause mistaken judgement, or the equipment may be dam-
aged. Therefore, before starting inspection or measurement, always read the instructions carefully,
and start the work in order from Item 1).
5) Troubleshooting tools
When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For details, see
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.
6) Installation position, pin number
A diagram or chart is given for the connector type, installation position, and connector pin number con-
nection. When carrying out troubleshooting, see this chart for details of the connector pin number and
location for inspection and measurement of the wiring connector number appearing in the troubleshoot-
ing flow chart for each problem.
D575A-3 SD 20-267
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
<Example>
➀ M-8 When starting switch is turned on, monitor panel gives no display
➃ ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted.
★ Always connect any disconnected connectors before going on to the next step.
➁ a) Caution module (Gauge/lamp unit) gives no display
Cause Remedy
1
Turn starting switch ON. Is voltage between CN1 (1) and NO
20 30 V (2) normal?
YES
Defective monitor panel
Replace
(caution module)
2
Defective contact or disconnection in
Turn starting switch ON. Is voltage between CN1 (1) and NO Repair or
wiring harness between CN1 (female)
20 30 V chassis ground normal? replace
(1) fuse 12
YES Defective contact or disconnection in

Repair or
replace
(2) chassis ground
M-8 a) Related electrical circuit diagram
20-268 D575A-3 SD
TROUBLESHOOTING OF NETWORK SYSTEM
(N MODE)
Action taken by controller when abnormality occurs and problems on machine......................................... 20-302
Electrical circuit diagram of N mode system ............................................................................................... 20-304
Service codes of network system ............................................................................................................... 20-305
N-1 [E0101] Abnormality in network system (engine controller system) is displayed................................ 20-306
N-2 [E0104] Abnormality in network system (monitor panel system) is displayed .................................... 20-307
N-3 [E0105] Abnormality in network system (steering controller system) is displayed.............................. 20-308
N-4 [E0101], [E0104], and [E0105] are displayed at same time
(Abnormality in network system is displayed) ..................................................................................... 20-309
N-5 [E0152] Abnormality in network system is displayed .......................................................................... 20-310
N-6 [E0164] Abnormality in network system is displayed .......................................................................... 20-310
N-7 [E0436] Abnormality in network system is displayed ...........................................................................20-311
D575A-3 SD 20-301
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE

OCCURS AND PROBLEMS ON MACHINE
User Service
Abnormal system Nature of abnormality
code code
When the monitor panel detects an abnormality in the network of the engine control-
ler system
• When service code E0101 is generated independently
1. Defective contact or disconnection in wiring harness between monitor panel T01
Abnormality in (9) and engine controller LE4 (6)
network system 2. Defective engine controller
E0101
(engine controller • When service codes E0104 and E0105 are generated at same time
system) 1. Short circuit with ground, defective contact, disconnection in wiring harness or hot
short between monitor panel T01(10) – monitor panel CN1 (11), monitor panel
T01(9) – engine controller LE4 (6) and monitor panel CN1 (12) – steering control-
ler NGICN2 (21)
2. Defective monitor panel (tachometer module)
When the monitor panel detects an abnormality in the network of the monitor panel
(caution module) system
1. Defective contact or disconnection in wiring harness between monitor panel T01
Abnormality in (10) and monitor panel CN1 (11)
network system 2. Defective monitor panel (caution module)
E0104
(monitor panel sys- • When service codes E0101 and E0105 are generated at same time
tem) 1. Short circuit with ground, defective contact, disconnection in wiring harness or hot
short between monitor panel T01(10) – monitor panel CN1 (11), monitor panel
T01(9) – engine controller LE4 (6) and monitor panel CN1 (12) – steering control-
ler NGICN2 (21)
When the monitor panel detects an abnormality in the network of the steering control-
ler system
CALL • When service code E0105 is generated independently
03 Abnormality in 1. Defective contact or disconnection in wiring harness between monitor panel CN1
network system (12) and steering controller NGICN2 (21)
E0105 2. Defective steering controller
(steering controller
system) • When service codes E0101 and E0104 are generated at same time
1. Short circuit with ground, defective contact, disconnection in wiring harness or hot
short between monitor panel T01 (9)(10) – monitor panel CN1 (11)(12) – engine
controller E41 (6) – machine controller M32 (4)
When the steering controller detects an abnormality in the network

1. Defective steering controller
Abnormality in • When service codes E0101, E0104, and E0105 are generated at same time
E0152
network system ! Same as for each service code
• When service code E0164 is generated at same time
1. Disconection in wiring haness between steering controller NGICN2 (21) – trans-
mission controller TMCN3(21)
When the transmission controller detects an abnormality in the network

Abnormality in • When service code E0164 is generated independently
E164 1. Defective transmission controller
network system
• When service codes E0152 is generated at same time
! Same as for each service code
When the engine controller detects an abnormality in the network

Abnormality in • When service code E0436 is generated independently
E0436 1. Defective engine controller
network system
• When service codes E0101, E0104, and E0105 are generated at same time
! Same as for each service code
20-302 D575A-3 SD
Condition when normal Action by controller when Problem that appears on machine
(voltage, current, resistance) abnormality is detected when there is abnormality
1. Flashes caution lamp.
2. Sounds alarm buzzer.
1. Flashes caution lamp.

2. Sounds alarm buzzer.
1. Flashes caution lamp. 1. Speed range display is not given.

2. Sounds alarm buzzer. 2. Tachometer display is not given.
3. Lock-up lamp goes out.
1. Speed range display is not given.

2. Tachometer display is not given.
3. Lock-up lamp goes out.
1. Speed range display is not given.

2. Shift mode display is not given.
D575A-3 SD 20-303
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM OF N MODE SYSTEM
ELECTRICAL CIRCUIT DIAGRAM OF N MODE SYSTEM
20-304 D575A-3 SD
TROUBLESHOOTING SERVICE CODES OF NETWORK SYSTEM
SERVICE CODES OF NETWORK SYSTEM

The monitor panel, engine controller, steering controller, and transmission controller make up a network having
the circuit shown in "Electrical circuit diagram of N mode system".
The monitor panel, engine controller, steering controller, and transmission controller monitor the communicating
condition of the network respectively. If any abnormality occurs, they display the corresponding service code.
1) Monitor panel
The monitor panel monitors the communicating condition of each network component device. If any abnor-
mality occurs in a device, the monitor panel displays one of the following service codes.
(1) E0101: An abnormality has occurred in the engine controller system.
(2) E0104: An abnormality has occurred in the monitor panel (caution module) system.
(3) E0105: An abnormality has occurred in the steering controller system.
2) Engine controller
The engine controller monitors the communicating condition of the whole network. If any abnormality occurs
in the communicating condition, the engine controller displays the following service code.
(4) E0436: An abnormality has occurred in a system of the whole network. (The name of the troubled sys-
tem is not displayed.)
3) Steering controller
The steering controller monitors the communicating condition of the whole network. If any abnormality
occurs in the communicating condition, the machine controller displays the following service code.
(4) E0152: An abnormality has occurred in a system of the whole network. (The name of the troubled sys-
tem is not displayed.)
4) Transmission controller
The transmission controller monitors the communicating condition of the whole network. If any abnormality
occurs in the communicating condition, the transmission controller displays the following service code.
5) E0164: An abnormality has occurred in a system of the whole network (The name of the troubled system is
not displayed.)
Since the network is monitors by the above three devices, if any abnormality occurs in the network system, mul-
tiple service codes are displayed at the same time.
For quick troubleshooting, it is important to know by using the monitoring mode, etc. what system each service
code indicates.
D575A-3 SD 20-305
TROUBLESHOOTING N-1
N-1 [E0101] Abnormality in network system (engine controller system) is

displayed
★ If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that
the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.)
★ Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Cause Remedy
1
Are service codes [E0104], NO
Turn starting switch ON.
[E0105] displayed at same time?
YES
Go to N-4.
2
Turn starting switch OFF. Is resistance between T01 Defective contact or disconnection in
NO Repair or
Disconnect T01 and E41. (female)(9) and LE4 (female) (6) wiring harness between T01 (female)
replace
Max. 1 Ω normal? (9) LE4
YES
Defective engine controller Replace
N-1 Related electrical circuit diagram
20-306 D575A-3 SD
TROUBLESHOOTING N-2
N-2 [E0104] Abnormality in network system (monitor panel system) is

displayed
Cause Remedy
1
YES
Go to N-4.
2
Turn starting switch OFF. Is resistance between T01 Defective contact or disconnection in
NO Repair or
Disconnect T01 and CN1. (female)(10) and CN1 (female) wiring harness between T01 (female)
replace
Max. 1 Ω (11) normal? (10) CN1 (female) (11)
YES
Defective monitor panel (caution
module) Replace
D575A-3 SD 20-307
TROUBLESHOOTING N-3
N-3 [E0105] Abnormality in network system (steering controller system)

is displayed
Cause Remedy
1
YES
Go to N-4.
2
Turn starting switch OFF. Is resistance between CN1 Defective contact or disconnection in
NO Repair or
Disconnect T01 and M32. (female)(12) and NGICN2 wiring harness between CN1 (female)
replace
Max. 1 Ω (female) (21) normal? (12) NGICN2 (female) (21)
YES
Defective machine controller Replace
20-308 D575A-3 SD
TROUBLESHOOTING N-4
N-4 [E0101], [E0104], and [E0105] are displayed at same time

(Abnormality in network system is displayed)
Cause Remedy
1
Disconnect CN1. NO
Do all service codes go off?
YES
Defective monitor panel (caution
Replace
module)
2
Disconnect NGICN2. NO
YES
Defective machine controller Replace
3
Disconnect LE4. NO
YES
4 Defective contact, disconnection or

short circuit with chassis ground in
Disconnect T01. Is voltage between T01 (female) wiring harness between T01 (female)
NO Repair or
Turn starting switch ON. (9) (10) and chassis ground (10) CN1 (female) (11) or T01
replace
Min. 7.5 V normal? (female) (9) LE4 (female) (6) or CN1
(female) (12) NG1CN2 (female) (21)
YES
Defective monitor panel (tachometer

Replace
module)
D575A-3 SD 20-309
TROUBLESHOOTING N-5, N-6
N-5 [E0152] Abnormality in network system is displayed

Cause Remedy
1
Turn starting switch ON. Are all of service codes [E0101], NO
[E0104], and [E105] displayed,
YES
Go to N-4.
2
Turn starting switch ON. Is any one of [E0101], [E0104], NO
and [E105] displayed, too?
YES Go to N-1, 2, or 3 according to
displayed service code.
3
Turn starting switch ON. Is service code [E0164] displayed NO Defective steering controller Replace
at some time ?
YES
4 Defective contact or disconnection in
Turn starting switch OFF. Is resistance between NGICN2 NO Repair or
Disconnect NGICN2 and (female) (21) and TMCN3 wiring harness between NGICN2 replace
TMCN3. (female) (21) normal? (female) (21) TMCN3 (female) (21)
Max. 1 Ω
YES Defective transmission controller Replace

Cause Remedy
1
Turn starting switch ON. Is service code [E0152] NO Go to N-5.
displayed, too?
YES
2
Turn starting switch OFF. Is resistance between NGICN2 Defective contact or disconnection in
Disconnect NGICN2 and (female) (21) and TMCN2 NO wiring harness between NGICN2 Repair or
TMCN2. (female) (21) normal? (female) (21) - TMCN2 (female) (21) replace
Max. 1 Ω YES
Defective transmission controller Replace
20-310 D575A-3 SD
TROUBLESHOOTING N-7

the service code displays”E” at the head. (If “P” is displayed, the condition has returned to normal.)
Cause Remedy
1
Are all of service codes [E0101],
NO
Turn starting switch ON. [E0104], and [E105] displayed,
too?
YES
Go to N-4.
2
Is any one of [E0101], [E0104], NO
Turn starting switch ON. Defective engine controller Replace
and [E105] displayed, too?
YES
Go to N-1, 2, or 3 according to
displayed service code.
D575A-3 SD 20-311
TROUBLESHOOTING OF
ENGINE CONTROLLER SYSTEM
(E MODE)
Electrical circuit diagram of E mode system ............................................................................................... 20-410
E- 1 [E0401] Abnormality in engine controller power source voltage is displayed ................................... 20-412
E- 2 [E0402] Abnormality in engine controller is displayed ...................................................................... 20-413
E- 3 [E0403] Mistaken connection in engine controller is displayed ........................................................ 20-413
E- 4 [E0405] Abnormality in fuel control dial system is displayed ............................................................ 20-414
E- 5 [E0406] Abnormality in deceleration potentiometer is displayed ...................................................... 20-416
E- 6 [E0407] Abnormality in shoe slip control command value is displayed ............................................ 20-418
E- 7 [E0409] Abnormality in engine speed sensor A system is displayed................................................ 20-419
E- 8 [E0410] Abnormality in engine speed sensor B system is displayed................................................ 20-420
E- 9 [E0411] Abnormality in right rack sensor system is displayed .......................................................... 20-421
E-10 [E0412] Abnormality in left rack sensor system is displayed ............................................................ 20-422
E-11 [E0413] Abnormality in rack sensor power source system is displayed ........................................... 20-423
E-12 [E0421] Short circuit in right governor solenoid system is displayed ................................................ 20-424
E-13 [E0422] Disconnection in right governor solenoid system is displayed ............................................ 20-425
E-14 [E0423] Short circuit in left governor solenoid system is displayed .................................................. 20-426
E-15 [E0424] Disconnection in left governor solenoid system is displayed .............................................. 20-427
E-16 [E0425] Short circuit in right governor cut relay system is displayed................................................ 20-428
E-17 [E0426] Disconnection in left governor cut relay system is displayed .............................................. 20-429
E-18 [E0427] Short circuit in left governor cut relay system is displayed .................................................. 20-430
E-19 [E0428] Disconnection in left governor cut relay system is displayed .............................................. 20-431
E-20 [E0433] Short circuit in left pre-stroke solenoid system is displayed ................................................ 20-432
E-21 [E0434] Disconnection in left pre-stroke solenoid system is displayed ............................................ 20-433
E-22 [E0435] Abnormality in engine water temperature sensor system is displayed................................ 20-434
E-23 [E0437] Abnormality in right governor servo is displayed ................................................................. 20-435
E-24 [E0438] Abnormality in left governor servo is displayed ................................................................... 20-435
E-25 [E0440] Disconnection solenoid power source 1 system is displayed.............................................. 20-436
E-26 [E0441] Disconnection in power supply system 2 of solenoid is displayed ...................................... 20-436
E-27 [E0442] Abnormality in engine controller backup power source system is displayed....................... 20-437
E-28 [E0443] Abnormality in engine controller switch power source system is displayed ........................ 20-438
E-29 [E0455] Engine overheating is displayed.......................................................................................... 20-439
E-30 [E0456] Short circuit in right pre-stroke solenoid system is displayed .............................................. 20-440
E-31 [E0457] Disconnection in right pre-stroke solenoid system is displayed .......................................... 20-441
E-32 Engine does not revolve when starting switch is turned to ON position ........................................... 20-442
E-33 Engine does not stop when starting switch is turned to OFF position .............................................. 20-445
D575A-3 SD 20-401

User Service Abnormal system Nature of abnormality
code code
Abnormality in engine When controller power source voltage is Max. 36 V
E0401 controller power source 1. Defective controlle
voltage
Data written to RAM inside controller do not match read data
Abnormality in engine
E0402 1. Defective controller
controller
CALL
When engine controller connector LE31 and connector LE51 are mistakenly connected
1. Mistaken connection of connector LE31 and connector LE51
Mistaken connection in 2. Controller LE31 (1) short circuiting with ground
E0403
engine controller 3. Defective contact or disconnection in wiring harness between controller LE51 (1) and
chassis ground
4. Defective controller
When input voltage from fuel control dial is less than 0.3 V or more than 4.55 V
1. Defective fuel control dial
2. Short circuit with power source, short circuit with ground, defective contact, or discon-
Abnormality in fuel nection in wiring harness between controller LE31 (6) and fuel control dial FCS (1)
E0405
control dial system 3. Short circuit with power source, short circuit with ground, defective contact, or discon-
nection in wiring harness between controller LE32 (1) and fuel control dial FCS (2)
4. Defective contact or disconnection in wiring harness between controller LE31 (16) and
fuel control dial FCS (3)
When input voltage from deceleration potentiometer is less than 0.3 V or more than
4.55 V
1. Defective deceleration potentiometer
Abnormality in deceler- 2. Short circuit with power source, short circuit with ground, defective contact, or discon-
E0406 ation potentiometer nection in wiring harness between controller LE31 (6) and fuel control dial DCL (1)
system 3. Short circuit with power source, short circuit with ground, defective contact, or discon-
nection in wiring harness between controller LE32 (11) and fuel control dial DCL (2)
fuel control dial FCD (3)
When input voltage from machine controller is less than 0.3 V or more than 4.55 V
Abnormality in shoe 1. Defective machine controller
E0407 slip control command 2. Short circuit with power source, short circuit with ground, defective contact, or discon-
value nection in wiring harness between controller LE31 (9) and SSC controller NGICN2 (11)
When input from engine speed sensor A becomes less than 300 rpm after engine is
CALL started
03 1. Defective left engine speed sensor
Abnormality in engine 2. Short circuit with ground, defective contact, or disconnection in wiring harness between
E0409 speed sensor A system controller LE31 (3) and speed sensor RRL (1)
speed sensor RRL (2)
When input from engine speed sensor B becomes less than 300 rpm after engine is
started
1. Defective right engine speed sensor
Abnormality in engine 2. Short circuit with ground, defective contact, or disconnection in wiring harness between
E0410
speed sensor B system controller LE31 (2) and speed sensor RRR (1)
speed sensor RRR (2)
When input voltage from rack sensor is less than 0.1 V or more than 4.4 V
1. Defective right rack sensor
2. Short circuit with ground, short circuit with power source, defective contact, or discon-
nection in wiring harness between controller LE21 (16) and rack sensor LER (1)
Abnormality in right 3. Defective contact or disconnection in wiring harness between controller LE51 (1) and
E0411 rack sensor LER (2)
rack sensor system
20-402 D575A-3 SD
Condition when normal Action by controller when Problem that appears onmachine
• Voltage between LE11 (7) – (8)(16): 20 – 30 V 1. Lights up caution lamp, sounds alarm 1. Engine cannot be controlled
• Voltage between LE11 (9)(17) – (8)(16) buzzer
: 20 – 30 V 2. Stops engine
1. Stops engine 1. Engine cannot be controlled
• Voltage between LE31 (1) – chassis: 20 – 30 V 1. Lights up caution lamp, sounds alarm
• Voltage between LE51 (1) – chassis: Max. 1 V buzzer
• Voltage between LE31 (6) – (16): 4.6 – 5.4 V 1. Lights up caution lamp, sounds alarm 1. Engine speed cannot be controlled
• Voltage between LE32 (1) – LE31 (16) buzzer
: 0.3 – 4.55 V 2. Controls with deceleration potentiom-
eter signal
3. After machine is stopped (neutral),
fixes engine speed at 1300 rpm
• Voltage between LE31 (6) – (16): 4.6 – 5.4 V 1. Lights up caution lamp, sounds alarm 1. Engine speed cannot be controlled
• Voltage between LE32 (11) – LE31 (16) buzzer
: 0.3 – 4.55 V 2. Controls with fuel control dial signal
3. After machine is stopped (neutral),
fixes engine speed at 1300 rpm
• Voltage between LE31 (9) – chassis 1. Lights up caution lamp, sounds alarm 1. Shoe slip control is not actuated
: 0.3 – 4.55 V buzzer
2. Controls with fuel control dial signal
3. After machine is stopped, stops shoe
slip control function
• Resistance of speed sensor: 500 – 1000 Ω 1. Lights up caution lamp, sounds alarm
• Voltage between LE31 (3) – (14): 0.5 – 3.0 V buzzer
(AC range) 2. Controls with signal from engine
speed sensor B
• Resistance of speed sensor: 500 – 1000 Ω 1. Lights up caution lamp, sounds alarm
• Voltage between LE31 (2) – (14): 0.5 – 3.0 V buzzer
(AC range) 2. Controls with signal from engine
speed sensor A
• Voltage between LE31 (7) – LE51 (1): 0.1 – 4.4 1. Lights up caution lamp, sounds alarm 1. Engine runs on one bank
V buzzer
• Voltage between LE31 (17) – LE51 (1) 2. Sets right fuel injection pump to NO
: 0.1 – 4.4 V INJECTION condition
D575A-3 SD 20-403

code code
When input from rack sensor is less than 0.1 V or more than 4.4 V
1. Defective left rack sensor
nection in wiring harness between controller LE21 (16) and rack sensor LEL (1)
Abnormality in left rack 3. Defective contact or disconnection in wiring harness between controller LE51 (1) and
E0412 sensor system rack sensor LEL (2)
nection in wiring harness between controller LE31 (8) and rack sensor LEL (3)
CALL 5. Short circuit with ground, short circuit with power source, defective contact, or discon-
03 nection in wiring harness between controller LE31 (18) and rack sensor LEL (4)
When power source voltage of rack sensor is less than 4.6 V
1. Defective right rack sensor or left rack sensor
Abnormality in rack 2. Short circuit with ground, defective contact, or disconnection in wiring harness between
E0413 sensor power source controller LE21 (16) and right rack sensor LER (1) or left rack sensor LEL (1)
system 3. Defective contact or disconnection in wiring harness between right rack sensor LER (2)
or left rack sensor LEL (2) and chassis
When output current to governor solenoid is more than 2.1 A
1. Defective right governor solenoid
Short circuit in right 2. Short circuit with ground or short circuit with power source in wiring harness between
E0421 governor solenoid controller LE21 (7) and governor solenoid GSR (1)
system 3. Short circuit with power source in wiring harness between controller LE21 (17) and gov-
ernor solenoid GSR (2)
When output current to governor solenoid is less than 0.1 A
1. Defective right governor solenoid
Disconnection in right 2. Defective contact or disconnection in wiring harness between controller LE21 (7) and
E0422 governor solenoid governor solenoid GSR (1)
system 3. Short circuit with ground, defective contact, or disconnection in wiring harness between
controller LE21 (17) and governor solenoid GSR (2)
CALL
When output current to governor solenoid is more than 2.1 A
1. Defective left governor solenoid
Short circuit in left 2. Short circuit with ground or short circuit with power source in wiring harness between
E0423 governor solenoid controller LE21 (8) and governor solenoid GSL (1)
system 3. Short circuit with power source in wiring harness between controller LE21 (18) and gov-
ernor solenoid GSL (2)
When output current to governor solenoid is less than 0.1 A
1. Defective left governor solenoid
Disconnection in left 2. Defective contact or disconnection in wiring harness between controller LE21 (8) and
E0424 governor solenoid governor solenoid GSL (1)
controller LE21 (18) and governor solenoid GSL (2)
When output voltage to right governor cut relay is more than 5 – 15 V
Short circuit in right 1. Defective right governor cut relay
E0425 governor cut relay 2. Short circuit with power source in wiring harness between controller LE11 (4) and relay
system GCR (2)
When output voltage to right governor cut relay is less than 5 – 15 V
1. Defective right governor cut relay
Disconnection in right 2. Defective contact or disconnection in wiring harness between starting switch ACC ter-
E01 E0426 governor cut relay minal and relay GCL (1)
controller LE11 (4) and relay GCR (2)
When output voltage to left governor cut relay is more than 5 – 15 V
Short circuit in left 1. Defective left governor cut relay
E0427 governor cut relay 2. Short circuit with power source in wiring harness between controller LE11 (5) and relay
system GCL (2)
20-404 D575A-3 SD
• Voltage between LE31 (8) – LE51 (1) 1. Lights up caution lamp, sounds alarm 1. Engine runs on one bank
: 0.1 – 4.4 V buzzer
• Voltage between LE31 (18) – LE51 (1) 2. Sets left fuel injection pump to NO
: 0.1 – 4.4 V INJECTION condition
• Voltage between LE21 (6) – chassis: 5 V 1. Lights up caution lamp, sounds alarm 1. Lacks power
buzzer
2. Reduces engine output by 20%
• Resistance of solenoid: 10 – 21 Ω 1. Lights up caution lamp, sounds alarm 1. Engine runs on one bank
buzzer
buzzer
buzzer
buzzer
• Resistance of relay: 200 – 900 Ω

• Voltage between LE11 (4) and (13): 20 – 30 V


D575A-3 SD 20-405

code code
When output voltage to left governor cut relay is less than 5 – 15 V
1. Defective left governor cut relay
Disconnection in left 2. Defective contact or disconnection in wiring harness between starting switch ACC termi
E01 E0428 governor cut relay nal and relay GCL (1)
controller LE11 (5) and relay GCL (2)
When output current to pre-stroke solenoid is more than 2.1 A
1. Defective left pre-stroke solenoid
Short circuit in left 2. Short circuit with ground or short circuit with power source in wiring harness between
E0433 pre-stroke solenoid controller LE21 (10) and pre-stroke solenoid PSL (1)
system 3. Short circuit with power source in wiring harness between controller LE21 (20) and pre-
stroke solenoid PSL (2)
When output current to pre-stroke solenoid is less than 0.1 A
1. Defective left pre-stroke solenoid
Disconnection in left 2. Defective contact or disconnection in wiring harness between controller LE21 (10) and
E0434 pre-stroke solenoid pre-stroke solenoid PSL (1)
CALL
03
controller LE21 (20) and pre-stroke solenoid PSL (2)
When input voltage from engine water temperature sensor is less than 0.3 V or more
than 0.5 V
1. Defective engine water temperature sensor
Abnormality in engine 2. Short circuit with power source, short circuit with ground, defective contact, or discon-
E0435 water temperature nection in wiring harness between controller LE32 (5), monitor panel CN2 (1) ñ engine
sensor system water temperature sensor (1)
3. Defective contact or disconnection in wiring harness between engine water temperature
sensor 402 (2) and chassis ground
4. Defective controller or monitor panel
1. Defective right governor solenoid system or rack sensor system (governor command
Abnormality in right value and rack sensor signal do not match)
E0437 governor servo 2. Abnormality in solenoid power source R system
1. Defective left governor solenoid system or rack sensor system (governor command
Abnormality in left value and rack sensor signal do not match)
E0438 governor servo 2. Abnormality in solenoid power source L system
When controller switch power source is more than 24 V but solenoid power source R is
less than 5 V
Disconnection in 1. Defective right governor cut relay
CALL E0440 solenoid power source 2. Short circuit with ground, defective contact, or disconnection in wiring harness between
1 system controller LE21 (1) and relay GCR (6)
3. Defective contact or disconnection in wiring harness between LE21 (21) and chassis
ground
When controller switch power source is more than 24 V but solenoid power source L is
less than 5 V
Disconnection in 1. Defective left governor cut relay
E0441 solenoid power source 2. Short circuit with ground, defective contact, or disconnection in wiring harness between
2 system controller LE21 (12) and relay GCL (6)
3. Defective contact or disconnection in wiring harness between LE21 (21) and chassis
ground
When backup power source voltage is more than 5 V lower than switch power source
Abnormality in engine voltage
E0442 controller backup 1. Blown fuse 1
power source system 2. Short circuit with ground, defective contact, or disconnection in wiring harness between
controller LE11 (7) and fuse 1
CALL 3. Defective controller
03 When switch power source voltage is more than 5 V lower than backup power source
Abnormality in engine voltage
E0443 controller switch power 1. Defective starting switch
source system 2. Short circuit with ground, defective contact, or disconnection in wiring harness between
controller LE11 (9)(17) and starting switch ACC terminal
20-406 D575A-3 SD
• Voltage between E11 (5) and (14): 20 – 30 V
• Resistance of solenoid: 10 – 21 Ω 1. Lights up caution lamp, sounds alarm 1. Lacks power

buzzer

buzzer
• Resistance of sensor: 3.8 – 80 k Ω 1. Lights up caution lamp, sounds alarm

buzzer
2. Controls with with engine water tem-
perature taken as 90°C
1. Lights up caution lamp, sounds alarm 1. Engine runs on one bank

buzzer
2. Sets right fuel injection pump to NO
INJECTION condition
1. Lights up caution lamp, sounds alarm 1. Engine runs on one bank
buzzer
2. Sets left fuel injection pump to NO
INJECTION condition
• Voltage between E21 (1) and (21): 20 – 30 V 1. Lights up caution lamp, sounds alarm 1. Engine runs on one bank
buzzer
• Voltage between E21 (12) and (21): 20 – 30 V 1. Lights up caution lamp, sounds alarm 1. Engine runs on one bank
buzzer
• Voltage between E11 (7) and (8)(16): 20 – 30 V 1. Lights up caution lamp, sounds alarm
buzzer
2. Drives with switch power source
• Voltage between E11 (9)(17) and (8)(16) 1. Lights up caution lamp, sounds alarm
: 20 – 30 V buzzer
2. Drives with backup power source
D575A-3 SD 20-407

code code
When engine water temperature is more than 105 °C
— E0455 Engine overheating
When output current to pre-stroke solenoid is more than 2.1 A

1. Defective right pre-stroke solenoid
Short circuit in right 2. Short circuit with ground or short circuit with power source in wiring harness between
E0456 pre-stroke solenoid controller LE21 (9) and pre- stroke solenoid PSR (1)
system 3. Short circuit with power source in wiring harness between controller LE21 (19) and pre-
stroke solenoid PSR (2)
When output current to pre-stroke solenoid is less than 0.1 A
CALL 1. Defective right pre-stroke solenoid
Disconnection in right 2. Defective contact or disconnection in wiring harness between controller LE21 (9) and
03
E0457 pre-stroke solenoid pre-stroke solenoid PSR (1)
controller LE21 (19) and pre-stroke solenoid PSR (2)
Harness logic does not match with model code.
Abnormality in engine 1. Disconnection, defective contact, or short circuit with chassis ground in wiring harness
E0492 controller specification between LE52 and SEL
selection 2. Defective model connector SEL
3. Defective engine controller
Neutral signal LE51 (5) is different from LE51 (6).
Abnormality in neutral 1. Disconnection, defective contact, or short circuit with chassis ground in wiring harness
E01 E0272 between LE51 and TMCN2
signal system
2. Defective engine controller
3. Defective transmission controller
20-408 D575A-3 SD
1. Lights up caution lamp, sounds alarm 1. Engine speed does not go up from
buzzer low idling
2. Runs engine at low idling
buzzer

buzzer
Starts engine with engine horsepower 1. Lacks power

reduced.
D575A-3 SD 20-409
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM OF E MODE SYSTEM
ELECTRICAL CIRCUIT DIAGRAM OF E MODE SYSTEM
20-410 D575A-3 SD
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM OF E MODE SYSTEM
D575A-3 SD 20-411
TROUBLESHOOTING E-1, E-2
E-1 [E0401] Abnormality in engine controller power source voltage is

displayed
Cause Remedy
1
Is service code [E0442] NO
displayed, too?
YES
Go to E-27
2
Is service code [E0443] NO
Turn starting switch ON. Defective engine controller Replace
displayed, too?
YES
Go to E-28
E-2 [E0402] Abnormality in engine controller is displayed

Cause Remedy
1
Turn starting switch ON. Is voltage between LE11 (9) (17) NO
Go to E-1.
20 30 V and (8) (16) normal?
YES
20-412 D575A-3 SD
TROUBLESHOOTING E-3
E-3 [E0403] Mistaken connection in engine controller is displayed

★ Check that connectors LE31, LE32, LE51, and LE52 on the chassis side are properly connected to the
engine controller.
Cause Remedy
1
• Turn starting switch ON. Is voltage between LE51 (1) and NO Repair or
wiring harness between LE51 (female)
• Max. 1 V chassis ground normal? replace
(1) – chassis ground
YES
E-3 Related electrical circuit diagram
D575A-3 SD 20-413
TROUBLESHOOTING E-4
E-4 [E0405] Abnormality in fuel control dial system is displayed

Cause Remedy
1
• Turn starting switch ON. Is voltage between LE31 (6) and NO
• 4.6 – 5.4 V (16) normal?
YES
2
• 0.7 – 4.3 V chassis ground normal?
YES
3
• Turn starting switch ON. Is voltage between FCS (2) and NO
Repair or
replace
(1) – FCS (female) (2)
4
• Turn starting switch OFF. Is resistance between LE32 Short circuit with chassis ground in
(female) (1) and chassis ground NO wiring harness between LE32 (female) Repair or
• Disconnect FCS and LE32.
normal? (1) – FCS (female) (2) replace
• Min. 1 MΩ
YES
Defective fuel control dial Replace
5
• Turn starting switch ON. Is voltage between FCS (1) and NO
YES
6
• Turn starting switch OFF. NO
Is resistance between FCS
• Disconnect FCS. Defective fuel control dial Replace
(male) (1) and (3) normal?
• 4.0 – 6.0 kΩ
Repair or
wiring harness between LE31
replace
(female) (16) – FCS (female) (3)
7
Repair or
wiring harness between E31 (female)
replace
(6) – FCS (female) (1)
8
NO Repair or
• Disconnect FCS and LE31. (female) (6) and chassis ground wiring harness between LE31 (female)
(6) and FCS (female) (1) replace
• Min. 1 MΩ normal?
YES
Defective fuel control dial Replace
20-414 D575A-3 SD
TROUBLESHOOTING E-4
D575A-3 SD 20-415
TROUBLESHOOTING E-5
E-5 [E0406] Abnormality in deceleration potentiometer is displayed

Cause Remedy
1
• 4.6 – 5.4 V (16) normal?
YES
2
YES
3
• Turn starting switch ON. Is voltage between DCL (2) and NO

Repair or
replace
(11) – DCL (female) (2)
4
NO Repair or
• Disconnect FCD and LE32. (female) (11) and chassis ground wiring harness between LE32 (female)
replace
• Min. 1 MΩ normal? (11) – DCL (female) (2)
YES
Defective deceleration potentiometer Replace
5
• Turn starting switch ON. Is voltage between DCL (1) and NO
YES
6
• Turn starting switch OFF.
Is resistance between FCD NO
• Disconnect FCD. Defective deceleration potentiometer Replace
• 4.0 – 6.0 kΩ (male) (1) and (3) normal?

Repair or
replace
(16) – DCL (female) (3)
7

Repair or
replace
(6) – DCL (female) (1)
8
• Disconnect FCD and LE31. NO Repair or
(female) (6) and chassis ground wiring harness between LE31 (female)
• Min. 1 MΩ normal? (6) – DCL (female) (1) replace
YES
Defective deceleration potentiometer Replace
20-416 D575A-3 SD
TROUBLESHOOTING E-5
D575A-3 SD 20-417
TROUBLESHOOTING E-6
E-6 [E0407] Abnormality in shoe slip control command value is

displayed
Cause Remedy
1
•1–4V (16) normal?
YES
2
• Turn starting switch ON. Is voltage between NGICN2 (11) NO Defective machine controller Replace
•1–4V and chassis ground normal?
YES
3
Is resistance between LE31 NO Defective contact or disconnection in
• Disconnect LE31 and Repair or
(female) (9) and NGICN2 wiring harness between LE31 (female)
NGICN2. replace
(female) (11) normal? (9) – NGICN2 (female) (11)
• Max. 1 Ω
YES
Short circuit with chassis ground in
Repair or
replace
(9) – NGICN2 (female) (11)
20-418 D575A-3 SD
TROUBLESHOOTING E-7
E-7 [E0409] Abnormality in engine speed sensor A system is displayed

★ If the starting switch was turned off after the abnormality occurred, start engine and check that the service
code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.)
Cause Remedy
1
Is resistance between LE31 NO
• Disconnect LE31.
(female) (2) and (14) normal?
• 500 – 1,000 Ω
YES
2
• See TESTING AND
If speed sensor A is adjusted, is NO
ADJUSTING. Defective engine controller Replace
service code P displayed?
• Start engine.
YES Wrong adjustment of engine speed
Adjust
sensor A
3
• Turn starting switch OFF. Is resistance between RRR NO Defective engine speed sensor A Replace
• Disconnect RRR. (male) (1) and (2) normal?
• 500 – 1,000 Ω
YES
4
• Turn starting switch OFF. Defective contact or disconnection in
Is resistance between LE31 NO Repair or
• Disconnect LE31 and RRR. wiring harness between LE31 (female)
(female) (2) and RRR (female) replace
• Max. 1 Ω (14) – RRR (female) (2)
YES
Defective contact, disconnection or
short circuit with chassis ground in Repair or
wiring harness between LE31 (female) replace
(2) – RRR (female) (1)
D575A-3 SD 20-419
TROUBLESHOOTING E-8
E-8 [E0410] Abnormality in engine speed sensor B system is displayed

Cause Remedy
1
Is resistance between LE31 NO
• Disconnect LE31.
• 500 – 1,000 Ω
YES
2
• See TESTING AND
If speed sensor B is adjusted, is NO
• Start engine.
YES Wrong adjustment of engine speed
Adjust
sensor B
3
• Turn starting switch OFF. Is resistance between RRL NO Defective engine speed sensor B Replace
• Disconnect RRL. (male) (1) and (2) normal?
• 500 – 1,000 Ω
YES
4
• Turn starting switch OFF. Is resistance between LE31 Defective contact or disconnection in
NO Repair or
• Disconnect LE31 and RRL. (female) (3) and RRL (female) (1) wiring harness between LE31 (female)
replace
• Max. 1 Ω normal? (14) – RRL (female) (2)
YES
Repair or
replace
(3) – RRL (female) (1) – M41 (female)
(1)
20-420 D575A-3 SD
TROUBLESHOOTING E-9
E-9 [E0411] Abnormality in right rack sensor system is displayed

★ If the operation can be continued, perform the checks in Steps 1 and 2 under the operating condition where
a trouble occurs.
Cause Remedy
1
• 0.1 – 4.5 V (17) normal?
YES
2
• Turn starting switch ON. Is voltage between LER (3) and NO
• 0.1 – 4.5 V (4) normal?
YES
wiring harness between LE31 (female) Repair or
(7) – LER (female) (3) or between replace
LE31 (female) (17) – LER (female) (4)
3
Is resistance between LER Short circuit with chassis ground in Repair wiring
NO wiring harness between LE31 (female) harness or
• Disconnect LE31 and LER. (female) (3) and (2) and between
(4) and (2) normal? (7) – LER (female) (3) or between replace
• 50 kΩ – 1 MΧ
LE31 (female) (17) – LER (female) (4)
YES
Defective right rack sensor Replace rack
sensor
D575A-3 SD 20-421
TROUBLESHOOTING E-10
E-10 [E0412] Abnormality in left rack sensor system is displayed

★ If the operation can be continued, perform the checks in Steps 1 and 2 under the operating condition where
a trouble occurs.
Cause Remedy
1
Turn starting switch ON. Is voltage between LE31 (8) and NO
0.1 4.5 V (18) normal?
YES
2
Turn starting switch ON. Is voltage between LEL (3) and NO
0.1 4.5 V (4) normal?

YES
(8) LEL (female) (3) or between replace
LE31 (female) (18) LEL (female) (4)
3
Short circuit with chassis ground in
Turn starting switch OFF. Is resistance between LEL Repair wiring
NO wiring harness between LE31 (female)
Disconnect LE31 and LEL. (female) (3) and (2) and between harness or
(8) LEL (female) (3) or between
50 kΩ 1 MΩ (4) and (2) normal? replace
LE31 (female) (18) LEL (female) (4)
YES
Replace rack
Defective right rack sensor
sensor
20-422 D575A-3 SD
E-11 [E0413] Abnormality in rack sensor power source system is

displayed
Cause Remedy
1
• Turn starting switch OFF. Is resistance between LE21
(female) (16) and LE51 (female)
NO
• Disconnect LE21 and LE51.
• Min. 500 kΩ (1) normal?
YES
2
• Turn starting switch OFF. Is resistance between LER (male)
NO Defective rack sensor having
• Disconnect LE21 and LE51. (1) and (2) and between LEL Replace
abnormal resistance
• Min. 500 kΩ (male) (1) and (2) normal?
YES
3
Is voltage between LER (1) and NO Defective contact or disconnection in
• Turn starting switch ON. chassis ground and between LEL wiring harness between LER (female) Repair or
• 4.6 – 5.4 V (1) and chassis ground normal? (2) – LEL (female) (2) – chassis replace
ground
YES
(16) – LER (female) (1) – LEL (female) replace
(1)
D575A-3 SD 20-423
E-12 [E0421] Short circuit in right governor solenoid system is displayed

Cause Remedy
1
Is voltage between LE2 (female)
• Turn starting switch OFF. (7) and (17) and between (7) (17) NO
• Disconnect LE2. and chassis ground as shown in
Table 1?
YES
2
Is resistance between GSR
• Turn starting switch OFF. (male) (1) and (2) and between NO Defective right governor solenoid Replace
• Disconnect GSR. (1) (2) and chassis ground as
shown in Table 2?
YES
3
• Disconnect GSR and LE2. NO Short circuit with power source in
Is voltage between LE2 (female) Repair or
• Turn starting switch ON. wiring harness between LE2 (female)
(17) and chassis ground normal? replace
• Max. 1 V (17) – GSR (female) (2)
YES
Short circuit with chassis ground or
power source in wiring harness Repair or
between LE2 (female) (7) – GSR replace
(female) (1)
Table 1 Table 2
LE2 (female) Resistance GSR (male) Resistance
Between (7) – (17) 10 – 21 Ω Between (1) – (2) 10 – 21 Ω
Between (7) (17) – chassis Min. 1 M Ω Between (1) (2) – chassis Min. 1 M Ω
20-424 D575A-3 SD
E-13 [E0422] Disconnection in right governor solenoid system is

displayed
Cause Remedy
1
Table 1?
YES
2
Is resistance between GSR
• Turn starting switch OFF. (male) (1) and (2) and between NO Defective right governor solenoid Replace
• Disconnect GSR. (1) (2) and chassis ground as
shown in Table 2?
YES
3
NO Short circuit with power source in
• Turn starting switch ON. Is voltage between GSR (1) and Repair or
• 20 – 30 V chassis ground normal? replace
(7) – GSR (female) (1)
YES
Defective contact, disconnection or short
circuit with chassis ground in wiring Repair or
harness between LE2 (female) (17) – replace
GSR (female) (2)
Table 1 Table 2
LE2 (female) Resistance GSR (male) Resistance
D575A-3 SD 20-425
E-14 [E0423] Short circuit in left governor solenoid system is displayed

Cause Remedy
1
Table 1?
YES
2
Is resistance between GSL (male)
• Turn starting switch OFF. (1) and (2) and between (1) (2) NO Defective left governor solenoid Replace
• Disconnect GSL. and chassis ground as shown in
Table 2?
YES
3
• Disconnect GSL and LE2. NO Short circuit with power source in
Is voltage between LE2 (female) Repair or
• Max. 1 V (18) – GSL (female) (2)
YES
power supply in wiring harness Repair or
between LE2 (female) (8) – GSL replace
(female) (1)
Table 1 Table 2
LE2 (female) Resistance GSL (male) Resistance
Between 8) – (18) 10 – 21 Ω Between (1) – (2) 10 – 21 Ω
20-426 D575A-3 SD
E-15 [E0424] Disconnection in left governor solenoid system is displayed

Cause Remedy
1
Turn starting switch OFF. (8) and (17) and between (8) (18) NO
Disconnect LE2. and chassis ground as shown in
Table 1?
YES
2
Is resistance between GSL (male)
Turn starting switch OFF. (1) and (2) and between (1) (2) NO
Defective left governor solenoid Replace
Disconnect GSL and chassis ground as shown in
Table 2?
YES
3
Short circuit with power source in
Turn starting switch ON. Is voltage between GSL (1) and NO Repair or
(8) GSl (female) (1)
YES
(18) GSL (female) (2)
Table 1 Table 2
LE2 (female) Resistance GSL (male) Resistance
D575A-3 SD 20-427
E-16 [E0425] Short circuit in right governor cut relay system is displayed
Cause Remedy
1
Is resistance between GCR NO
• Disconnect GCR. Defective right governor cut relay Replace
• 200 – 900 Ω
YES
2
• Disconnect GCR and LE11. Short circuit with power source in
Is voltage between LE11 (female) NO Repair or
• Max. 1 V (4) – GCR (female) (2)
YES
20-428 D575A-3 SD
E-17 [E0426] Disconnection in left governor cut relay system is displayed

Cause Remedy
1
• Turn starting switch OFF. Is resistance between GCR NO Defective right governor cut relay Replace
• Disconnect GCR. (male) (1) and (2) normal?
• 200 – 900 Ω
YES
2
• 20 – 30 V chassis ground normal?
YES

• Turn starting switch ON. Is voltage between GCR (1) and NO short circuit with chassis ground in Repair or
• 20 – 30 V chassis ground normal? wiring harness between GCR (female) replace
(1) – ACC terminal of starting switch
YES
Repair or
replace
(4) – GCR (female) (2)
D575A-3 SD 20-429
E-18 [E0427] Short circuit in left governor cut relay system is displayed
Cause Remedy
1
• Turn starting switch OFF. Is resistance between GCL NO Defective left governor cut relay
• Disconnect GCL. Replace
• 200 – 900 Ω
YES
2
• Disconnect GCL and LE11. Short circuit with power source in
Is voltage between LE11 (female) NO Repair or
• Max. 1 V (5) – GCL (female) (2)
YES
20-430 D575A-3 SD
E-19 [E0428] Disconnection in left governor cut relay system is displayed

Cause Remedy
1
Is resistance between GCL NO Defective left governor cut relay Replace
• Disconnect GCL.
• 200 – 900 Ω
YES
2
• 20 – 30 V chassis ground normal?
YES

• Turn starting switch ON. Is voltage between GCL (1) and NO short circuit with chassis ground in Repair or
• 20 – 30 V chassis ground normal? wiring harness between GCL (female) replace
(1) – ACC terminal of starting switch
YES
Repair or
replace
(5) – GCL (female) (2)
D575A-3 SD 20-431
E-20 [E0433] Short circuit in left pre-stroke solenoid system is displayed

Cause Remedy
1
Is resistance between LE2 (female)
Table 1?
YES
2
Is resistance between PSL (male)
• Turn starting switch OFF. (1) and (2) and between (1) (2) NO Defective left pre-stroke solenoid Replace
• Disconnect PSL. and chassis ground as shown in
Table 2?
YES
3
• Disconnect PSL and LE2. Short circuit with power source in
Is voltage between LE2 (female) NO wiring harness between LE2 (female)
Repair or
• Turn starting switch ON. replace
(20) and chassis ground normal? (20) – PSL (female) (2)
• Max. 1 V
YES
power supply in wiring harness Repair or
between LE2 (female) (10) – PSL replace
(female) (1)
Table 1 Table 2
LE2 (female) Resistance PSL (male) Resistance
20-432 D575A-3 SD
E-21 [E0434] Disconnection in left pre-stroke solenoid system

isdisplayed
Cause Remedy
1
Is resistance between LE2 (female)
Table 1?
YES
2
Is resistance between PSL (male)
• Turn starting switch OFF. (1) and (2) and between (1) (2) NO Defective left pre-stroke solenoid Replace
• Disconnect PSL. and chassis ground as shown in
Table 2?
YES
3
• Turn starting switch ON. Is voltage between PSL (female) NO Repair or
• 20 – 30 V (1) and chassis ground normal? replace
(10) – PSL (female) (1)
YES
(20) – PSL (female) (2)
Table 1 Table 2
LE2 (female) Resistance PSL (male) Resistance
D575A-3 SD 20-433
E-22 [E0435] Abnormality in engine water temperature sensor system is

displayed
Cause Remedy
1
Is resistance between LE32
(female) 5 and chassis ground
NO
• Disconnect E32.
as shown in following table?
YES
2
Is resistance between 402
• Turn starting switch OFF. NO Defective engine water temperature
(female) (1) and 2 as shown in Replace
• Disconnect 402. sensor
following table?
YES
3
• Turn starting switch OFF. Is resistance between 402 Defective contact or disconnection in
(female) and chassis ground
NO Repair or
• Disconnect 402. wiring harness between CN2 (female)
replace
• Max. 1 Ω normal? (2) – chassis ground
YES
wiring harness between E32 (female) replace
(5) – 402 (female) (1) – CN2 (female)
(1)
Table
Engine water temperature Resistance
10 – 100°C Approx. 80 – 3.8 kΩ
20-434 D575A-3 SD
E-23 [E0437] Abnormality in right governor servo is displayed

Cause Remedy
Go to Troubleshooting for fuel

injection pump.
E-24 [E0438] Abnormality in left governor servo is displayed

Cause Remedy
Go to Troubleshooting for fuel

injection pump.
D575A-3 SD 20-435
E-25 [E0440] Disconnection solenoid power source 1 system is displayed

Cause Remedy
Go to E-17.
E-26 [E0441] Disconnection in power supply system 2 of solenoid is

displayed
Cause Remedy
Go to E-19.
20-436 D575A-3 SD
E-27 [E0442] Abnormality in engine controller backup power source sys-

tem is displayed
★ Check that fuse 1 is not broken. (If it is broken, check the circuit related to it for short circuit with chassis
ground.)
Cause Remedy
1
Turn starting switch OFF. Is voltage between E11 (7) and NO
20 30 V (8) (16) normal?
YES
2
Turn starting switch OFF. Is voltage between E11 (7) and NO Repair or
(7) fuse 1
YES
Repair or
replace
(8) (16) chassis ground
D575A-3 SD 20-437
E-28 [E0443] Abnormality in engine controller switch power source

system is displayed
ground.)
Cause Remedy
1
Turn starting switch ON. Is voltage between E11 (9) (17) NO
20 30 V and (8) (16) normal?
YES
2 Defective contact or disconnection in

Turn starting switch ON. Is voltage between E11 (9) (17) NO wiring harness between E11 (female) Repair or
20 30 V and chassis ground normal? (9) (17) ACC terminal of starting replace
switch
YES
Repair or
replace
(8) (16) chassis ground
20-438 D575A-3 SD
E-29 [E0455] Engine overheating is displayed

Cause Remedy
1
Go to
Is any other service code NO Problem probably caused by
• Turn starting switch ON. troubleshooting
displayed, too? abnormality in engine.
for engine.
YES Check
Problem probably caused by other according to
abnormality occurring at same time. displayed
service code.
D575A-3 SD 20-439
E-30 [E0456] Short circuit in right pre-stroke solenoid system is

displayed
Cause Remedy
1
Is resistance between E21 (female)
• Disconnect E21. and chassis ground as shown in
Table 1?
YES
2
Is resistance between E14 (male)
• Turn starting switch OFF. (1) and (2) and between (1) (2) and NO Defective right pre-stroke solenoid Replace
• Disconnect E14. chassis ground as shown in Table
2?
YES
3
• Disconnect E14 and E21. Short circuit with power source in
Is voltage between E14 (female) NO Repair or
• Turn starting switch ON. wiring harness between E21 (female)
• Max. 1 V (19) – E14 (female) (2)
YES
power supply in wiring harness
Replace
between E21 (female) (9) – E14
(female) (1)
Table 1 Table 2
E21 (female) Resistance E14 (female) Resistance
20-440 D575A-3 SD
E-31 [E0457] Disconnection in right pre-stroke solenoid system is

displayed
Cause Remedy
1
Is resistance between E21 (female)
Table 1?
YES
2
Is resistance between E14 (male)
• Turn starting switch OFF. (1) and (2) and between (1) (2) NO Replace
Defective right pre-stroke solenoid
Table 2?
YES
3
• Turn starting switch ON. Is voltage between E14 (1) and NO Repair or
(9) – E14 (female) (1)
YES
wiring harness between E21 (female) replace
(19) – E14 (female) (2)
Table 1 Table 2
E21 (female) Resistance E14 (female) Resistance
D575A-3 SD 20-441
E-32 Engine does not revolve when starting switch is turned to ON

position
★ Check that any service code is not displayed. (If any service code is displayed, check according to it.)
ground.)
★ When performing any part of troubleshooting, turn the parking lever to the LOCK position.
Cause Remedy
1
Voltage: Min. 24 V Are voltage and specific gravity of NO
Defective battery Replace
Specific gravity: Min. 1.26 battery normal?
YES
Turn starting switch ON and 2

OFF. Does operating sound of battery NO
20 30 V relay come out?
« Check both sides. YES
3
Turn starting switch to
Is voltage between 103 (1), 104 NO
START position.
(1) and chassis ground normal?
20 30 V
YES
4
Turn starting switch ON. Is voltage between 103 (2), 104 NO
Max. 1 V (2) and chassis ground normal?
YES
5
Is connection of power supply Defective connection in power supply
Check visually. NO Repair or
« Check both sides.
harness between starting motor
and battery relay normal?
harness between starting motor and
battery relay
replace
YES
Defective starting motor Replace
6
Disconnect ANR.
Is voltage between 103 (2), 104 NO
Max. 1 V
YES
Defective alternator Replace
7
Disconnect 220. Short circuit with power source in wiring
Is voltage between 103 (2), 104 NO Repair or
Turn starting switch ON. harness between 103 (female) (2) Ð 104
Max. 1 V (female) (2) CNR or 220 (male) (2)
YES
Defective diode (220) Replace
8
Turn starting switch to
Is voltage between TL2 (3) and NO
START position.
chassis ground normal?
20 30 V
YES
9
Turn starting switch OFF.
Is resistance between TL2 (male) NO
Disconnect TL2. Defective neutral safety switch Replace
(1) and (3) normal?
Max. 1 Ω
Repair or
wiring harness between TL2 (female) (1)
replace
103 (female) (1) 104 (female) (1)
Go to next page Go to next page
20-442 D575A-3 SD
Cause Remedy
From previous page From previous page
10
Turn starting switch to Is voltage between terminal C of
NO
START position. starting switch and chassis Defective starting switch Replace
20 30 V ground normal?
YES
wiring harness between terminal C Repair or
(280) of starting switch TL2 (female) replace
(3)
11
Turn starting switch ON. Is voltage between terminal B of
NO
20 30 V battery relay and chassis ground
« Check both sides. normal?
YES
Defective battery relay Replace
12
Is voltage between terminal BR of
Turn starting switch ON. NO
starting switch and chassis
20 30 V
ground normal?
YES
wiring harness between terminal BR Repair or
(260) of starting switch terminal BR replace
of battery relay
13
Disconnect terminals B and
NO
BR of starting switch. Is resistance between terminals B Defective starting switch Replace
Turn starting switch ON. and BR of starting switch normal?
Max. 10 Ω
YES Repair or
wiring harness between terminal B
(250) of starting switch terminal B of replace
battery relay
D575A-3 SD 20-443
20-444 D575A-3 SD
E-33 Engine does not stop when starting switch is turned to OFF position
★ Check that any service code is not displayed. (If any service code is displayed, check according to it.)
★
Cause Remedy
1
Turn starting switch OFF. Is voltage between E11 (9) (17) NO
Max. 1 V and (8) (16) normal?
YES
2
Is resistance between terminals B NO
Disconnect terminals B and Defective starting switch Replace
and ACC of starting switch
ACC.
normal?
Min. 1 MΩ
YES Short circuit with power source in
wiring harness between E11 (female) Repair or
(9) (17) terminal ACC of starting replace
switch
D575A-3 SD 20-445
TROUBLESHOOTING OF
STEERING CONTROLLER SYSTEM
(ST MODE)
Service code and abnormal system ............................................................................................................ 20-502

Electrical circuit diagram of st mode system ............................................................................................... 20-506
ST-1 [E0111] Abnormality in steering controller power source voltage is displayed................................ 20-512
ST-2 [E0143] Abnormality in steering controller 5V power source is displayed ...................................... 20-513
ST-3 [E0145] Abnormality in steering controller sensor power source is displayed ................................ 20-514
ST-4 [E0151] Abnormality in specification selection is displayed............................................................ 20-515
ST-5 [E0161] Abnormality in steering controller E2PROM is displayed .................................................. 20-516
ST-6 [E0660] Disconnection in ACC signal drive relay system ............................................................... 20-517
ST-7 [E0661] Short circuit in ACC signal drive relay system................................................................... 20-517
ST-8 [E0721] Abnormality in pitch angle sensor system is displayed ..................................................... 20-518
ST-9 [E0730, E0731, E0732] Abnormality in travel lower swing system................................................. 20-519
ST-10 [E0733] Abnormality in swing potentiometer 1 system is displayed ............................................... 20-519
ST-11 [E0734] Abnormality in swing potentiometer 2 system is displayed ............................................... 20-521
ST-12 [E0735] Lag of swing signal............................................................................................................ 20-522
ST-13 [E0736] Abnormality in brake potentiometer system is displayed .................................................. 20-523
ST-14 [E0750] Disconnection in right steering clutch ECMV system ........................................................ 20-525
ST-15 [E0751] Short circuit in right steering clutch ECMV system............................................................ 20-526
ST-16 [E0752] Disconnection in left steering clutch ECMV system .......................................................... 20-527
ST-17 [E0753] Short circuit in left steering clutch ECMV system.............................................................. 20-528
ST-18 [E0754] Disconnection in right steering brake ECMV system ........................................................ 20-529
ST-19 [E0755] Short circuit in right steering brake ECMV system ............................................................ 20-531
ST-20 [E0756] Disconnection in left steering brake ECMV system........................................................... 20-530
ST-21 [E0757] Short circuit in left steering brake ECMV system .............................................................. 20-532
ST-22 [E0760] Abnormality in right steering clutch oil pressure system ................................................... 20-533
ST-23 [E0761] Short circuit in right steering clutch oil pressure system ................................................... 20-533
ST-24 [E0762] Abnormality in left steering clutch oil pressure system...................................................... 20-234
ST-25 [E0763] Short circuit in left steering clutch oil pressure system...................................................... 20-534
ST-26 [E0764] Abnormality in right steering brake oil pressure system.................................................... 20-535
ST-27 [E0765] Short circuit in right steering brake oil pressure system.................................................... 20-535
ST-28 [E0766] Abnormality in left steering brake oil pressure system ...................................................... 20-536
ST-29 [E0767] Short circuit in left steering brake oil pressure system ...................................................... 20-536
ST-30 [E0779] Disconnection in emergency stop prevention solenoid system......................................... 20-537
ST-31 [E0780] Short circuit in emergency stop prevention solenoid system ............................................ 20-538
ST-32 [E0781] Abnormality in travel lock switch system
a) When only E0781 is displayed ................................................................................................... 20-541
b) When both E0781 and E0238 are displayed .............................................................................. 20-542
ST-33 [E0782] Disagreement in travel lock ............................................................................................... 20-543
ST-34 [E0930] Abnormality in engine speed sensor B system is displayed.............................................. 20-543
ST-35 [E0933] Abnormality in bevel speed sensor A system is displayed................................................ 20-544
D575A-3 SD 20-501
TROUBLESHOOTING SERVICE CODE AND ABNORMAL SYSTEM
SERVICE CODE AND ABNORMAL SYSTEM
Service
code Abnormal system Criterion
E0111 Abnormality in steering controller power source volt- <17V

age
E0143 Abnormality in steering controller 5V power source <4.5V or >5.5V
E0145 Abnormality in steering controller sensor power source <17V or >30V
E0151 Abnormality in specification selection of steering con- Check of wire logic

troller
E0161 Abnormality in steering controller E2PROM Abnormality in reading NvRam
E0176 Disconnection in battery relay holding relay system Disagreement in output, F/B voltage (Hsw Out Check)
E0177 Short circuit in battery relay holding relay system Detection of short circuit (Hsw Out Check)
E0660 Disconnection in ACC signal drive relay system Disagreement in output, F/B voltage (Hsw Out Check)
E0661 Short circuit in ACC signal drive relay system Detection of short circuit (Hsw Out Check)
E0721 Abnormality in pitch angle sensor system >4.85V (A In Check)
E0730 Abnormality in travel lever swing system (E3_733a or E3_733b) & (E3_734a or E3_734b)
E0731 Abnormality in travel lever swing system (E3_735) & (When key is on, both are normal)
E0732 Abnormality in travel lever swing system When key is on, 1 potentiometer is normal, and it has
abnormality.
E0733 Abnormality in swing potentiometer 1 system >4.5V (A In Check), <0.5V (A In Check)
E0734 Abnormality in swing potentiometer 2 system >4.5V (A In Check), <0.5V (A In Check)
E0735 Lag of swing signal Potentiometer 1 + 2 <4.41 V or > 5.59 V
E0736 Abnormality in brake potentiometer system >4.5V (A In Check), <0.5V (A In Check)
Output current > 0 mA, Current signal [1A = 1V] + 0.05

E0750 Disconnection in right steering clutch ECMV system < Output voltage
(A_Out_Check)
E0751 Short circuit in right steering clutch ECMV system Detection of OS short circuit (A_Out_Check)

E0752 Disconnection in left steering clutch ECMV system < Output voltage
(A_Out_Check)
E0753 Short circuit in left steering clutch ECMV system Detection of OS short circuit (A_Out_Check)

E0754 Disconnection in right brake ECMV system < Output voltage
(A_Out_Check)
E0755 Short circuit in right brake ECMV system Detection of OS short circuit (A_Out_Check)

E0756 Disconnection in left brake ECMV system < Output voltage
(A_Out_Check)
20-502 D575A-3 SD
Problem that appears on machine when there is

Action by controller
abnormality
In some cases, system cannot drive solenoid and relay and
Lights up caution lamp, sounds alarm buzzer
cannot work normally
In some cases, sensor value becomes abnormal and sys-
tem cannot work normally
Turns off all outputs (Turn ON brake) Machine cannot move
Lights up caution lamp, sounds alarm buzzer In some cases, steering performance lowers
Turbocharger timer function (optional) does not work
Turbocharger timer function (optional) does not work
Steering system is always set in inclination mode and steer-

Always sets steering system in inclination mode.
ing performance lowers.
Lights up caution lamp and sounds alarm buzzer. Sets If machine is turning, turning is continued. Machine cannot
steering system in neutral. move once it stops.
Engine output is reduced to half. Only 1st gear speed is
Continues control with turning potentiometer 2
available.
Continues control with turning potentiometer 1
available.
If machine is turning, turning is continued. Machine cannot
move once it stops.
available. Brake cannot be controlled normally with pedal.
Machine cannot turn to right. Once machine stops, engine
Lights up caution lamp and sounds alarm buzzer. Stops
outputting to right clutch ECMV. output is reduced to half and only 1st gear speed is avail-
able.
Machine cannot turn to right. Once machine stops, engine
outputting to right clutch ECMV. output is reduced to half and only 1st gear speed is avail-
able.
Machine cannot turn to left. Once machine stops, engine
Lights up caution lamp and sounds alarm buzzer. Stops output is reduced to half and only 1st gear speed is avail-
outputting to left clutch ECMV.
able.
Machine cannot turn to left. Once machine stops, engine
Lights up caution lamp and sounds alarm buzzer. Stops output is reduced to half and only 1st gear speed is avail-
outputting to left clutch ECMV.
able.
Lights up caution lamp and sounds alarm buzzer. Stops Machine cannot move.
outputting to right brake ECMV.

outputting to right brake ECMV Machine cannot move.

outputting to left brake ECMV Machine cannot move
D575A-3 SD 20-503
Service
E0757 Short circuit in left brake ECMV system Detection of OS short circuit (A_Out_Check)
Engine speed > 600 rpm, Output > 0.5 A, Fill switch
Abnormality in right steering clutch oil pressure system
E0760 OFF
(Clutch is not engaged)
(Fill_Sw_Check)
E0761 Abnormality in right steering clutch oil pressure system Engine speed > 600 rpm, Output = 0 A, Fill switch ON
(Clutch is not disengaged) (Fill_Sw_Check)
Abnormality in left steering clutch oil pressure system
E0762 OFF
(Fill_Sw_Check)
E0763 Abnormality in left steering clutch oil pressure system Engine speed > 600 rpm, Output = 0 A, Fill switch ON
Abnormality in right brake oil pressure system (Brake
E0764 OFF
is not engaged)
(Fill_Sw_Check)
E0765 Abnormality in right brake oil pressure system (Brake Engine speed > 600 rpm, Output = 0 A, Fill switch ON
is not disengaged) (Fill_Sw_Check)
Abnormality in left brake oil pressure system (Brake is
E0766 OFF
not engaged)
(Fill_Sw_Check)
E0767 Abnormality in left brake oil pressure system (Brake is Engine speed > 600 rpm, Output = 0 A, Fill switch ON
not disengaged) (Fill_Sw_Check)
E0779 Disconnection in emergency stop prevention solenoid Output current > 0 mA, Current signal [1A = 1V] +
system 0.05V < Output voltage (Fill_Sw_Check)
E0780 Short circuit in emergency stop prevention solenoid Detection of OS short circuit (A_Out_Check)
system
E0781 Abnormality in travel lock switch system Both NO and NC are NO or NC (No_nc_Check)
E0782 Disagreement in travel lock Transmission controller travel lock (Snet) and steering
controller travel lock are different.
No pulses are input when terminal voltage is above
E0930 Disconnection in engine speed sensor system specification level (2.2 V).
(P_In_Check)
E0933 Disconnection in transmission speed sensor system specification level (2.2 V).
(P_In_Check)
20-504 D575A-3 SD

abnormality
Lights up caution lamp and sounds alarm buzzer. Stops Machine cannot move
outputting to left brake ECMV
Lights up caution lamp and sounds alarm buzzer. Applies Machine cannot move
brake.
brake.
brake.
brake.
brake.
brake.
brake.
brake.
Even if parking brake is released, brake is applied half.
outputting to emergency stop prevention solenoid.
Even if parking brake is released, brake is applied half.
outputting to emergency stop prevention solenoid.
Lights up caution lamp and sounds alarm buzzer.
available.
Lights up caution lamp and sounds alarm buzzer. Engine output is reduced to half. Only 1st gear speed is
available.
Engine speed is not displayed. In some cases, steering

performance lowers.
In some cases, steering performance lowers.
D575A-3 SD 20-505
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM OF ST MODE SYSTEM
ELECTRICAL CIRCUIT DIAGRAM OF ST MODE SYSTEM

Single-tilt specification model and dual-tilt specification model
(1/3)
20-506 D575A-3 SD
(2/3)
D575A-3 SD 20-507
(3/3)
20-508 D575A-3 SD
Super-dozer specification model

(1/3)
D575A-3 SD 20-509
(2/3)
20-510 D575A-3 SD
(3/3)
D575A-3 SD 20-511
TROUBLESHOOTING ST-1
ST-1 [E0111] Abnormality in steering controller power source voltage is

displayed
★ Check that circuit breaker CB4 is not broken. (If it is broken, check the circuit related to it for short circuit
with chassis ground.)
Cause Remedy
1
Is voltage between NGICN3 (1)
(11) and (21) (31) (32) (33)
20 30 V
normal?
YES
Defective steering controller Replace
2
Turn starting switch ON. Is voltage between NGICN3 (1) NO Repair or
wiring harness between NGICN3
20 30 V (11) and chassis ground normal? replace
(female) (1) (11) circuit breaker 4
YES
Repair or
wiring harness between NGICN3
replace
(female) (21) (31) (32) (33) chassis
ground
ST-1 Related electrical circuit diagram
20-512 D575A-3 SD
ST-2 [E0143] Abnormality in steering controller 5V power source is

displayed
Cause Remedy
1
Turn starting switch ON. Is voltage between NGICN1
NO
4.5 5.5 V (male) (22) and chassis ground
Disconnect NGICN1. normal?
YES
Defective steering control Replace
2
Turn starting switch ON. When C24 is disconnected, does NO
Disconnect C24. caution lamp [E0143] go off?
YES
3
Turn starting switch ON. When TL1 is disconnected, does NO
Disconnect TL1. caution lamp [E0143] go off?
YES Short circuit or short circuit with

Go to [E0733],
chassis ground in swing lever
[E0734]
assembly
4
Short circuit or short circuit with
Turn starting switch ON. When C22 is disconnected, does NO
chassis ground in wiring harness
Disconnect C22. caution lamp [E0143] go off?
between NGICN1 C22 C24
YES Short circuit or short circuit with

between C22 SS3
5
Short circuit or short circuit with Go to [E0736],
When W22 is disconnected, does NO
chassis ground in wiring harness [E0733],
caution lamp [E0143] go off?
between C24 W22 TL1 [E0734]
YES Defective contact in wiring harness

between W22 brake pedal Go to [E0736]
potentiometer or defective brake
pedal potentiometer
D575A-3 SD 20-513
ST-3 [E0145] Abnormality in steering controller sensor power source is

displayed
Cause Remedy
1
• Turn starting switch ON.
Is voltage between NGICN1 (16) NO
• 17 – 30 V Defective steering controller Replace
and chassis ground normal?
• Disconnect NGICN1.
YES
2
When C22 is disconnected, does Short circuit or short circuit with
• Turn starting switch ON. NO chassis ground in wiring harness Go to [E0721]
• Disconnect C22. caution lamp [E0143] go off? between NGICN1 – C22
YES Defective contact in wiring harness
between C22 – PAS or defective pitch Go to [E0721]
angle sensor
20-514 D575A-3 SD
ST-4 [E0151] Abnormality in specification selection is displayed

Cause Remedy
1
• Check on monitor panel in Is specification setting in
adjustment mode [5A]. controller correct?
Is [222] displayed? NO
YES
3
Is left of display other than 2? NO
[ ]
YES
4
• Turn starting switch OFF. Is resistance between NGICN3 Disconnection or defective contact in
Repair or
• Disconnect NGICN3. (female) (20) and chassis ground NO wiring harness between NGICN3
replace
• Max. 1Ω normal? (female) (20) – chassis ground
YES
5
Is center of display other than 2? NO
[ ]
Set
YES specification in
Wrong specification setting in
controller adjustment
mode [5A]
6
Is harness disconnected from NO Defective harness of NGICN3 Repair or
NGICN3 (female) (10)? (female) (10) replace
YES
7
Is right of display other than 2?
[ ]
D575A-3 SD 20-515
TROUBLESHOOTING ST-4, ST-5
ST-5 [E0161] Abnormality in steering controller E2PROM is displayed

Cause Remedy
Defective steering controller
20-516 D575A-3 SD
ST-6 [E0660] Disconnection in ACC signal drive relay system

Cause Remedy
1
Is voltage between NGICN3 (18) NO
Disconnect NGICN3.
(female) and chassis ground
Max. 1 V
YES
2
Is resistance between SDR NO
Disconnect SDR. Defective engine shut-down relay
200 400 Ω
YES
3
Turn starting switch OFF. Is resistance between SDR Disconnection, short circuit, or
NO
Disconnect SDR. (female) (2) and chassis ground defective contact in wiring harness
Max. 1 Ω normal? between SDR (2) GND004
YES Disconnection, short circuit, or

defective contact in wiring harness
between NGICN3 (18) SDR (1)
ST-7 [E0661] Short circuit in ACC signal drive relay system

Cause Remedy
1
Turn starting switch OFF. Is resistance between NGICN3
NO
Disconnect NGICN3. (18) (female) and chassis
200 400 Ω groundnormal?
YES
2
Is resistance between SDR NO
Disconnect SDR. Defective engine shut-down relay
200 400 Ω
YES Short circuit with chassis ground in
harness between NGICN3 (18) SDR
(1)
ST-6, ST-7 Related electrical circuit diagram
D575A-3 SD 20-517
ST-8 [E0721] Abnormality in pitch angle sensor system is displayed

Cause Remedy
1
Is voltage between NGICN1
(female) (13) and chassis ground
0.15 4.85 V
normal?
YES
2
Disconnection, short circuit, or
Turn starting switch ON. Is voltage between PAS (3) and NO
0.15 4.85 V chassis ground normal?
between NGICN1 (13) PAS (B)
YES
3
Turn starting switch ON. Is voltage between PAS (3)
NO
17 30 V (male) (C) and chassis ground
Disconnect PAS. normal?
YES
4
Turn starting switch ON. Is voltage between PAS (3) Disconnection, short circuit, or
NO
Max. 1 V (female) (A) and chassis ground defective contact in wiring harness
Disconnect PAS. normal? between NGICN1 (21) PAS (A)
YES
Defective pitch angle sensor Replace
5
(male) (16) and chassis ground Defective steering controller
17 30 V
normal?

between NGICN1 (16) PAS (C)
20-518 D575A-3 SD
ST-9 [E0730, E0731, E0732] Abnormality in travel lower swing system

→ Check according to the procedures of [E0733] and [E0734].
ST-10 [E0733] Abnormality in swing potentiometer 1 system is displayed

Cause Remedy
1
Is swing lever potentiometer 1 NO
Adjust swing lever potentiometer 1.
adjusted correctly?
YES
2
Turn starting switch ON. Is voltage between NGICN1 (2) NO
0.5 4.5 V and chassis ground normal?
YES
3
Turn starting switch ON. Is voltage between TL1 (H) and NO

between NGICN1 (2) TL1 (H)
4
Turn starting switch ON. Is voltage between TL1 (A)
NO
4.5 5.5 V (female) and chassis ground
Disconnect TL1. normal?
YES
5
Turn starting switch ON. Is voltage between TL1 (G) NO
Max. 1 V (female) and chassis ground
YES
Defective swing potentiometer 1
6
Turn starting switch ON. Is voltage between NGICN1 (22)
NO
4.5 5.5 V (male) and chassis ground Defective steering controller Replace

between NGICN1 (22) TL1 (A)
7
NO
(male) and chassis ground Defective steering controller
normal?

between NGICN1 (21) TL1 (G)
D575A-3 SD 20-519
20-520 D575A-3 SD
ST-11 [E0734] Abnormality in swing potentiometer 2 system is displayed

Cause Remedy
1
Is swing lever potentiometer 2 NO
Adjust swing lever potentiometer 2.
adjusted correctly?
YES
2
YES
3
Turn starting switch ON. Is voltage between TL1 (E) and NO

between NGICN1 (19) TL1 (E)
4
Turn starting switch ON. Is voltage between TL1 (M)
NO
YES
5
Turn starting switch ON. Is voltage between TL1 (F) NO
YES
Defective swing potentiometer 2
6
NO

between NGICN1 (22) TL1 (M)
7
NO
(male) and chassis ground Defective steering controller
normal?

between NGICN1 (21) TL1 (F)
D575A-3 SD 20-521
ST-12 [E0735] Lag of swing signal

→ Check according to the procedures of [E0733] and [E0734].
20-522 D575A-3 SD
ST-13 [E0736] Abnormality in brake potentiometer system is displayed

Cause Remedy
1
Is brake pedal potentiometer NO
Adjust brake pedal potentiometer.
adjusted correctly?
YES
2
YES
3
Turn starting switch ON. Is voltage between BRK (B) and NO

between NGICN1 (3) BRK (B)
4
Turn starting switch ON. Is voltage between BRK (A)
NO
Disconnect BRK. normal?
YES
5
Turn starting switch ON. Is voltage between BRK (C) NO
Disconnect BRK. normal?
YES
Defective brake pedal potentiometer 2 Replace
6
NO

between NGICN1 (22) BRK (A)
7
NO
Max. 1 V (male) and chassis ground Defective steering controller Replace

between NGICN1 (21) BRK (C)
D575A-3 SD 20-523
20-524 D575A-3 SD
ST-14 [E0750] Disconnection in right steering clutch ECMV system

★ If the starting switch was turned off after the abnormality occurred, turn the starting switch on and set the
joystick in the right steering position and check that the service code displays "E" at the head. (If "P" is dis-
played, the condition has returned to normal.)
Cause Remedy
1
Is resistance between NGICN3 NO
Disconnect NGICN3.
5 25 Ω
YES
2
Turn starting switch ON. Is voltage between NGICN3
NO
Disconnect NGICN3. (female) (35) and chassis ground
Max. 1 V normal?
YES
3
Is resistance between SRC NO
Disconnect SRC.
5 - 25 Ω
YES
Defective right steering clutch ECMV Replace
4
Is voltage between NGICN3 Short circuit with power source in Repair or
Disconnect NGICN3 and NO
(female) (35) and chassis ground wiring harness between NGICN3 (35) replace
SRC.
normal? SRC (1)
Max. 1 V
Repair or
wiring harness between NGICN3 (23)
replace
SRC (2)

5
Is resistance between NGICN3 Disconnection or defective contact in
Disconnect NGICN3 and NO Repair or
(female) (35) and SRC (female) wiring harness between NGICN3 (23)
SRC. replace
(1) normal? SRC (2)
Max. 1 W
YES Disconnection or defective contact in
Repair or
wiring harness between NGICN3 (35) -
replace
SRC (1)
D575A-3 SD 20-525
ST-15 [E0751] Short circuit in right steering clutch ECMV system

Cause Remedy
1
Turn starting switch OFF. Is resistance between NGICN3 Short circuit with chassis ground in
Disconnect NGICN3. (female) (35) and chassis ground NO harness between NGICN3 (35) - SRC Repair or
replace
Min. 1 M Ω normal? (1)
YES 2
Turn starting switch OFF. Is resistance between NGICN3 NO
Disconnect NGICN3. (female) (35) and (23) normal?
5 25 Ω
YES
3
Is resistance between SRC
Turn starting switch OFF. (male) (1) and (2) and between NO Defective right steering clutch ECMV Replace
Disconnect SRC. (1), (2) and chassis ground as
shown in Table 1?
YES Short circuit in wiring harness between Repair or
NGICN3 (35) SRC (1) and between replace
SRC (male) Resistance NGICN3 (23) SRC (2)
Between (1) (2) 5 25 Ω
Between (1), (2) chassis Min. 1 M Ω
20-526 D575A-3 SD
ST-16 [E0752] Disconnection in left steering clutch ECMV system

joystick in the left steering position and check that the service code displays "E" at the head. (If "P" is dis-
Cause Remedy
1
• 5 – 25 Ω
YES
2
• Turn starting switch ON. Is voltage between NGICN3 NO
• Disconnect NGICN3. (female) (25) and chassis ground
• Max. 1 V normal?
YES
Defective steering controller Repair or
replace
3
• Turn starting switch OFF. Is resistance between SLC (male) NO
• Disconnect SLC. (1) and (2) normal?
• 5 – 25 Ω
YES
Defective left steering clutch ECMV Replace
4
• Turn starting switch OFF. Short circuit with power source in
• Disconnect NGICN3 and NO wiring harness between NGICN3 (25) Repair or
SLC. – SLC (1) replace
normal?
• Max. 1 V
Repair or
replace
– SLC (2)
5
• Turn starting switch OFF. Is resistance between NGICN3 Short circuit with power source in
(female) (25) and SLC (female)
SLC. – SLC (2) replace
(1) normal?
• Max. 1 Ω
Repair or
replace
– SLC (1)
D575A-3 SD 20-527
ST-17 [E0753] Short circuit in left steering clutch ECMV system

Cause Remedy
1
Turn starting switch OFF. Is resistance between NGICN3 NO Short circuit with chassis ground in
Disconnect NGICN3. (female) (25) and chassis ground harness between NGICN3 (25) SLC Repair or
Min. 1 M Ω normal? (1) replace
YES 2
5 25 Ω
YES
3
Is resistance between SLC (male)
Turn starting switch OFF. (1) and (2) and between (1), (2) NO Defective left steering clutch ECMV Replace
Disconnect SLC. and chassis ground as shown in
Table 1?
NGICN3 (25) SLC (1) and between replace
SLC (male) Resistance NGICN3 (23) SLC (2)
Between (1) (2) 5 25 Ω
20-528 D575A-3 SD
ST-18 [E0754] Disconnection in right steering brake ECMV system

Cause Remedy
1
• 5 – 25 Ω
YES
2
YES
replace
3
• Turn starting switch OFF. Is resistance between SR8 (male) NO
• Disconnect SR8. (1) and (2) normal?
• 5 – 25 Ω
YES
Defective right steering brake ECMV Replace
4
• Turn starting switch OFF. Is voltage between NGICN3 Short circuit with power source in
SR8. – SR8 (1) replace
normal?
• Max. 1 V
Repair or
replace
– SR8 (2)
5
(female) (15) and SR8 (female)
SR8. – SR8 (2) replace
(1) normal?
• Max. 1 Ω
Repair or
replace
– SR8 (1)
D575A-3 SD 20-529
ST-19 [E0755] Short circuit in right steering brake ECMV system

★ f the starting switch was turned off after the abnormality occurred, turn the starting switch on and set the joy-
stick in the right steering position and check that the service code displays "E" at the head. (If "P" is dis-
Cause Remedy
1
Disconnect NGICN3. (female) (15) and chassis ground harness between NGICN3 (15) SR8 Repair or
YES 2
5 25 Ω
YES
3
Is resistance between SR8 (male)
Turn starting switch OFF. (1) and (2) and between (1), (2) NO Defective right steering brake ECMV Replace
Disconnect SR8. and chassis ground as shown in
Table 1?
NGICN3 (15) SR8 (1) and between replace
SR8 (male) Resistance NGICN3 (13) SR8 (2)
Between (1) (2) 5 25 Ω
20-530 D575A-3 SD
ST-20 [E0756] Disconnection in left steering brake ECMV system

Cause Remedy
1
• 5 – 25 Ω
YES
2
YES
replace
3
• Turn starting switch OFF. Is resistance between SL8 (male) NO
• Disconnect SL8. (1) and (2) normal?
• 5 – 25 Ω
YES
Defective left steering brake ECMV Replace
4
SL8. – SL8 (1) replace
normal?
• Max. 1 V
Repair or
replace
– SL8 (2)
5
(female) (35) and SL8 (female)
SL8. – SL8 (2) replace
(1) normal?
• Max. 1 Ω
Repair or
wiring harness between NGICN3 (5) –
replace
SL8 (1)
D575A-3 SD 20-531
ST-21 [E0757] Short circuit in left steering brake ECMV system

Cause Remedy
1
Disconnect NGICN3. (female) (5) and chassis ground harness between NGICN3 (5) SL8 Repair or
YES 2
5 25 Ω
YES
3
Is resistance between SL8 (male)
Turn starting switch OFF. (1) and (2) and between (1), (2) NO Defective left steering brake ECMV Replace
Disconnect SL8. and chassis ground as shown in
Table 1?
NGICN3 (5) SL8 (1) and between replace
SL8 (male) Resistance NGICN3 (13) SL8 (2)
Between (1) (2) 5 25 Ω
20-532 D575A-3 SD
ST-22 [E0760] Abnormality in right steering clutch oil pressure system

★ Before carrying out the following check, measure the right steering clutch oil pressure. If the result is nor-
mal, check the electric system according to the following procedure.
Cause Remedy
1
• Disconnect NGICN3 and (female) (39) and FRC (1)
NO Repair or
FRC. replace
normal? and FRC (1)
• Max. 1 Ω
YES
Defective right steering clutch fill
Replace
switch
ST-23 [E0761] Short circuit in right steering clutch oil pressure system
★ Before carrying out the following check, measure the right steering clutch oil pressure. If the result is nor-
Cause Remedy
1
• Turn starting switch OFF. Is resistance between NGICN3
• Disconnect NGICN3 and (female) (39) and chassis ground
NO Short circuit in wiring harness between Repair or
FRC. normal? NGICN3 (39) and FRC (1) replace
• Min. 1 M Ω
YES
Defective right steering clutch fill
Replace
switch
ST-22, 23 Related electrical circuit diagram
D575A-3 SD 20-533
TROUBLESHOOTING ST-24, ST25
ST-24 [E0762] Abnormality in left steering clutch oil pressure system

★ Before carrying out the following check, measure the left steering clutch oil pressure. If the result is normal,
check the electric system according to the following procedure.
Cause Remedy
1
• Disconnect NGICN3 and (female) (29) and FLC (1)
NO Repair or
FLC. replace
normal? and FLC (1)[
• Max. 1 Ω
YES
Defective left steering clutch fill switch Replace
ST-25 [E0763] Short circuit in left steering clutch oil pressure system
★ Before carrying out the following check, measure the left steering clutch oil pressure. If the result is normal,
★ • Always connect any disconnected connectors before going on to the next step.
Cause Remedy
1
FLC. normal? NGICN3 (29) and FLC (1) replace
• Max. 1 Ω
YES
Defective left steering clutch fill switch Replace
20-534 D575A-3 SD
ST-26 [E0764] Abnormality in right steering brake oil pressure system

★ Before carrying out the following check, measure the right steering brake oil pressure. If the result is nor-
Cause Remedy
1
• Disconnect NGICN2 and (female) (25) and FR8 (1)
NO Repair or
FR8. replace
normal? and FR8 (1)
• Max. 1 Ω
YES
Defective right steering brake fill switch
Replace
ST-27 [E0765] Short circuit in right steering brake oil pressure system
★ Before carrying out the following check, measure the right steering brake oil pressure. If the result is nor-
Cause Remedy
1
FR8. NGICN2 (25) and FR8 (1) replace
normal?
• Max. 1 Ω
YES
Defective right steering brake fill switch
Replace
D575A-3 SD 20-535
TROUBLESHOOTING ST28, ST-29
ST-28 [E0766] Abnormality in left steering brake oil pressure system

★ Before carrying out the following check, measure the left steering brake oil pressure. If the result is normal,
Cause Remedy
1
• Disconnect NGICN2 and (female) (35) and FL8 (1)
NO Repair or
FL8. replace
normal? and FL8 (1)
• Max. 1 Ω
YES
Defective left steering brake fill switch Replace
ST-29 [E0767] Short circuit in left steering brake oil pressure system
★ Before carrying out the following check, measure the left steering brake oil pressure. If the result is normal,
Cause Remedy
1
FL8. NGICN2 (35) and FL8 (1) replace
normal?
• Max. 1 Ω
YES
Defective left steering brake fill switch Replace
20-536 D575A-3 SD
ST-30 [E0779] Disconnection in emergency stop prevention solenoid

system
the service code displays "E" at the head. (If "P" is displayed, the condition has returned to normal.)
Cause Remedy
1
• 5 – 25 Ω
YES
2
YES Repair or
replace
3
• Turn starting switch OFF. Is resistance between ST8 (male)
(1) and (2) normal? NO
• Disconnect ST8.
• 5 – 25 Ω
YES
Defective emergency stop prevention
Replace
solenoid
4
NO wiring harness between NGICN3 (7) – Repair or
ST8. normal? ST8 (1) replace
• Max. 1 V
YES Short circuit with power source in Repair or
wiring harness between NGICN3 (13) replace
– ST8 (2)
5
• Turn starting switch OFF. Disconnection or defective contact in
Is resistance between NGICN3 NO Repair or
• Disconnect NGICN3 and wiring harness between NGICN3 (13)
(female) (7) and ST8 (female) (1) replace
ST8. – ST8 (2)
normal?
• Max. 1 Ω
YES Disconnection or defective contact in Repair or
wiring harness between NGICN3 (7) – replace
ST8 (1)
D575A-3 SD 20-537
ST-31 [E0780] Short circuit in emergency stop prevention solenoid

system
Cause Remedy
1
Turn starting switch OFF. Is resistance between NGICN3 NO Short circuit with chassis ground in Repair or
Disconnect NGICN3. (female) (7) and chassis ground harness between NGICN3 (7) ST8 replace
Min. 1 M Ω normal? (1)
YES 2
5 25 Ω
YES
3
Is resistance between ST8 (male)
Turn starting switch OFF. (1) and (2) and between (1), (2) NO Defective emergency stop prevention Replace
Disconnect ST8. and chassis ground as shown in solenoid
Table 1?
YES
Short circuit in wiring harness between Repair or
ST8 (male) Resistance NGICN3 (7) ST8 (1) and between replace
Between (1) (2) 5 25 Ω NGICN3 (13) ST8 (2)
20-538 D575A-3 SD
ST-32 [E0781] Abnormality in travel lock switch system

★ If the starting switch was turned off after the abnormality occurred, turn the starting switch on, turn on and
off the parking brake lever, and check that the service code displays "E" at the head. (If "P" is displayed, the
condition has returned to normal.)
a) When only E0781 is displayed
Cause Remedy
1
Are both [E0238] and [E0781] NO
Go to [E0238], [E0781]
displayed?
YES
2
Check operation of travel lock
switch on monitor panel in
monitoring mode [L9].
YES
3
When parking brake lever is at
LOCK position, is x x x x _ _
displayed? NO
RELEASE position, is x x x x _ o
displayed?
YES
4
NO Disconnection in wiring harness Repair or
Disconnect NGICN2 and C24. (female) (5) and C24 (27)
between NGICN2 (5) C24 (27) replace
Max. 1 Ω normal?
YES
5
LOCK position, is x x x x o _
displayed? NO
RELEASE position, is x x x x o o
displayed?
YES
6
NO Repair or
Disconnect NGICN2 and C24. (female) (5) and chassis ground wiring harness between NGICN2 (5)
replace
Min. 1 MΩ normal? C24 (27)
YES
7
displayed? NO
RELEASE position, is x x x x _ _
displayed?
YES
8
Disconnect NGICN2 and C24. (female) (15) and C24 (24)
between NGICN2 (12) C24 (24) replace
Max. 1 Ω normal?
YES
D575A-3 SD 20-539
From previous From previous

page page Cause Remedy
9
LOCK position, is x x x x o o
displayed? NO
displayed?
YES
10
NO Repair or
Disconnect NGICN2 and C24. (female) (15) and chassis ground wiring harness between NGICN2 (15)
replace
YES
11
Is voltage at NSW (female) (B) NO
Disconnect TL1 and NGICN2.
normal?
20 30 V
YES
12
Is voltage at NSW (female) (C) NO
Disconnect NSW and TMCN1.
normal?
20 30 V
YES
13
Turn starting switch ON. Is resistance between NSW
NO Repair or
Disconnect NSW and TMCN1. (female) (A) and chassis ground Defective switch assembly
replace
Max. 1 Ω normal?
YES
Disconnection in wiring harness Repair or
between NSW (A) GND004 replace
14
Is voltage at NGICN2 (male) (15) NO
Disconnect NGICN2 Defective transmission controller Replace
normal?
20 30 V
YES Disconnection or short circuit with

Repair or
replace
between NGICN2 (15) NSW (C)
15
Is voltage at NGICN2 (male) (5) NO
Disconnect NGICN2 Defective transmission controller Replace
normal?
20 30 V

Repair or
replace
between NGICN2 (5) NSW (B)
ST-32 a) Related electrical circuit diagram
20-540 D575A-3 SD
b) When both E0781 and E0238 are displayed
Cause Remedy
1
YES
2
displayed? NO
displayed?
YES
3
Is resistance between C24 (27) Disconnection in wiring harness Repair or
Disconnect C24 and NSW.
and NSW (B) normal? between C24 (27) NSW (B) replace
Max. 1 Ω
YES
4
displayed? NO
displayed?
YES
5
Is voltage between C24 (27) and NO Repair or
Disconnect C24. Defective switch assembly
chassis ground normal? replace
20 30 V
YES
between TMCN1 (18) C24 (27) replace
6
Turn starting switch OFF. Short circuit with chassis ground in
Is resistance between C24 (27) NO Repair or
Disconnect C24 and NSW. wiring harness between C24 (27)
and chassis ground normal? replace
Min. 1 MΩ NSW (B)
YES
7
displayed? NO
displayed?
YES
8
Turn starting switch ON. Short circuit with chassis ground in
Disconnect C24. wiring harness between TMCN1 (18)
20 30 V C24 (27)
YES
Repair or
Defective switch assembly
replace
9
Is resistance between C24 (24) NO Disconnection in wiring harness Repair or
and NSW (C) normal? between C24 (24) NSW (C)
Max. 1 Ω replace
YES
D575A-3 SD 20-541
From previous page From previous page Cause Remedy
10
displayed? NO
displayed?
YES
11
Is voltage between C24 (24) and NO Disconnection in wiring harness Repair or
Disconnect C24.
chassis ground normal? between TMCN1 (12) C24 (27) replace
20 30 V
YES
Repair or
replace
12
Min. 1 MΩ NSW (C)
YES
13
displayed? NO
Go to E0238 B
displayed?
YES
14
20 30 V C24 (24)
YES
Defective switch assembly Repair or
replace
15
Is resistance between NSW (A) NO Disconnection in wiring harness Repair or
and chassis ground normal? between NSW (A) GND004 replace
Max. 1 Ω
YES
Repair or
replace
ST-32 b) Related electrical circuit diagram
20-542 D575A-3 SD
TROUBLESHOOTING ST-33, ST34
ST-33 [E0782] Disagreement in travel lock

→ Check according to the procedure of E0781.
ST-34 [E0930] Abnormality in engine speed sensor B system is displayed

Cause Remedy
1
• 500 – 1,000 Ω
YES
2
• See TESTING AND NO
If speed sensor B is adjusted, is
• Start engine.
YES
Wrong adjustment of steering speed Adjust
sensor B
3
Is resistance between RRL NO Replace
• Disconnect E12. Defective engine speed sensor B
• 500 – 1,000 Ω
YES

4
Is resistance between NGICN2 NO Defective contact or disconnection in wiring
Repair or
• Disconnect NGICN2 and harness between NGICN[2 (female) (39) –
(female) (3) and RRL (female) (1) replace
RRL. RRL (female) (2)
normal?
• Max. 1 Ω
YES
circuit with chassis ground in wiring harness Repair or
between NGICN2 (female) (40) – RRL replace
(female) (1) – M41 (female) (1)
ST34 Related electrical circuit diagram
D575A-3 SD 20-543
ST-35 [E0933] Abnormality in bevel speed sensor A system is displayed

Cause Remedy
1
Disconnect NGICN2.
500 1,000 Ω
YES
2
See TESTING AND
If speed sensor is adjusted, is NO
ADJUSTING. Defective transmission controller Replace
Monitoring mode [Co]
YES
Wrong adjustment of bevel speed
Adjust
sensor A
3
Is resistance between TCI (male) NO
Disconnect TCI. Defective bevel speed sensor A Replace
(1) and (2) normal?
500 1,000 Ω
YES

4
Is resistance between NGICN2 Defective contact or disconnection in Repair or
Disconnect NGICN2 and NO
(female) (2) and TCI (female) (1) wiring harness between ngicn2 replace
ETCI.
normal? (female) (14) TCI (female) (2)
Max. 1 Ω
YES
wiring harness between NGICN2 replace
(female) (2) TCI (female) (1)
20-544 D575A-3 SD
TROUBLESHOOTING OF
TRANSMISSION CONTROLLER SYSTEM
(T MODE)
SERVICE CODE AND ABNORMAL SYSTEM ........................................................................................... 20-604

T-1 [E0112] Abnormality in transmission controller power source voltage is displayed .......................... 20-612
T-2 [E0142] Abnormality in transmission controller 5V power source is displayed ................................. 20-613
T-3 [E0146] Abnormality in transmission controller sensor power source is displayed........................... 20-614
T-4 [E0160] Abnormality in transmission controller E2ROM is displayed ............................................... 20-614
T-5 [E0178], [E0179] Disconnection in neutral safety relay system is displayed ................................... 20-615
T-6 [E0212] Short circuit in torque converter lock-up solenoid system is displayed ............................... 20-616
T-7 [E0213] Disconnection in torque converter lock-up solenoid system is displayed............................ 20-617
T-8 [E0221] Abnormality in pitch angle sensor system is displayed ....................................................... 20-618
T-9 [E0222] Disconnection in bevel speed sensor system is displayed.................................................. 20-619
T-10 [E0225] Slip of power train clutch ..................................................................................................... 20-620
T-11 [E0230], [E0231], [E0232] Abnormality in travel lever directional system is displayed..................... 20-620
T-12 [E0233] Abnormality in joystick (directional shift lever) potentiometer 1 system is displayed........... 20-621
T-13 [E0234] Abnormality in joystick (directiopnal shift lever) potentiometer 2 system is displayed......... 20-622
T-14 [E0235} Lag of forward-reverse signal.............................................................................................. 20-623
T-15 [E0236] Abnormality in shift-up switch system is displayed.............................................................. 20-623
T-16 [E0237] Abnormality in shift-down switch system ............................................................................. 20-625
T-17 [E0238] Abnormality in travel lock switch system ............................................................................. 20-627
a) When only E0238 is displayed ..................................................................................................... 20-627
b) When both E0238 and E0781 are displayed ................................................................................ 20-629
T-18 [E0239] Disagreement in travel lock ................................................................................................. 20-631
T-19 [E0250] Disconnection in forward clutch ECMV system ................................................................... 20-631
T-20 [E0251] Short circuit in forward clutch ECMV system ...................................................................... 20-632
T-21 [E0252] Disconnection in reverse clutch ECMV system ................................................................... 20-633
T-22 [E0253] Short circuit in reverse clutch ECMV system ...................................................................... 20-634
T-23 [E0254] Disconnection in 1st clutch ECMV system .......................................................................... 20-635
T-24 [E0255] Short circuit in 1st clutch ECMV system.............................................................................. 20-636
T-25 [E0256] Disconnection in 2nd clutch ECMV system ......................................................................... 20-637
T-26 [E0257] Short circuit in 2nd clutch ECMV system ............................................................................ 20-638
T-27 [E0258] Disconnection in 3rd clutch ECMV system.......................................................................... 20-639
T-28 [E0259] Short circuit in 3rd clutch ECMV system ............................................................................. 20-640
T-29 [E0260] Abnormality in forward clutch oil pressure system .............................................................. 20-641
T-30 [E0261] Short circuit in forward clutch oil pressure system .............................................................. 20-642
T31 [E0262] Abnormality in reverse clutch oil pressure system .............................................................. 20-642
T-32 [E0263] Short circuit in reverse clutch oil pressure system .............................................................. 20-642
T-33 [E0264] Abnormality in 1st clutch oil pressure system ..................................................................... 20-643
T-34 [E0265] Short circuit in 1st clutch oil pressure system ..................................................................... 20-643
T-35 [E0266] Abnormality in 2nd clutch oil pressure system .................................................................... 20-644
T-36 [E0267] Short circuit in 2nd clutch oil pressure system .................................................................... 20-644
T-37 [E0268] Abnormality in 3rd clutch oil pressure system ..................................................................... 20-645
T-38 [E0269] Short circuit in 3rd clutch oil pressure system ..................................................................... 20-645
T-39 [E0270] Double failure in transmission clutch (clutch is not engaged) ............................................. 20-646
T-40 [E0271] Double failure in transmission clutch (clutch is not disengaged) ......................................... 20-646
T-41 [E0273] Abnormality in neutral signal system is displayed ............................................................... 20-646
T-42 [E0301] Abnormality in left blade tilt angle sensor system is displayed............................................ 20-647
T-43 [E0302] Abnormality in left blade tilt angle sensor system is displayed............................................ 20-648
T-44 [E0303] Abnormarity in right blade tilt angle sensor system is displayed ......................................... 20-649
T-45 [E0304] Abnormality in right blade tilt angle sensor system is displayed ......................................... 20-650
T-46 [E0305] Short circuit in blade RAISE oil pressure switch system is displayed ................................. 20-651
T-47 [E0311] Abnormality in pitch-dump switch system............................................................................ 20-652
D575A-3 SD 20-601
T-48 [E0312] Abnormality in pitch-back switch system ............................................................................. 20-654
T-49 [E0313] Disconnection in pitch back solenoid system is displayed .................................................. 20-656
T-50 [E0314] Short circuit in pitch back solenoid system is displayed ...................................................... 20-657
T-51 [E0315] Disconnection in pitch dump solenoid system is displayed ................................................. 20-658
T-52 [E0316] Short circuit in pitch dump solenoid system is displayed..................................................... 20-659
T-53 [E0317] Disconnection in lift tilt limit solenoid system is displayed ................................................... 20-660
T-54 [E0318] Short circuit in left tilt limit solenoid system is displayed ..................................................... 20-661
T-55 [E0319] Disconnection in right tilt limit solenoid system is displayed................................................ 20-662
T-56 [E0320] Short circuit in right tilt limit solenoid system is displayed ................................................... 20-663
T-57 [E0341] Disconnection in blade lift 1 pump cut solenoid system is displayed .................................. 20-664
T-58 [E0342] Short circuit in blade lift 1 pump cut solenoid system is displayed ...................................... 20-665
T-59 [E0343] Disconnection in pitch dump assist relay system is displayed ............................................ 20-666
T-60 [E0344] Short circuit in pitch dump assist relay system is displayed ................................................ 20-666
T-61 [E0345] Disconnection in pitch solenoid system is displayed ........................................................... 20-667
T-62 [E0346] Short circuit in pitch solenoid system is displayed............................................................... 20-668
T-63 [E0347] Disconnection in pitch priority solenoid system is displayed ............................................... 20-669
T-64 [E0348] Short circuit in pitch priority solenoid system is displayed................................................... 20-670
T-65 [E0364] Disconnection in work equipment oil pressure sensor 1 (200 pump) system is displayed.. 20-671
T-66 [E0365] Short circuit in work equipment oil pressure sensor 1 (200 pump) system is displayed ..... 20-672
T-67 [E0366] Disconnection in work equipment oil pressure sensor 2 (200 pump) system is displayed.. 20-673
T-68 [E0367] Short circuit in work equipment oil pressure sensor 2 (200 pump) system is displayed ..... 20-674
T-69 [E0372] Short circuit in blade RAISE (full) oil pressure switch system is displayed ......................... 20-675
T-70 [E0486] Abnormality in specification selection is displayed .............................................................. 20-676
T-71 [E0610], [E0611] Disconnection in backup alarm relay system is displayed..................................... 20-677
T-72 [E0931] Abnormality in engine speed sensor B system is displayed................................................ 20-678
T-73 [E0932] Abnormality in bevel speed sensor A system is displayed .................................................. 20-679
20-602 D575A-3 SD
SERVICE CODE AND ABNORMAL SYSTEM
Service
E0112 Abnormality in transmission controller power source <17V

voltage
E0142 Abnormality in transmission controller 5-V power <4.5V or >5.5V

source
E0146 Abnormality in transmission controller sensor power <17V or 30V

source
E0160 Abnormality in transmission controller E2PROM Abnormality in reading Nv Ram
E0178 Disconnection in neutral safety relay system Sig_Out_Check (Disagreement in output, F/B voltage)
E0179 Short circuit in neutral safety relay system Sig_Out_Check (Detection of short circuit)
E0212-a. Output current > 0 mA, Current signal [1A =

Short circuit in torque converter lock-up solenoid sys-
E0212 1V] + 0.05 < Output voltage
tem
(Fill_Sw_Check)
E0213 Short circuit in torque converter lock-up solenoid sys- Detection of OS short circuit (A_Out_Check)
tem
E0221 Abnormality in pitch angle sensor system >4.85V (A_In Check), <0.15V (A_In Check)
E0222 Short circuit in torque converter speed sensor system
E0223 —
E0224 —
E0225 Slip in P/L clutch In L/U, |Engine speed - Torque converter speed| > 200
rpm
E0230 Abnormality in travel lever directional system (E3_233a or E3_233b) & (E3_234a or E3_234b)
E0231 Abnormality in travel lever directional system (E3_235) & (When key is on, both are normal)
E0232 Abnormality in travel lever directional system When key is on, 1 potentiometer is normal, and it has
abnormality.
E0233 Abnormality in joystic potentiometer 1 system >4.5V (A_In_Chek), <0.5V (A_In_Chek)
E0234 Abnormality in joystic potentiometer 2 system >4.5V (A_In_Chek), <0.5V (A_In_Chek)
E0235 Lag of forward-reverse signal Potentiometer 1 + 2 < 4.41 V or > 5.59 V
E0236 Abnormality in shift-up switch system Both NO and NC are NO or NC (No_nc_Check)
E0237 Abnormality in shift-down switch system Both NO and NC are NO or NC (No_nc_Check)
E0238 Abnormality in travel lock switch system Both NO and NC are NO or NC (No_nc_Check)
E0239 Disagreement in travel lock Transmission controller travel lock (Snet) and steering
controller travel lock are different.
E0250 Disconnection in forward clutch ECMV system < Output voltage
(A_Cut_Check)
E0251 Short circuit in forward clutch ECMV system Detection of OS short circuit (A_Cut_Check)
20-604 D575A-3 SD

abnormality
In some cases, system cannot drive solenoid and relay and
cannot work normally
In some case, transmission gear shift shock and time lag
become bad.
Lights up caution lamp and sounds alarm buzzer. Engine can be started even if travel lever is not in N.
Stops outputting to lock-up solenoid Torque converter cannot be locked up.
Stops outputting to lock-up solenoid Torque converter cannot be locked up.
Gear does not shift down automatically. In some cases,

transmission gear shift shock becomes bad.
Lights up caution lamp and sounds alarm buzzer Gear does not shift down automatically.
Lights up caution lamp and sounds alarm buzzer. If machine is traveling, current condition is maintained.
Sets transmission in N. Machine cannot move once it stops.
Continues control with forward/reverse potentiometer 2. available.
Continues control with forward/reverse potentiometer 1. available.
Lights up caution lamp and sounds alarm buzzer. Gear cannot be shifted up. Gear cannot be shifted down
Sets transmission in N automatically.
Lights up caution lamp and sounds alarm buzzer. Gear cannot be shifted up. Gear cannot be shifted down
Sets transmission in N automatically.
Sets transmission in N Engine output is reduced to half. Only 1st gear speed is
Sets transmission in N available. Gear cannot be shifted down automatically.
Lights up caution lamp and sounds alarm buzzer. Stops Machine can travel at only R1. Engine output is reduced to
outputting to forward clutch ECMV. half.
Lights up caution lamp and sounds alarm buzzer. Stops Machine can travel at only R1. Engine output is reduced to
outputting to forward clutch ECMV. half.
D575A-3 SD 20-605
Service
Abnormal system Criterion
code
E0252 Disconnection in reverse clutch ECMV system < Output voltage
(A_Cut_Check)
E0253 Short circuit in reverse clutch ECMV system Detection of OS short circuit (A_Cut_Check)

E0254 Disconnection in 1st clutch ECMV system < Output voltage
(A_Cut_Check)
E0255 Short circuit in 1st clutch ECMV system Detection of OS short circuit (A_Cut_Check)

E0256 Disconnection in 2nd clutch ECMV system < Output voltage
(A_Cut_Check)
E0257 Short circuit in 2nd clutch ECMV system Detection of OS short circuit (A_Cut_Check)

E0258 Disconnection in 3rd clutch ECMV system < Output voltage
(A_Cut_Check)
E0259 Short circuit in 3rd clutch ECMV system Detection of OS short circuit (A_Cut_Check)
Abnormality in forward clutch oil pressure system Engine speed > 600 rpm, Output > 0.5 A, Fill Sw OFF
E0260
(Clutch is not engaged) (Fill_Sw_Check)
Abnormality in forward clutch oil pressure system Engine speed > 600 rpm, Output = A, Fill switch ON
E0261
Abnormality in reverse clutch oil pressure system Engine speed > 600 rpm, Output > 0.5 A, Fill Sw OFF
E0262
Abnormality in reverse clutch oil pressure system Engine speed > 600 rpm, Output = A, Fill switch ON
E0263
Abnormality in 1st clutch oil pressure system Engine speed > 600 rpm, Output > 0.5 A, Fill Sw OFF
E0264
Abnormality in 1st clutch oil pressure system Engine speed > 600 rpm, Output = A, Fill switch ON
E0265
Abnormality in 2nd clutch oil pressure system Engine speed > 600 rpm, Output > 0.5 A, Fill Sw OFF
E0266
Abnormality in 2nd clutch oil pressure system Engine speed > 600 rpm, Output = 0 A, Fill Switch ON
E0267
Abnormality in 3rd clutch oil pressure system Engine speed > 600 rpm, Output > 0.5 A, Fill Sw OFF
E0268
Abnormality in 3rd clutch oil pressure system Engine speed > 600 rpm, Output = 0 A, Fill Switch ON
E0269
Double failure in transmission clutch
E0270 (E_255 or E6_254) & (E6_257 or E6_257 or E6_256)
(E_251 or E5_250) & (E5_253  E5_252), (E6_259 or
E6_258) & (E8_270), (E8_260) & (E8_262), (E8_261)
Double failure in transmission clutch
E0271 & (E8_263), (E9_264) & (E_266) & (E9_268),
(Clutch is not disengaged)
(E9_265) & (E9_267), (E9_265) & (E9_269), (E9_267)
& (E9_269)
E0301 Disconnection in left yoke angle sensor system >4.5V (A In Check)
E0302 Short circuit in left yoke angle sensor system <0.5V (A In Check)
20-606 D575A-3 SD

abnormality
Lights up caution lamp and sounds alarm buzzer. Stops Machine can travel at only F1. Engine output is reduced to
outputting to reverse clutch ECMV. half.
Lights up caution lamp and sounds alarm buzzer. Stops Machine can travel at only F1. Engine output is reduced to
outputting to reverse clutch ECMV. half.
Lights up caution lamp and sounds alarm buzzer. Stops Machine can travel at only 2nd gear. Engine output is
outputting to 1st clutch ECMV. reduced to half.
Lights up caution lamp and sounds alarm buzzer. Stops Machine can travel at only 2nd gear. Engine output is
outputting to 1st clutch ECMV. reduced to half.
Lights up caution lamp and sounds alarm buzzer. Stops Engine output is reduced to half. Only 1st gear speed is
outputting to 2nd clutch ECMV. available.
outputting to 2nd clutch ECMV. available.
outputting to 3rd clutch ECMV. available.
outputting to 3rd clutch ECMV. available.
Lights up caution lamp and sounds alarm buzzer. Judges Machine can travel at only R1 gear. Engine output is
forward travel operation as N. reduced to half.
Lights up caution lamp and sounds alarm buzzer. Judges Machine cannot travel in reverse. Engine output is reduced
reverse travel operation as N.reverse. to half. Only 1st gear speed is available.
Lights up caution lamp and sounds alarm buzzer. Judges Machine can travel at only F1. Engine output is reduced to
reverse travel operation as N.reverse. half.
Lights up caution lamp and sounds alarm buzzer. Judges Machine cannot travel forward. Engine output is reduced to
forward travel operation as N. half. Only 1st gear speed is available.
Lights up caution lamp and sounds alarm buzzer. Allows Machine can travel at only 2nd gear. Engine output is
use of only 2nd gear. reduced to half.
Lights up caution lamp and sounds alarm buzzer. Allows Engine output is reduced to half. Only 1st gear speed is
use of only 1st gear. available.
Lights up caution lamp and sounds alarm buzzer. Allows Engine output is reduced to half. Only 2nd gear speed is
use of only 2nd gear.s available.
Lights up caution lamp and sounds alarm buzzer. Allows Engine output is reduced to half. Only 3rd gear speed is
use of only 3rd gear. available.
Lights up caution lamp and sounds alarm buzzer. Allows Engine output is reduced to half. Only 3rd gear speed is
use of only 3rd gear. available.
Lights up caution lamp and sounds alarm buzzer. Sets

transmission in N. Machine cannot move.
Lights up caution lamp and sounds alarm buzzer. Tilt limit function does not work.
D575A-3 SD 20-607
Service
code
E0303 Disconnection in right yoke angle sensor system >4.5V (A_In_Check)
E0304 Short circuit in right yoke angle sensor system <0.5V (A_In_Check)
E0305 Short circuit in PPC lift RAISE oil pressure switch sys- Turned on for 180 sec continuously
tem
E0311 Abnormality in knob switch DOWN (Pitch dump knob) Both NO and NC are NO or NC (No_nc_Check)
system
E0312 Abnormality in knob switch UP (Pitch back knob) sys- Both NO and NC are NO or NC (No_nc_Check)
tem
E0313 Disconnection in pitch back solenoid system < Output voltage
(A_Cut_Check)
E0314 Short circuit in pitch back solenoid system Detection of OS short circuit (A_Cut_Check)

E0315 Disconnection in pitch dump solenoid system < Output voltage
(A_Cut_Check)
E0316 Short circuit in pitch dump solenoid system Detection of OS short circuit (A_Cut_Check)

E0317 Disconnection in left tilt limit solenoid system < Output voltage
(A_Cut_Check)
E0318 Short circuit in left tilt limit solenoid system Detection of OS short circuit (A_Cut_Check)

E0319 Disconnection in right tilt limit solenoid system < Output voltage
(A_Cut_Check)
E0320 Short circuit in right tilt limit solenoid system Detection of OS short circuit (A_Cut_Check)
E0341 Disconnection in lift 1 pump solenoid system
E0342 Short circuit in lift 1 pump solenoid system
E0343 Disconnection in pitch dump assist relay system ????
E0344 Short circuit in pitch dump assist relay system Detection of OS short circuit (A_Cut_Check)

E0345 Disconnection in pitch solenoid system < Output voltage
(A_Cut_Check)
E0346 Short circuit in pitch solenoid system Detection of OS short circuit (A_Cut_Check)

E0347 Disconnection in pitch priority solenoid < Output voltage
(A_Cut_Check)
E0348 Short circuit in pitch priority solenoid Detection of OS short circuit (A_Cut_Check)
E0364 Disconnection in work equipment oil pressure sensor >6.0V (A_In_Check)

1 (Pump 200) system
E0365 Short circuit in work equipment oil pressure sensor 1 <0.5V (A_In_Check)
(Pump 200) system
E0366 Disconnection in work equipment oil pressure sensor >6.0V (A_In_Check)

2 (Pump 200) system
20-608 D575A-3 SD

abnormality
Stops blade lift 1 pump cut function Blade lift 1 pump cut function (Optional) does not work.
Stops pitch dump function Pitch dump is impossible.
Stops pitch back function Pitch back is impossible
Lights up caution lamp and sounds alarm buzzer. Stops Pitch back is impossible
outputting to pitch back solenoid.
Lights up caution lamp and sounds alarm buzzer. Stops Pitch back is impossible
outputting to pitch back solenoid.
Lights up caution lamp and sounds alarm buzzer. Stops Pitch dump is impossible.
outputting to pitch dump solenoid.

Pitch dump is impossible.
outputting to pitch dump solenoid

outputting to left tilt limit solenoid. Left tilt limit function does not work.

outputting to left tilt limit solenoid. Left tilt limit function does not work.

outputting to right tilt limit solenoid. Right tilt limit function does not work.

outputting to right tilt limit solenoid. Right tilt limit function does not work.
Stops outputting to lift 1 pump cut solenoid Blade lift 1 pump cut function (Optional) does not work.
Stops outputting to lift 1 pump cut solenoid Blade lift 1 pump cut function (Optional) does not work.
Stops outputting to pitch dump assist relay Pitch dump speed is low.
Stops outputting to pitch dump assist relay Pitch dump speed is low.
Lights up caution lamp and sounds alarm buzzer. Stops Pitching is impossible.
outputting to pitch selection solenoid.
Lights up caution lamp and sounds alarm buzzer. Stops Pitching is impossible.
outputting to pitch selection solenoid.
Stops outputting to pitch priority solenoid. Pitch priority function does not work.
Stops outputting to pitch priority solenoid. Pitch priority function does not work.
Work equipment pump 1 oil pressure is not displayed
D575A-3 SD 20-609
Service
code
E0367 Short circuit in work equipment oil pressure sensor 2 <0.5V (A_In_Check)
(Pump 200) system
E0372 Short circuit in PPC lift RAISE FULL oil pressure Turned on for 180 sec continuously
switch system
E0486 Abnormality in transmission controller specification Check of wire logic

selection
E0610 Disconnection in backup alarm relay system Sig_Out_Check (Disagreement in output, F/B voltage)
E0611 Short circuit in backup alarm relay system Sig_Out _Check (Detection of short circuit)

E0931 Disconnection in engine speed sensor system specification level (2.2 V).
(P_In_Check)
E0932 Disconnection in transmission speed sensor system specification level (2.2 V).
(P_In_Check)
20-610 D575A-3 SD

abnormality
Auto pitch back function does not work.
Stops all outputs (Turns on brake) Engine cannot start. Machine cannot move.
Stops outputting to backup alarm relay Backup alarm does not sound.
Stops outputting to backup alarm relay Backup alarm does not sound.

become bad. Auto shift-down function does not work.
Pitch-down speed lowers.
become bad. Auto shift-down function does not work.
Pitch-down speed lowers. Lock-up function does not work.
D575A-3 SD 20-611
TROUBLESHOOTING T-1
T-1 [E0112] Abnormality in transmission controller power source

voltage is displayed
ground.)
Cause Remedy
1
• Turn starting switch ON. Is voltage between TMCN3 (1) (11) NO
• 20 – 30 V and (21) (31) (32) (33) normal?
YES
2
• Turn starting switch ON. Is voltage between TMCN3 (1) NO Defective contact or disconnection in Repair or
wiring harness between TMCN3
• 20 – 30 V (11) and chassis ground normal? (female) (1) (11) – circuit breaker 3 replace
YES Defective contact or disconnection in Repair or
(female) (21) (31) (32) (33) – chassis replace
ground
T-1 Related electrical circuit diagram
20-612 D575A-3 SD
TROUBLESHOOTING T-2
T-2 [E0142] Abnormality in transmission controller 5V power source is

displayed
Cause Remedy
1
Is voltage between TMCN1 (22) NO
• 4.5 – 5.5 V
and chassis ground normal?
• Disconnect TMCN1.
YES
2
• Turn starting switch ON. When C24 is disconnected, does NO
• Disconnect C24. caution lamp [E0142] go off?
YES
[E0233, 0234]
between C24 – TL1 or defective travel
lever potentiometer
3
Short circuit or short circuit with [E0233, 0234,
• Turn starting switch ON. When C22 is disconnected, does NO chassis ground in wiring harness 0301, 0302,
• Disconnect C22. caution lamp [E0142] go off? 0303, 0304]
between TMCN1 – C24 – C22
YES
4
When CSR is disconnected, does NO

caution lamp [E0142] go off?
YES
Wrong adjustment or trouble in right
[E0303, 0304]
blade yoke angle sensor
5
When CSL is disconnected, does NO [E0301, 0302,
caution lamp [E0142] go off? 0303, 0304]
between C22 – CSR – CSL
YES Wrong adjustment or trouble in left
[E0301, 0302]
blade yoke angle sensor
D575A-3 SD 20-613
TROUBLESHOOTING T-3, T-4
T-3 [E0146] Abnormality in transmission controller sensor power source

is displayed
→ Check according to the procedure of [E0364], [E0365], [E0366] and [E0367].
T-4 [E0160] Abnormality in transmission controller E2PROM is

displayed
Cause Remedy
20-614 D575A-3 SD
TROUBLESHOOTING T-5
T-5 [E0178] , [E0179] Disconnection in neutral safety relay system is

displayed
★ If the starting switch was turned off after the abnormality occurred, turn the starting switch on and operate
the parking lever to the LOCK and FREE position and check that the service code displays “E” at the head.
(If “P” is displayed, the condition has returned to normal.)
Cause Remedy
1
• Turn starting switch ON. Is voltage between TMCN2 (8) NO
• 20 – 30 V and chassis ground normal?
YES
2
Is resistance between NSF(male) NO
• Disconnect NSF. Defective neutral safety relay Replace
(1) and (2) normal?
• 200 – 400 Ω
YES
3
• Turn starting switch OFF. NO Defective contact or disconnection in
Is voltage between NSF (female) Repair or
• Disconnect NSF. wiring harness between NSF (female)
(1) and chassis ground normal? (1) – circuit breaker (CB3) replace
• 20 – 30 V
YES
short circuit with power source in Repair or
wiring harness between TMCN2 replace
(female) (8) – NSF (female) (2)
D575A-3 SD 20-615
TROUBLESHOOTING T-6
T-6 [E0212] Short circuit in torque converter lock-up solenoid system is

displayed
★ If the starting switch was turned off after the abnormality occurred, run the engine and drive so that the lock-
up solenoid will work, and check that the service code displays “E” at the head. (If “P” is displayed, the con-
dition has returned to normal.)
Cause Remedy
1
• Turn starting switch OFF. Is resistance between Short circuit with chassis ground in
NO Repair or
• Disconnect TMCN3. TMCN3(female) (38) and chassis wiring harness between TMCN3 (38) –
replace
• Min. 1MΩ ground normal? LU2 (1)
YES
2
• Turn starting switch OFF. Is resistance between
NO
TMCN3(female) (38) and (23)
• Solenoid resistance normal?
YES
3
Is resistance between LU2(male)
• Turn starting switch OFF. (1) and (2) and between (1) (2) NO Defective torque converter lock-up
Repair
• Disconnect LU2. and chassis ground as shown in solenoid
following table?
Repair or
wiring harness between TMCN3 (38) –
replace
LU2 (1) and TMCN3 (23) – LU2 (2)
Table
LU2 (male) Resistance
Between (1) – (2)
20-616 D575A-3 SD
TROUBLESHOOTING T-7
T-7 [E0213] Disconnection in torque converter lock-up solenoid system

is displayed
Cause Remedy
1
Turn starting switch OFF. Is resistance between TMCN3
NO
Disconnect TMCN3. (female) (38) and chassis ground
Ω normal?
YES
2
Turn starting switch ON. Is voltage between TMCN3
NO
Max. 1 V normal?
YES
3
Turn starting switch ON. Is voltage between TMCN3 Short circuit with power source in
NO Repair or
Disconnect TMCN3, LU2. (female) (38) and LU2 (female) wiring harness between TMCN3 (38)
replace
Max. 1 V (1) normal? LU2 (1)

Repair or
wiring harness between TMCN3 (23)
replace
LU2 (2)
4
Is resistance between LU2 (male) NO Defective torque converter lock-up
Disconnect LU2. Replace
(1) and (2) normal? solenoid
40 90 Ω
YES
5
Turn starting switch OFF. Is resistance between TMCN3 Defective contact or disconnection in
NO Repair or
Disconnect LU2, TMCN3. (female) (38) and LU2 (female)
LU2 (1) replace
Max. 1 Ω (1) normal?

wiring harness between TMCN3 Replace
(female) (23) LU2 (female) (2)
D575A-3 SD 20-617
TROUBLESHOOTING T-8
T-8 [E0221] Abnormality in pitch angle sensor system is displayed

Cause Remedy
1
NO
Turn starting switch ON. Is [E0721] displayed?
YES
Check according to procedure of

[E0721]
2
Turn starting switch ON. Is voltage between TMCN1 (1) NO
between C22 (H) TMCN1 (1)
YES
Defective transmission controller
20-618 D575A-3 SD
TROUBLESHOOTING T-9
T-9 [E0222] Disconnection in bevel speed sensor system is displayed

★ If the starting switch was turned off after the abnormality occurred, start the engine and check that the ser-
vice code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.)
Cause Remedy
1
Disconnect NGICN2.
(female) (30) (29) normal?
500 1,000 Ω
YES
2
Is resistance between TC1 NO
Disconnect TC1. Defective bevel speed sensor Replace
500 1,000 Ω
YES
3
Turn starting switch OFF. Is resistance between NGICN2 NO Defective contact or disconnection in
Repair or
Disconnect NGICN2 and TC1. (female) (30) and TC1 (female) (1) wiring harness between NGICN2
replace
Max. 1 Ω normal? (female) (29) TC1 (female) (1)
YES
circuit with chassis ground in wiring Repair or
harness between NGICN2 (female) (30) replace
TC1 (female) (2)
D575A-3 SD 20-619
T-10 [E0225] Slip of power train clutch

★ This error detects slip of the clutch in lock-up mode.
★ If the engine speed (1) and bevel gear speed (2) are normal, the hydraulic pressure or lock-up system of the
transmission is abnormal.
Cause Remedy
1
Monitoring mode
Engine speed 3E Is engine speed displayed NO
Go to [E0931]
Slow: 650 rpm, normally?
Full: 2,000 rpm
YES
2
Monitoring mode
Is transmission speed displayed NO
Transmission output speed Go to [E0932]
normally?
7P
YES
Go to check of hydraulic pressure
T-11 [E0230], [E0231], [E0232] Abnormality in travel lever directional

system is displayed
→ Checking according to process [E0233] and [E0234]
20-620 D575A-3 SD
TROUBLESHOOTING T-12
T-12 [E0233] Abnormality in joystick (directional shift lever)

potentiometer 1 system is displayed
Cause Remedy
• Turn starting switch ON. 1

• Joystick Is voltage between TMCN3 (2) NO
Newtral : 2.5 ± 0.05 V
Forward : 1.73 ± 0.11 V and (21) normal?
Reverse : 3.27 ± 0.11 V YES
2
• 4.75 – 5.25 V and (21) normal?
YES
3
• Turn starting switch OFF. Is resistance between TMCN3 Short circuit with chassis ground in
NO Repair or
• Disconnect TL1 and TMCN3. (female) (2) and chassis ground wiring harness between TMCN3
replace
• Min. 1 MΩ normal? (female) (2) – TL1 (female) (K)
YES

• Joystick Is voltage between TL1 (K) and NO Defective joystick (directionnal gear
Newtral : 2.5 ± 0.05 V Replace
(J) normal? shift lever) potentio 1
Forward : 1.73 ± 0.11 V
Reverse : 3.27 ± 0.11 V
Repair or
replace
(female) (2) – TL1 (female) (K)
5
NO Repair or
normal? replace
• Min. 1 MΩ (female) (22) – TL1 (female) (L)
YES
6
Is resistance between TL1 (male) NO Defective joystick (directionnal gear
• Disconnect TL1. Replace
(L) and (J) normal? shift lever) potentio 1
• 4.6 – 6.0 kΩ
wiring harness between TMCN3 Repair or
(female) (22) – TL1 (female) (L) replace
D575A-3 SD 20-621
T-13 [E0234] Abnormality in joystick (directiopnal shift lever)

potentiometer 2 system is displayed
Cause Remedy

• Joystick
Newtral : 2.5 ± 0.05 V Is voltage between TMCN3 (19) NO
Forward : 3.27 ± 0.11 V and (21) normal?
Reverse : 1.73 ± 0.11 V
YES
2
• 4.75 – 5.25 V and (21) normal?
YES
3
NO Repair or
replace
• Min. 1 MΩ normal? (female) (19) – TL1 (female) (P)
YES

• Joystick
Is voltage between TL1 (P) and NO Defective joystick (directionnal gear
Newtral : 2.5 ± 0.05 V Replace
Forward : 3.27 ± 0.11 V (Q) normal? shift lever) potentio 2
Reverse : 1.73 ± 0.11 V
Repair or
replace
(female) (19) – TL1 (female) (P)
5
NO Repair or
normal? replace
• Min. 1 MΩ (female) (22) – TL1 (female) (O)
YES
6
• Disconnect TL1. Is resistance between TL1 (male) NO Defective joystick (directionnal gear
Replace
(O) and (Q) normal? shift lever) potentio 2
• 4.6 – 6.0 kΩ
(female) (22) – TL1 (female) (O) replace
20-622 D575A-3 SD
T-14 [E0235] Lag of forward-reverse signal

→ Checking according to process [E0233] and [E0234]
T-15 [E0236] Abnormality in shift-up switch system is displayed

off the shift-up switch, and check that the service code displays "E" at the head. (If "P" is displayed, the
Cause Remedy
1
Check operation of shift-up switch
on monitor panel in monitoring
mode [L5].
2
When shift-up switch is turned
OFF, is _ _ x x x x displayed? NO
ON, is _ o x x x x displayed?
YES 3
• Turn starting switch OFF. Is resistance between TMCN1
(female) (6) and TL1 (female) (U)
• Disconnect TMCN1 and TL1.
• Max. 1 Ω normal? between TMCN1 (6) – TL1 (U) replace
YES 4
• Turn starting switch OFF. Is resistance between TL1
(female) (N) and chassis ground NO Disconnection in wiring harness Repair or
• Disconnect TL1.
between TL1 (N) – GND004 replace
• Max. 1 Ω normal?
YES Repair or
replace
5
OFF, is o _ x x x x displayed? NO
ON, is o o x x x x displayed?
YES 6
(female) (6) and chassis ground NO Repair or
• Disconnect TMCN1 and TL1. wiring harness between TMCN1 (6) –
normal? replace
• Min. 1 MΩ TL1 (U)
YES Repair or
replace
7
ON, is _ _ x x x x displayed?
YES 8
• Disconnect TMCN2 and TL1. (female) (37) and TL1 (female)
between TMCN2 (37) – TL1 (B) replace
• Max. 1 Ω (B) normal?
YES 9
Is voltage between TL1 (female) NO Disconnection in wiring harness Repair or
• Disconnect TL1.
(N) and chassis ground normal? between TL1 (N) – GND004 replace
• Max. 1 Ω
YES
Defective switch assembly Repair or
replace
Go to next page
D575A-3 SD 20-623
From previous page Cause Remedy
10
OFF, is o o x x x x displayed?
NO
When shift-up switch is turned (A)
YES
11
Is resistance between TMCN2 NO Repair or
Disconnect TMCN2 and TL1. wiring harness between TMCN2 (37)
Min. 1 MΩ TL1 (B)
YES
Repair or
replace
20-624 D575A-3 SD
T-16 [E0237] Abnormality in shift-down switch system

off the shift-down switch, and check that the service code displays "E" at the head. (If "P" is displayed, the
Cause Remedy
1
Check operation of shift-down
2
When shift-down switch is turned
OFF, is x x _ _ x x displayed? NO
ON, is x x _ o x x displayed?
YES
3
NO Disconnection in wiring harness
Disconnect TMCN3 and TL1. (female) (19) and TL1 (V)
between TMCN3 (19) TL1 (V)
Max. 1 Ω normal?
YES
4
Turn starting switch OFF. Is resistance between TL1
Disconnect TL1. (female) (D) and chassis ground
between TL1 (D) GND004 replace
Max. 1 Ω normal?
YES
Repair or
replace
5
OFF, is x x o _ x x displayed? NO
ON, is x x o o x x displayed?
YES
6
Turn starting switch OFF. Is resistance between TMCN3 Short circuit with chassis ground in
NO Repair or
Disconnect TMCN3 and TL1. (female) (19) and chassis ground wiring harness between TMCN3 (19)
replace
Min. 1 MΩ normal? TL1 (V)
YES
Repair or
replace
7
ON, is x x _ _ x x displayed?
YES
8
NO
Disconnect TMCN3 and TL1. (female) (29) and TL1 (C)
Max. 1 Ω normal? YES
Disconnection in wiring harness

between TMCN3 (29) TL1 (C)
9
Is voltage between TL1 (female) NO Disconnection in wiring harness Repair or
Disconnect TL1.
(D) and chassis ground normal? between TL1 (D) GND004 replace
Max. 1 Ω YES
Repair or
replace
Go to next page
D575A-3 SD 20-625
10
OFF, is x x o o x x displayed? NO
YES
11
NO Repair or
Disconnect TMCN3 and TL1. (female) (29) and chassis ground wiring harness between TMCN3 (29)
replace
Min. 1 MΩ normal? TL1 (C)
YES
Repair or
replace
12
Is voltage at TL1 (female) (C) NO
Disconnect TL1.
normal?
20 30 V
YES
13
Is voltage at TL1 (female) (V) NO
Disconnect TL1.
normal?
20 30 V
YES
14
Turn starting switch ON. Is resistance between TL1
Disconnect TL1. (female) and chassis ground
between TL1 (D) GD004 replace
Max. 1 Ω normal?
YES
Repair or
replace
15
Is voltage at TMCN3 (male) (19) NO
Disconnect TMCN3. Defective transmission controller Replace
normal?
20 30 V

Repair or
replace
between TMCN3 (19) TL1 (V)
16
normal?
20 30 V

Repair or
replace
between TMCN3 (29) TL1 (C)
20-626 D575A-3 SD
T-17 [E0238] Abnormality in travel lock switch system

off the parking brake lever, and check that the service code displays "E" at the head. (If "P" is displayed, the
a) When only E0238 is displayed
Cause Remedy
1
Are both [E0238] and [E0781] NO
Go to [E0238], [E0781]
displayed?
YES
2
B
3
displayed? NO
displayed?
YES
4
Disconnect TMCN1 and (female) (18) and C24 (27)
between TMCN1 (18) C24 (27) replace
C24. normal?
YES
A
5
displayed? NO
displayed?
YES
6
NO Repair or
Disconnect TMCN1 and C24. (female) (18) and chassis ground wiring harness between TMCN1 (18)
replace
YES
A
7
displayed? NO
displayed?
YES
8
NO
Disconnect TMCN1 and (female) (12) and C24 (24) Disconnection in wiring harness Repair or
C24. normal? between TMCN1 (12) C24 (24) replace
YES
A
9
displayed? NO
displayed?
YES
D575A-3 SD 20-627
10
NO Repair or
Disconnect TMCN1 and (female) (12) and chassis ground wiring harness between TMCN1 (12)
replace
C24. normal? C24 (24)
YES
A
A
11
Is voltage at NSW (female) (B) NO
Disconnect TL1 and
normal?
NGICN2.
YES
12
Disconnect NSW and Is voltage at NSW (female) (C) NO
NGICN2. normal?
20 30 V
YES
13
Turn starting switch ON. Is resistance between NSW
Disconnect NSW and NO Repair or
(female) (A) and chassis ground Defective switch assembly
NGICN2. replace
normal?
Max. 1 Ω
YES
between NSW (A) GND004 replace
14
normal?
20 30 V

Repair or
replace
between TMCN1 (12) NSW (C)
15
Disconnect TMCN1 Defective transmission controller Replace
normal?
20 30 V

Repair or
replace
between TMCN1 (18) NSW (B)
T-17 a) Related electrical circuit diagram
20-628 D575A-3 SD
b) When both E0238 and E0781 are displayed
Cause Remedy
1
2
displayed? NO
displayed?
YES
3
• Turn starting switch OFF. Disconnection in wiring harness
• Disconnect C24 and NSW. between C24 (27) – NSW (B)
and NSW (B) normal? replace
• Max. 1 Ω
YES
4
• Turn starting switch ON. Is voltage between C24 (27) and NO Disconnection in wiring harness Repair or
• Disconnect C24. chassis ground normal? between TMCN1 (18) – C24 (27) replace
• 20 – 30 V
YES
Repair or
replace
5
displayed? NO
displayed?
YES
6
• Turn starting switch OFF. Short circuit with chassis ground in
Is resistance between C24 (27) NO wiring harness between C24 (27) –
Repair or
• Disconnect C24 and NSW.
• Min. 1 MΩ NSW (B)
YES
7
• Turn starting switch ON. Short circuit with chassis ground in
Is voltage between C24 (27) and NO wiring harness between TMCN1 (18) – Repair or
• Disconnect C24.
chassis ground normal? C24 (27) replace
• 20 – 30 V
YES
Repair or
replace
8
displayed? NO
displayed?
YES 9
• Turn starting switch OFF. Is resistance between C24 (24) NO Disconnection in wiring harness Repair or
• Disconnect C24 and NSW. and NSW (C) normal? between C24 (24) – NSW (C) replace
• Max. 1 Ω
YES
D575A-3 SD 20-629
10
Is voltage between C24 (24) and NO Disconnection in wiring harness Repair or
Disconnect C24.
chassis ground normal? between TMCN1 (12) C24 (27) replace
20 30 V
YES
Repair or
replace
11
displayed? NO
displayed?
YES
12
Min. 1 MΩ NSW (C)
YES
13
20 30 V C24 (24)
YES
Repair or
replace
14
displayed? NO
Go to [E0238] B
displayed?
YES
15
Is resistance between NSW (A) NO Disconnection in wiring harness Repair or
and chassis ground normal? between NSW (A) GND004 replace
Max. 1 Ω
YES
Repair or
replace
T-17 b) Related electrical circuit diagram
20-630 D575A-3 SD
T-18 [E0239] Disagreement in travel lock

→ Checking according to process [E0238]
T-19 [E0250] Disconnection in forward clutch ECMV system

★ If the starting switch was turned off after the abnormality occurred, set the joystick in the forward travel posi-
tion and turn the starting switch on and check that the service code displays "E" at the head. (If "P" is dis-
Cause Remedy
1
Is resistance between TMCN3 NO
Disconnect TMCN3.
5 25 Ω
YES
2
NO
Max. 1 V normal?
YES
Repair or
replace
3
Turn starting switch OFF. Is voltage between TMCN3 Short circuit with power source in
NO Repair or
Disconnect TMCN3 and SFT. (female) (35) and chassis ground wiring harness between TMCN3 (35)
replace
Max. 1 V normal? SFT (1)

Repair or
replace
SFT (2)
4
Is resistance between SFT (male) NO
Disconnect SFT.
(1) and (2) normal?
5 25 Ω
YES
Defective forward clutch ECMV Replace
5
Turn starting switch OFF. Is resistance between TMCN3 Disconnection or defective contact in
NO Repair or
Disconnect TMCN3 and SFT. (female) (35) and SFT (female) wiring harness between TMCN3 (13)
replace
Max. 1 Ω (1) normal? SFT (2)

Repair or
replace
SFT (1)
D575A-3 SD 20-631
T-20 [E0251] Short circuit in forward clutch ECMV system

★ If the starting switch was turned off after the abnormality occurred, set the joystick in the forward travel posi-
Cause Remedy
1
NO Repair or
• Disconnect TMCN3. (female) (35) and chassis ground harness between TMCN3 (35) – SFT replace
• Min. 1 M Ω normal? (1)
YES
2
• 5 – 25 Ω
YES
3
Is resistance between SFT (male) (1)
and (2) and between (1), (2) and Defective forward clutch ECMV Replace
• Disconnect SFT.
chassis ground as shown in Table 1?
YES Short circuit in wiring harness between
Repair or
TMCN3 (35) – SFT (1) and between
replace
Table 1 TMCN3 (13) – SFT (2)
SFT (male) Resistance
Between (1) – (2) 5 – 25 Ω
Between (1), (2) – chassis Min. 1 M Ω
20-632 D575A-3 SD
T-21 [E0252] Disconnection in reverse clutch ECMV system

★ If the starting switch was turned off after the abnormality occurred, set the joystick in the reverse travel posi-
Cause Remedy
1
Disconnect TMCN3.
5 25 Ω
YES
2
NO
Max. 1 V normal?
YES
Repair or
replace
3
NO Repair or
Disconnect TMCN3 and SRT. (female) (25) and chassis ground wiring harness between TMCN3 (25)
replace
Max. 1 V normal? SRT (1)

Repair or
replace
SRT (2)
4
Is resistance between SRT (male) NO
Disconnect SRT.
(1) and (2) normal?
5 25 Ω
YES
Defective reverse clutch ECMV Replace
5
NO Repair or
Disconnect TMCN3 and SRT. (female) (25) and SRT (female) wiring harness between TMCN3 (3)
replace
Max. 1 Ω (1) normal? SRT (2)

Repair or
replace
SRT (1)
D575A-3 SD 20-633
T-22 [E0253] Short circuit in reverse clutch ECMV system

★ If the starting switch was turned off after the abnormality occurred, set the joystick in the reverse travel posi-
Cause Remedy
1
NO Repair or
• Disconnect TMCN3. (female) (25) and chassis ground harness between TMCN3 (25) – SRT replace
YES
2
• 5 – 25 Ω
YES
3
Is resistance between SRT (male)
(1) and (2) and between (1), (2) and Defective reverse clutch ECMV Replace
• Disconnect SRT.
TMCN3 (25) – SRT (1) and between replace
Table 1 TMCN3 (3) – SRT (2)
SRT (male) Resistance
Between (1) – (2) 5 – 25 Ω
20-634 D575A-3 SD
T-23 [E0254] Disconnection in 1st clutch ECMV system

★ If the starting switch was turned off after the abnormality occurred, set the joystick in the 1st gear speed
position and turn the starting switch on and check that the service code displays "E" at the head. (If "P" is
displayed, the condition has returned to normal.)
Cause Remedy
1
Disconnect TMCN3.
5 25 Ω
YES
2
NO
Max. 1 V normal?
YES
Repair or
replace
3
NO Repair or
Disconnect TMCN3 and S1T. (female) (15) and chassis ground wiring harness between TMCN3 (15)
replace
Max. 1 V normal? S1T (1)

Repair or
replace
S1T (2)
4
Is resistance between S1T (male) NO
Disconnect S1T.
(1) and (2) normal?
5 25 Ω
YES
Defective 1st clutch ECMV Replace
5
NO Repair or
Disconnect TMCN3 and S1T. (female) (15) and S1T (female) wiring harness between TMCN3 (13)
replace
Max. 1 Ω (1) normal? S1T (2)

Repair or
replace
S1T (1)
D575A-3 SD 20-635
T-24 [E0255] Short circuit in 1st clutch ECMV system

★ If the starting switch was turned off after the abnormality occurred, set the joystick in the 1st gear speed
Cause Remedy
1
NO Repair or
• Disconnect TMCN3. (female) (15) and chassis ground harness between TMCN3 (15) – S1T replace
YES
2
• 5 – 25 Ω
YES
3
Is resistance between S1T (male) (1)
and (2) and between (1), (2) and Defective 1st clutch ECMV Replace
• Disconnect S1T.
Repair or
TMCN3 (15) – S1T (1) and between
replace
Table 1 TMCN3 (13) – S1T (2)
S1T (male) Resistance
Between (1) – (2) 5 – 25 Ω
20-636 D575A-3 SD
T-25 [E0256] Disconnection in 2nd clutch ECMV system

★ If the starting switch was turned off after the abnormality occurred, set the joystick in the 2nd gear speed
Cause Remedy
1
Disconnect TMCN3.
5 25 Ω
YES
2
NO
Max. 1 V normal?
YES
Repair or
replace
3
NO Repair or
replace

Repair or
replace
S2T (2)
4
Disconnect S2T.
(1) and (2) normal?
5 25 Ω
YES
Defective 2nd clutch ECMV Replace
5
NO Repair or
replace

Repair or
replace
S2T (1)
D575A-3 SD 20-637
T-26 [E0257] Short circuit in 2nd clutch ECMV system

★ If the starting switch was turned off after the abnormality occurred, set the joystick in the 2nd gear speed
Cause Remedy
1
NO Repair or
YES
2
• 5 – 25 Ω
YES
3
and (2) and between (1), (2) and Defective 2nd clutch ECMV Replace
• Disconnect S2T.
Repair or
replace
Table 1 TMCN3 (3) – S2T (2)
Between (1) – (2) 5 – 25 Ω
20-638 D575A-3 SD
T-27 [E0258] Disconnection in 3rd clutch ECMV system

★ If the starting switch was turned off after the abnormality occurred, set the joystick in the 3rd gear speed
Cause Remedy
1
Disconnect TMCN3.
5 25 Ω
YES
2
NO
Max. 1 V normal?
YES
Repair or
replace
3
NO Repair or
replace

Repair or
replace
S3T (2)
4
Disconnect S3T.
(1) and (2) normal?
5 25 Ω
YES
Defective 3rd clutch ECMV Replace
5
NO Repair or
replace

Repair or
replace
S3T (1)
D575A-3 SD 20-639
T-28 [E0259] Short circuit in 3rd clutch ECMV system

★ If the starting switch was turned off after the abnormality occurred, set the joystick in the 3rd gear speed
Cause Remedy
1
NO Repair or
YES
2
• 5 – 25 Ω
YES
3
and (2) and between (1), (2) and Defective 3rd clutch ECMV Replace
• Disconnect S3T.
Repair or
replace
Table 1 TMCN3 (13) – S3T (2)
Between (1) – (2) 5 – 25 Ω
20-640 D575A-3 SD
T-29 [E0260] Abnormality in forward clutch oil pressure system

★ Before carrying out the following check, measure the forward clutch oil pressure. If the result is normal,
Cause Remedy
1
• Disconnect TMCN1 and FFT. wiring harness between TMCN1 (5)
(female) (5) and FFT (1) normal? replace
• Max. 1 Ω and FFT (1)
YES
Defective forward clutch fill switch Replace
T-30 [E0261] Short circuit in forward clutch oil pressure system

★ Before carrying out the following check, measure the forward clutch oil pressure. If the result is normal,
Cause Remedy
1
• Disconnect TMCN1 and FFT. (female) (5) and chassis ground
TMCN1 (5) and FFT (1) replace
• Min. 1 M Ω normal?
YES
Defective forward clutch fill switch Replace
T-29, 30 Related electrical circuit diagram
D575A-3 SD 20-641
T-31 [E0262] Abnormality in reverse clutch oil pressure system

★ Before carrying out the following check, measure the reverse clutch oil pressure. If the result is normal,
Cause Remedy
1
• Turn starting switch OFF. Is resistance between TMCN1 Disconnection or defective contact in
NO Repair or
• Disconnect TMCN1 and FRT. (female) (24) and FRT (1) wiring harness between TMCN1 (24)
replace
• Max. 1 Ω normal? and FRT (1)
YES
Defective reverse clutch fill switch Replace
T-32 [E0263] Short circuit in reverse clutch oil pressure system

★ Before carrying out the following check, measure the reverse clutch oil pressure. If the result is normal,
Cause Remedy
1
• Disconnect TMCN1 and FRT. (female) (24) and chassis ground
TMCN1 (24) and FRT (1) replace
YES
Defective reverse clutch fill switch Replace
20-642 D575A-3 SD
T-33 [E0264] Abnormality in 1st clutch oil pressure system

★ Before carrying out the following check, measure the 1st clutch oil pressure. If the result is normal, check
the electric system according to the following procedure.
Cause Remedy
1
NO Repair or
• Disconnect TMCN1 and F1T. (female) (23) and F1T (1) wiring harness between TMCN1 (23)
replace
• Max. 1 Ω normal? and F1T (1)
YES
Defective 1st clutch fill switch Replace
T-34 [E0265] Short circuit in 1st clutch oil pressure system

★ Before carrying out the following check, measure the 1st clutch oil pressure. If the result is normal, check
Cause Remedy
1
• Disconnect TMCN1 and F1T. (female) (23) and chassis ground
TMCN1 (23) and F1T (1) replace
YES
Defective 1st clutch fill switch Replace
D575A-3 SD 20-643
T-35 [E0266] Abnormality in 2nd clutch oil pressure system

★ Before carrying out the following check, measure the 2nd clutch oil pressure. If the result is normal, check
Cause Remedy
1
NO Repair or
• Disconnect TMCN1 and F2T. (female) (17) and F2T (1) wiring harness between TMCN1 (17)
• Max. 1 Ω normal? replace
and F2T (1)
YES
Defective 2nd clutch fill switch Replace
T-36 [E0267] Short circuit in 2nd clutch oil pressure system

★ Before carrying out the following check, measure the 2nd clutch oil pressure. If the result is normal, check
Cause Remedy
1
TMCN1 (17) and F2T (1) replace
YES
Defective 2nd clutch fill switch Replace
20-644 D575A-3 SD
T-37 [E0268] Abnormality in 3rd clutch oil pressure system

★ Before carrying out the following check, measure the 3rd clutch oil pressure. If the result is normal, check
Cause Remedy
1
• Disconnect TMCN1 and F3T. wiring harness between TMCN1 (11)
(female) (11) and F3T (1) replace
• Max. 1 Ω and F3T (1)
YES
Defective 3rd clutch fill switch Replace
T-38 [E0269] Short circuit in 3rd clutch oil pressure system

★ Before carrying out the following check, measure the 3rd clutch oil pressure. If the result is normal, check
Cause Remedy
1
• Min. 1 M Ω normal? TMCN1 (11) and F3T (1) replace
YES
Defective 3rd clutch fill switch Replace
D575A-3 SD 20-645
TROUBLESHOOTING T-39, T40, T-41
T-39 [E0270] Double failure in transmission clutch (clutch is not engaged)

→ Go to [E0254], [E0255], [E0256], [E0257].
T-40 [E0271] Double failure in transmission clutch

(clutch is not disengaged)
→ Go to ERROR THAT OCCURRED IN E0250 AND E0270 SIMULTANEOUSLY.
T-41 [E0273] Abnormality in neutral signal system is displayed

Cause Remedy
When normal; 1
At N position of transmission,
is o o _ _ _ _ displayed? Is display of monitoring mode Ld NO
At any other position of normal?
transmission, is _ _ _ _ _ _
displayed?
YES
2
At N position of transmission, is _
x x x x x displayed? Disconnection, short circuit, or
NO
At any other position of defective contact in wiring harness
transmission, is o x x x x x between TMCN2 (9) LE51 (6)
displayed?

between TMCN2 (19) LE51 (5)
20-646 D575A-3 SD
T-42 [E0301] Abnormality in left blade tilt angle sensor system is

displayed
★ Check that the left blade tilt angle sensor is installed normally. (If not, adjust.)
Cause Remedy
• T adapter or Monitoring 1
mode [Lb]. Is voltage between TMCN1 (7) NO
• Set blade in standard position. and (21) normal?
• 1.5 ± 0.5 V YES
2
Is reistance between CSL(male) NO
• Disconnect CSL. Defective left blade tilt angle sensor Replace
(1) and (C) normal?
• 4.0 – 6.0 kΩ
Repair or
replace
CSL (female) (C)
D575A-3 SD 20-647
T-43 [E0302] Abnormality in left blade tilt angle sensor system is

displayed
★ Check that the left blade tilt angle sensor is installed normally. (If not, adjust.)
Cause Remedy
mode [Lb].
• Set blade in standard position.
• Turn starting switch ON. and (21) normal?
• 1.5 ± 0.5 V
YES
2
• 4.75 – 5.25 V and (22) normal?
YES
3
(female) (7) and chassis ground NO wiring harness between TMCN1 Repair or
• Disconnect CSL and TMCN1.
normal? (female) (7) – CSL (female) (B) replace
• Min. 1 MΩ
YES
4
• Set blade in standard
position. Is voltage between CSL (B) and NO
Defective left blade tilt angle sensor Replace
• Turn starting switch ON. (C) normal?
• 1.5 ± 0.5 V
(female) (7) – CSL (female) (B) replace
5
NO Repair or
• Disconnect CSL and TMCN1. (female) (22) and chassis ground wiring harness between TMCN1
• Min. 1 MΩ normal? (female) (22) – CSL (female) (A) replace
YES
6
Is resistance between CSL (male) NO
• Disconnect CSL. Defective left blade tilt angle sensor Replace
(A) and (C) normal?
• 4.6 – 6.0 kΩ
wiring harness between TMCN1 (female)
Repair or
(22) – CSL (female) (A) replace
20-648 D575A-3 SD
T-44 [E0303] Abnormarity in right blade tilt angle sensor system is

displayed
★ Check that the right blade tilt angle sensor is installed normally. (If not, adjust.)
Cause Remedy
mode [Rb].
• 3.5 ± 0.5 V
YES
2
• Disconnect CSR.
Is reistance between CSR(male) NO
Defective right blade tilt angle sensor Replace
(A) and (C) normal?
• 4.0 – 6.0 kΩ
YES Defective contact or disconnection in Repair or
(female) (21) – CSR (female) (C)
D575A-3 SD 20-649
T-45 [E0304] Abnormality in right blade tilt angle sensor system is

displayed
★ Check that the right blade tilt angle sensor is installed normally. (If not, adjust.)
Cause Remedy
mode [Rb].
• 3.5 ± 0.5 V
YES
2
• 4.75 – 5.25 V and (22) normal?
YES
3
NO wiring harness between TMCN1 Repair or
• Disconnect CSR and TMCN1. (female) (13) and chassis ground
(female) (13) – CSR (female) (B) replace
YES
4
• Set blade in
standard position. Is voltage between CSR (B) and NO
Defective right blade tilt angle sensor Replace
• Turn starting switch ON. (C) normal?
• 3.5 ± 0.5 V
(female) (13) – CSR (female) (B) replace
5
NO Repair or
• Disconnect CSR and TMCN1. (female) (22) and chassis ground wiring harness between TMCN1
• Min. 1 MΩ normal? (female) (22) – CSR (female) (A) replace
YES
6
Is resistance between CSR (male) NO
• Disconnect CSR. Defective right blade tilt angle sensor Replace
(A) and (C) normal?
• 4.6 – 6.0 kΩ
wiring harness between TMCN1 (female)
Repair or
(22) – CSR (female) (A) replace
20-650 D575A-3 SD
T-46 [E0305] Short circuit in blade RAISE oil pressure switch system is
displayed
★ If the starting switch was turned off after the abnormality occurred, hold the starting switch in the ON posi-
tion for 180 seconds, and check that the service code displays “E” at the head. (If “P” is displayed, the con-
Cause Remedy
1
YES
Replace
(See Note)
2
Is resistance between PP4 (male) NO Defective blade raise oil pressure
• Disconnect PP4. Replace
(1) and (2) normal? switch
• Min 1 MΩ
YES Short circuit with chassis ground in Repair or
(female) (26) – PP4 (female) (1)
D575A-3 SD 20-651
T-47 [E0311] Abnormality in pitch-dump switch system

off the pitch-dump switch, and check that the service code displays "E" at the head. (If "P" is displayed, the
★ The marks of x in the boxes denote items that do not correspond to items (1) – (6) on the monitor shown on
page 55.
Cause Remedy
1
Check operation of pitch-dump
switch ON monitor panel in
monitoring mode [bd].
2
When pitch-dump switch is turned
OFF, is x x _ _ x x displayed? NO
YES
3
Is resistance between TMCN2 NO Disconnection in wiring harness
Disconnect TMCN2 and PO3.
(female) (15) and PO3 (5) between TMCN2 (15) PO3 (5)
Max. 1 Ω
YES
4
Turn starting switch OFF. Is resistance between PO3
Disconnect PO3. (female) (1) and chassis ground
between PO3 (1) GND006 replace
Max. 1 Ω normal?
YES
Repair or
replace
5
ON, is x x o o x x displayed?
YES
6
Is resistance between TMCN2 Short circuit with chassis ground in
Turn starting switch OFF. Repair or
NO
(female) (15) and chassis ground wiring harness between TMCN2 (15)
Disconnect TMCN2 and PO3. replace
Min. 1 MΩ normal? PO3 (5)
YES
Repair or
replace
7
ON, is x x _ _ x x displayed?
YES
8
Disconnect TMCN2 and PO3.
(female) (5) and PO3 (2) normal?
Max. 1 Ω
YES
between TMCN2 (5) PO3 (2)
9
Is voltage between PO3 (female) NO
Disconnect PO3. Disconnection in wiring harness Repair or
Max. 1 Ω between PO3 (1) GND006 replace
YES
Repair or
replace
Go to next page
20-652 D575A-3 SD
10
OFF, is x x o o x x displayed? NO
YES
11
NO Repair or
Disconnect TMCN2 and PO3. (female) (5) and chassis ground wiring harness between TMCN2 (5)
replace
YES
Repair or
replace
12
Is voltage at PO3 (female) (2) NO
Disconnect PO3.
normal?
20 30 V
YES
13
Disconnect PO3.
normal?
20 30 V
YES
14
Is resistance between PO3 NO Disconnection in wiring harness Repair or
Disconnect PO3.
(female) (1) and chassis ground between PO3 (1) GND004 replace
Max. 1 Ω
YES Repair or
replace
15
Turn starting switch ON. Disconnection or short circuit with
Is voltage at TMCN2 (male) (15) NO Repair or
Disconnect TMCN2. chassis ground in wiring harness
normal? replace
20 30 V between TMCN2 (15) PO3 (5)
YES
16
normal?
20 30 V

Repair or
replace
D575A-3 SD 20-653
T-48 [E0312] Abnormality in pitch-back switch system

off the pitch-back switch, and check that the service code displays "E" at the head. (If "P" is displayed, the
Cause Remedy
1
Check operation of pitch-back
monitoring mode [bd].
2
When pitch-back switch is turned
OFF, is _ _ x x x x displayed? NO
YES
3
NO Disconnection in wiring harness
Disconnect TMCN2 and PO3. (female) (35) and PO3 (6)
Max. 1 Ω normal?
YES
4
Turn starting switch OFF. Is resistance between PO3
Disconnect PO3. (female) (3) and chassis ground
between PO3 (3) GND006 replace
Max. 1 Ω normal?
YES
Repair or
replace
5
ON, is o o x x x x displayed?
YES
6
Is resistance between TMCN2 Short circuit with chassis ground in
Turn starting switch OFF. Repair or
NO
(female) (35) and chassis ground wiring harness between TMCN2 (35)
Disconnect TMCN2 and PO3. replace
YES
Repair or
replace
7
ON, is _ _ x x x x displayed?
YES
8
NO
Disconnect TMCN2 and PO3. (female) (25) and PO3 (4)
Max. 1 Ω normal?
YES
9 between TMCN2 (25) PO3 (4)
NO
Is voltage between PO3 (female) Disconnection in wiring harness Repair or
Disconnect PO3.
(3) and chassis ground normal? between PO3 (3) GND006 replace
Max. 1 Ω
YES
Repair or
replace
Go to next page
20-654 D575A-3 SD
10
OFF, is o o x x x x displayed? NO
YES
11
NO Repair or
Disconnect TMCN2 and PO3. (female) (25) and chassis ground wiring harness between TMCN2 (25)
replace
YES
Repair or
replace
12
Disconnect PO3.
normal?
20 30 V
YES
13
Disconnect PO3.
normal?
20 30 V
YES
14
Is resistance between PO3 NO Disconnection in wiring harness Repair or
Disconnect PO3.
(female) (3) and chassis ground between PO3 (3) GND004 replace
Max. 1 Ω
YES Repair or
replace
15
normal?
20 30 V

Repair or
replace
16
normal?
20 30 V

Repair or
replace
D575A-3 SD 20-655
T-49 [E0313] Disconnection in pitch back solenoid system is displayed

★ If the starting switch was turned off after the abnormality occurred, turn the starting switch on and perform
the pitch back operation, check that the service code displays “E” at the head. (If “P” is displayed, the condi-
tion has returned to normal.)
Cause Remedy
1
Disconnect TMCN3.
20 60 Ω
YES
2
NO
Max. 1 V normal?
YES
3
Turn starting switch ON. Short circuit with power source in
Is voltage between TMCN3 NO Repair or
Disconnect TMCN3, SoL1. wiring harness between TMCN3 (26)
(female) (26) and SoL1 normal? replace
Max. 1 V SoL1 (1)

Repair or
replace
SoL1 (2)
4
Is resistance between SoL1 NO
Disconnect SoL1. Defective pitch back solenoid Replace
20 60 Ω
YES
5
Turn starting switch OFF. Defective contact or disconnection in
Disconnect SoL1. wiring harness between TMCN3 (26)
(26) and SoL1 (1) normal? replace
Max. 1 Ω SoL1 (1)
YES
wiring harness between TMCN3 (23) replace
SoL1 (2)
20-656 D575A-3 SD
T-50 [E0314] Short circuit in pitch back solenoid system is displayed

pitch back operation, and check that the service code displays “E” at the head. (If “P” is displayed, the con-
Cause Remedy
1
NO Repair or
• Disconnect TMCN3, SoL1. (female) (26) and chassis ground wiring harness between TMCN3 (26) –
replace
• Min. 1MΩ normal? SoL1 (1)
YES
2
• Disconnect SoL1.
• 20 – 60 Ω
YES
3
Is resistance between SoL1 (male)
• Turn starting switch OFF. (1) and (2) and between (1) (2) and NO
• Disconnect SoL1. chassis ground as shown in Defective pitch back solenoid Replace
• 20 – 60 Ω following table?
Repair or
replace
SoL1 (1) and TMCN3 (23) – SoL1 (2)
Table
SoL1 (male) Resistance
Between (1) – (2) 20 – 60 Ω
D575A-3 SD 20-657
T-51 [E0315] Disconnection in pitch dump solenoid system is displayed

the pich dump operation, and check that the service code displays “E” at the head. (If “P” is displayed, the
Cause Remedy
1
Disconnect TMCN3.
20 60 Ω
YES
2
NO
Max. 1 V normal?
YES
3
Max. 1 V SoL3 (1)

Repair or
replace
SoL3 (2)
4
Disconnect SoL3. Defective pitch dump solenoid Replace
20 60 Ω
YES
5
Max. 1 Ω SoL3 (1)

YES
SoL3 (2)
20-658 D575A-3 SD
T-52 [E0316] Short circuit in pitch dump solenoid system is displayed

pitch dump operation, and check that the service code displays “E” at the head. (If “P” is displayed, the con-
Cause Remedy
1
NO Repair or
• Disconnect TMCN3. (female) (16) and chassis ground wiring harness between TMCN3 (16) –
replace
• 20 – 60 Ω normal? SoL3 (1)
YES
2
• 20 – 60 Ω
YES
3
• Disconnect SoL3. chassis ground as shown in Defective pitch dump solenoid Replace
Repair or
replace
SoL3 (1) and TMCN3 (23) – SoL3 (2)
Table
Between (1) – (2) 20 – 60 Ω
D575A-3 SD 20-659
T-53 [E0317] Disconnection in lift tilt limit solenoid system is displayed

the left tilt operation, and check that the service code displays “E” at the head. (If “P” is displayed, the condi-
Cause Remedy
1
Disconnect TMCN3.
20 60 Ω
YES
2
NO
Max. 1 V normal?
YES
3
Max. 1 V SoL2 (1)

Repair or
replace
SoL2 (2)
4
Disconnect SoL2. Defective left tilt limit solenoid Replace
20 60 Ω
YES
5
Max. 1 Ω SoL2 (1)
YES Defective contact, disconnection or

SoL2 (2)
20-660 D575A-3 SD
T-54 [E0318] Short circuit in left tilt limit solenoid system is displayed
left tilt operation, and check that the service code displays “E” at the head. (If “P” is displayed, the condition
has returned to normal.)
Cause Remedy
1
NO Repair or
replace
• 20 – 60 Ω normal? SoL2 (1)
YES
2
• 20 – 60 Ω
YES
3
• Disconnect SoL2. Defective left tilt limit solenoid Replace
chassis ground as shown in
Repair or
replace
SoL2 (1) and TMCN3 (23) – SoL2 (2)
Table
Between (1) – (2) 20 – 60 Ω
Between (1), (2) – chassis Min. 1MΩ
D575A-3 SD 20-661
T-55 [E0319] Disconnection in right tilt limit solenoid system is displayed

the right tilt operation, and check that the service code displays “E” at the head. (If “P” is displayed, the con-
Cause Remedy
1
Disconnect TMCN3.
20 60 Ω
YES
2
NO
Max. 1 V normal?
YES
3 Repair or
Turn starting switch ON. Short circuit with power source in replace
Is voltage between TMCN3 NO
(female) (37) and SoL4 normal?
Max. 1 V SoL4 (1)

Repair or
replace
SoL4 (2)
4
Disconnect SoL4. Defective right tilt limit solenoid Replace
20 60 Ω
YES
5
Max. 1 Ω SoL4 (1)

YES
SoL4 (2)
20-662 D575A-3 SD
T-56 [E0320] Short circuit in right tilt limit solenoid system is displayed
right tilt operation, and check that the service code displays “E” at the head. (If “P” is displayed, the condi-
Cause Remedy
1
NO Repair or
replace
• Min. 1MΩ normal? SoL4 (1)
YES
2
• 20 – 60 Ω
YES
3
• Disconnect SoL4. chassis ground as shown in Defective right tilt limit solenoid Replace
Repair or
replace
SoL4 (1) and TMCN3 (23) – SoL4 (2)
Table
Between (1) – (2) 20 – 60 Ω
D575A-3 SD 20-663
T-57 [E0341] Disconnection in blade lift 1 pump cut solenoid system is

displayed
blade raise operation, and check that the service code displays “E” at the head. (If “P” is displayed, the con-
Cause Remedy
1
NO
20 60 Ω normal?
YES
2
NO
Max. 1 V normal?
YES
3
Max. 1 V SoL8 (1)

Repair or
wiring harness between GND 005
replace
SoL8 (2)
4
Is resistance between SoL8 NO Defective blade lift 1 pump cut
Disconnect SoL8. Replace
(male) (1) and (2) normal? solenoid
20 60 Ω
YES
5
Is resistance between TMCN3 (8) NO Repair or
and SoL8 (1) normal? replace
Max. 1 Ω SoL8 (1)
YES
wiring harness between GND 005 replace
SoL8 (2)
20-664 D575A-3 SD
T-58 [E0342] Short circuit in blade lift 1 pump cut solenoid system is
displayed
blade raise operation, and check that the service code displays “E” at the head. (If “P” is displayed, the con-
Cause Remedy
1
NO Repair or
replace
• 20 – 60 Ω normal? SoL8 (1)
YES
2
NO
• 20 – 60 Ω normal?
YES
3
• Turn starting switch OFF. (1) and (2) and between (1) (2) and NO Defective blade lift 1 pump cut
• Disconnect TMCN3, SoL8. Replace
chassis ground as shown in solenoid
• Min. 1 MΩ following table?
Repair or
replace
SoL8 (1) and GND 005 – SoL8 (2)
Table
Between (1) – (2) 20 – 60 Ω
D575A-3 SD 20-665
T-59 [E0343] Disconnection in pitch dump assist relay system is

displayed
Cause Remedy
1
NO
Max. 1 V normal?
YES
2
Is resistance between APD NO
Disconnect APD. Defective assist pump solenoid relay Replace
200 400 Ω
YES
3
Turn starting switch OFF. Is resistance between APD NO Disconnection, short circuit, or
Repair or
Disconnect APD. (female) (2) and chassis ground defective contact in wiring harness
replace
Min. 1 MΩ normal? between APD (2) GND004
YES
Repair or
replace
between TMCN3 (18) APD (1)
T-60 [E0344] Short circuit in pitch dump assist relay system is displayed
Cause Remedy
1
NO
200 400 Ω normal?
YES
2
Is resistance between APD NO
Disconnect APD. Defective assist pump solenoid relay Replace
200 400 Ω
Repair or
harness between TMCN3 (18) APD
replace
(1)
20-666 D575A-3 SD
T-61 [E0345] Disconnection in pitch solenoid system is displayed

pitch operation, check that the service code displays “E” at the head. (If “P” is displayed, the condition has
returned to normal.)
Cause Remedy
1
Disconnect TMCN3.
20 60 Ω
YES
2
NO
Max. 1 V normal?
YES
3
Max. 1 V SoL5 (1)

Repair or
replace
SoL5 (2)
4
Disconnect SoL5. Defective pitch solenoid Replace
20 60 Ω
YES
5
Max. 1 Ω SoL5 (1)
YES
SoL5 (2)
D575A-3 SD 20-667
T-62 [E0346] Short circuit in pitch solenoid system is displayed

pitch operation, and check that the service code displays “E” at the head. (If “P” is displayed, the condition
Cause Remedy
1
NO Repair or
• Disconnect TMCN3, SoL5. (female) (28) and chassis ground wiring harness between TMCN3 (28) –
replace
• Min. 1MΩ normal? SoL5
YES
2
• 20 – 60 Ω
YES
3
• Disconnect SoL5. chassis ground as shown in Defective pitch solenoid Replace
Repair or
replace
SoL5 (1) and TMCN3 (23) – SoL5 (2)
Table
Between (1) – (2) 20 – 60 Ω
20-668 D575A-3 SD
T-63 [E0347] Disconnection in pitch priority solenoid system is displayed

Cause Remedy
1
Disconnect TMCN3.
20 60 Ω
YES
2
NO
Max. 1 V normal?
YES
3
Max. 1 V SoL7 (1)

Repair or
replace
SoL7 (2)
4
Disconnect SoL7. Defective pitch priority solenoid Replace
20 60 Ω
YES
5
Is resistance between TMCN3 (6) NO Repair or
and SoL7 (1) normal? replace
Max. 1 Ω SoL7 (1)

SoL7 (2)
D575A-3 SD 20-669
T-64 [E0348] Short circuit in pitch priority solenoid system is displayed

Cause Remedy
1
NO Repair or
replace
• Min. 1MΩ normal? SoL7
YES
2
• 20 – 60 Ω
YES
3
• Disconnect SoL7. chassis ground as shown in Defective pitch priority solenoid Replace
Repair or
replace
SoL7 (1) and TMCN3 (23) – SoL7 (2)
Table
Between (1) – (2) 20 – 60 Ω
20-670 D575A-3 SD
T-65 [E0364] Disconnection in work equipment oil pressure sensor 1 (200

pump) system is displayed
Cause Remedy
1
• Start engine.
• Raise ripper to relieve.
and (21) normal?
• 1.5 – 2.0 V
YES
2
• 20 – 30 V and (21) normal?
YES
3
NO Repair or
• Disconnect FPP and TMCN1. (female) (9) and chassis ground wiring harness between TMCN1
replace
• Min. 1 MΩ normal? (female) (9) – FPP (female) (C)
YES
4
• Start engine. NO Defective work equipment oil pressure
Is voltage between FPP (C) and
• Raise ripper to relieve. Replace
(A) normal? sensor 1 (200 pump)
• 1.5 – 2.0 V
Repair or
replace
(female) (9) – FPP (female) (C)
5
NO Repair or
• Disconnect FPP and TMCN1. (female) (16) and chassis ground wiring harness between TMCN1
(female) (16) – FPP (female) (B) replace
(female) (16) – FPP (female) (B) replace
D575A-3 SD 20-671
T-66 [E0365] Short circuit in work equipment oil pressure sensor 1 (200
Cause Remedy
1
• Start engine.
and (21) normal?
• 1.5 – 2.0 V
YES
2
• Disconnect FPP. Short circuit with power source in
Is voltage between TMCN1 (9) NO Repair or
• Turn starting switch ON. wiring harness between TMCN1
• Max. 1 V (female) (9) – FPP (female) (C)
YES
3
• Turn starting switch OFF. Is resistance between FPP NO Defective contact or disconnection in
Repair or
• Disconnect FPP. (female) (A) and chassis ground wiring harness between TMCN1
replace
• Max. 1Ω normal? (female) (21) – FPP (female) (A)
YES
Defective work equipment oil pressure
Replace
sensor 1 (200 pump)
20-672 D575A-3 SD
T-67 [E0366] Disconnection in work equipment oil pressure sensor 2 (200

Cause Remedy
1
• Start engine.
and (21) normal?
• 1.5 – 2.0 V
YES
2
• 20 – 30 V and (21) normal?
YES
3
NO Repair or
• Disconnect RPP and TMCN1. (female) (3) and chassis ground wiring harness between TMCN1
replace
• Min. 1 MΩ normal? (female) (3) – RPP (female) (C)
YES
4
• Start engine. NO Defective work equipment oil pressure
Is voltage between RPP (C) and
• Raise ripper to relieve. Replace
(A) normal? sensor 2 (200 pump)
• 1.5 – 2.0 V
Repair or
replace
(female) (3) – RPP (female) (C)
5
NO Repair or
• Disconnect RPP and TMCN1. (female) (16) and chassis ground wiring harness between TMCN1
(female) (16) – RPP (female) (B) replace
(female) (16) – RPP (female) (B) replace
D575A-3 SD 20-673
T-68 [E0367] Short circuit in work equipment oil pressure sensor 2 (200
Cause Remedy
1
• Start engine.
and (21) normal?
• 1.5 – 2.0 V
YES
2
• Disconnect RPP. Short circuit with power source in
Is voltage between TMCN1 (3) NO Repair or
• Turn starting switch ON. wiring harness between TMCN1
• Max. 1 V (female) (3) – RPP (female) (C)
YES
3
• Turn starting switch OFF. Is resistance between RPP NO Defective contact or disconnection in
Repair or
• Disconnect RPP. (female) (A) and chassis ground wiring harness between TMCN1
replace
• Max. 1Ω normal? (female) (21) – RPP (female) (A)
YES
Defective work equipment oil pressure
Replace
sensor 2 (200 pump)
20-674 D575A-3 SD
T-69 [E0372] Short circuit in blade RAISE (full) oil pressure switch system
is displayed
★ If the starting switch was turned off after the abnormality occurred, hold the starting switch in the ON posi-
tion for 100 seconds, and check that the service code displays “E” at the head. (If “P” is displayed, the con-
Cause Remedy
1
YES
Replace
(See Note)
2
Is resistance between PP2 (male) NO Defective blade raise (full) oil pressure
• Disconnect PP2. Replace
(1) and (2) normal? switch
• Min 1 MΩ
YES Short circuit with chassis ground in Repair or
(female) (36) – PP2 (female) (1)
D575A-3 SD 20-675
T-70 [E0486] Abnormality in specification selection is displayed

Cause Remedy
1
• Check on monitor panel in Is specification setting in controller NO
adjustment mode [7A]. correct?
YES
2
Is [111] displayed? NO
YES
3
Is left of display other than 1? NO
[ ]
YES
4
• Disconnect TMCN3. Is resistance between TMCN3 Disconnection or defective contact in
NO Repair or
• Max. 1 Ω (female) (10) and chassis ground wiring harness between TMCN3
(female) (10) – chassis ground replace
• Turn starting switch OFF. normal?
YES
5
Is harness disconnected from NO Defective harness of TMCN3 (female) Repair or
TMCN3 (female) (20)? (20) replace
YES
6
Is center of display other than 1? NO
[ ]
YES Set
specification in
Wrong specification setting in controller adjustment
mode [7A]
7
Is right of display other than 1?
[ ]
YES
20-676 D575A-3 SD
T-71 [E0610], [E0611] Disconnection in backup alarm relay system is

displayed
★ If the starting switch was turned off after the abnormality occurred, turn the starting switch on and operate
the joystick to the REVERSE position, and check that the service code displays “E” at the head. (If “P” is
Cause Remedy
1
YES
2
Is resistance between BKA (male) NO
• Disconnect BKA. Defective backup alarm relay Replace
(1) and (2) normal?
• 200 – 400 Ω
YES
3
• Turn starting switch OFF. NO Defective contact or disconnection in
Is rvoltage between BKA (female) Repair or
• Disconnect BKA. wiring harness between BKA (female)
• 20 – 30 V (1) – fuse (FB15)
(female) (18) – BKA (female) (2)
D575A-3 SD 20-677
T-72 [E0931] Abnormality in engine speed sensor B system is displayed

Cause Remedy
1
• 500 – 1,000 Ω
YES 2
• See TESTING AND
If speed sensor B is adjusted, is NO
ADJUSTING. Defective transmission controller Replace
• Start engine.
YES
Wrong adjustment of engine speed
Adjust
sensor B
3
Is resistance between RRL Replace
• Disconnect RRL. Defective engine speed sensor B
• 500 – 1,000 Ω
YES
4
• Turn starting switch OFF. Is resistance between TMCN2 NO Defective contact or disconnection in
Repair or
• Disconnect TMCN2 and RRL. (female) (40) and RRL (female) wiring harness between TMCN2
replace
• Max. 1 Ω (1) normal? (female) (39) – RRL (female) (2)
YES
Repair or
replace
(female) (40) – RRL (female) (1) –
M41 (female) (1)
20-678 D575A-3 SD
T-73 [E0932] Abnormality in bevel speed sensor A system is displayed

★ check the engine.)
Cause Remedy
1
• 500 – 1,000 Ω
YES 2
• See TESTING AND
ADJUSTING. If speed sensor is adjusted, is NO
• Start engine and check in service code P displayed?
monitoring mode [Co].
YES
Wrong adjustment of bevel speed
Adjust
sensor
3
Is resistance between TC1 (male) NO Replace
• Disconnect TC1. Defective engine speed sensor A
(1) and (2) normal?
• 500 – 1,000 Ω
YES
4
• Turn starting switch OFF. Is resistance between TMCN2 NO Defective contact or disconnection in
Repair or
• Disconnect TMCN2 and TC1. (female) (2) and TC1 (female) (1) wiring harness between TMCN2
replace
• Max. 1 Ω normal? (female) (14) – TC1 (female) (2)
YES
(female) (2) – TC1 (female) (1)
D575A-3 SD 20-679
A
TROUBLESHOOTING OF HYDRAULIC
MECHANICAL SYSTEM
(H MODE)
Table of failure modes and causes (electric, hydraulic, mechanical system).............................................. 20-702
H-1 Brakes do not work ........................................................................................................................... 20-704
H-2 Machine does not turn
(Machine can travel only in a straight line) ....................................................................................... 20-705
H-3 There is travel deviation.................................................................................................................... 20-706
H-4 Machine turns only in one direction (Lever operated)....................................................................... 20-707
H-5 Time lag is excessive........................................................................................................................ 20-708
H-6 Machine travels only in one direction (Forward or in reverse) .......................................................... 20-709
H-7 Machine does not move (2nd, 3rd) ................................................................................................... 20-710
H-8 Machine does not move in any speed range .................................................................................... 20-712
H-9 Torque converter overheats .............................................................................................................. 20-713
H-10 Abnormal noise from around hydraulic pump ................................................................................... 20-715
H-11 Blade RAISE speed slow or work equipment lacks power ............................................................... 20-716
H-12 Blade pitch speed slow or blade pitch lacks power .......................................................................... 20-717
H-13 Excessive hydraulic drift of blade ..................................................................................................... 20-718
H-14 Excessive hydraulic drift of blade pitch ............................................................................................. 20-718
D575A-3 SD 20-701
TABLE OF FAILURE MODES AND CAUSES
TROUBLESHOOTING (ELECTRIC, HYDRAULIC, MECHANICAL SYSTEM)

(ELECTRIC, HYDRAULIC, MECHANICAL SYSTEM)
Electrical system
Parts causing failure
Torque converter
Torque converter oil temperature sensor

Transmission oil pressure sensor
Alternator electrical system
Water temperature sensor
Pitch/tilt selector solenoid

Lock-up selector switch
Oil temperature sensor
Pitch assist solenoid
Power train oil level

Lift merge solenoid
Lock-up controller
Power train pump

Lock-up solenoid
Wiring harness
Pitch solenoid
Speed sensor
Panel switch
Knob switch
Failure mode
1 Brakes do not work

Machine does not turn
2 (Machine can travel in a straight line.)
3 Machine overruns when turning
4 Machine turns in one direction
5 Time lag is excessive
Machine travels only in one direction
6 (forward or reverse)
7 Machine does not move
8 Machine does not start in any speed range
9 Torque converter overheats
10 Abnormal noise from around hydraulic pump
11 Blade RAISE speed slow or lacks power
Blade pitch movement slow or blade
12 pitch lacks power
13 Excessive hydraulic drift of blade

14 Excessive hydraulic drift of blade pitch
15 Torque converter lock-up does not work
There is abnormality in torque converter
16 lock-up display
17 Engine does not start

18 Blade does not move to tilt posture
19 Blade does not move to pitch posture
20 Blade does not move to tilt or pitch posture
21 Front lamp does not light up
22 Rear lamp does not light up
23 Work lamp does not light up
20-702 D575A-3 SD
Steering clutch ECMV
Steering brake ECMV
Main rellef valve
D575A-3 SD
Transmiddion ECMV
Torque converter valve Power train
Hydraulic pump
TROUBLESHOOTING
Hydraulic tank oil level

Straainer
Hydraulid system
Hydraulic cylinder
Main control valve
Main relief valve
Work
equipment
PPC valve
Linkage
Steering clutch (disc, plate)
Brake clutch (disc, plate)
Internal parts of transmissisn
Internal parts of torque converter
Bevel gear shaft (bevel, transfer)
Final drive
Engine
Radeator core
Fan belt, pulley
Michanical system
Cooling water level

Fuel system
Cooling system
Loose piping clamps, air in circuit, leakage of oil
Torque converter lick-up clutch
—
—
—
—
—
—
—
—
—
—
—
—
—
—
E-9
E-8
E-7
E-6
E-5
E-4
E-3
E-2
E-1
Table E-
system,
YES/NO
—
—
—
—
—
—
—
—
—
shooting
H-9
H-8
H-7
H-6
H-5
H-4
H-3
H-2
H-1
mechani-
hydraulic
electrical
H-11
NO TableH-
H-14
H-13
H-12
H-10
ing YES/
cal system,
• For abnor-
• For abnou-
malitles in
malities in
system, go
go to Trou-
to Trouble-
Troubleshouting
ble shoot-
20-703
(ELECTRIC, HYDRAULIC, MECHANICAL SYSTEM)
TROUBLESHOOTING H-1
H-1 Brakes do not work

★ Check the power train oil level before starting troubleshooting.
★ When power train main oil pressure is normal.
Cause Remedy
1
Is error code displayed on NO
monitor panel?
YES
Defective electrical system
Check
(See E-MODE)
• See Note 1. Is braking capacity sufficient? NO
YES
Defective clutch (See H-2) —
3
Is oil pressure in brake, clutch NO
• See Note 1.
circuit normal?
YES
Brake disc, plate deformed or worn Replace
4
• See TESTING AND When brake link-age is adjusted, NO
ADJUSTING. does condition become normal?
YES
Defective adjustment of brake linkage Adjust
5
Does brake valve spool move NO Correct or
Defective actuation of spool
smoothly? replace
YES
Defective seal ring of clutch chamber Replace
Note 1
Depress the brake pedal fully, place the transmission in R1, and pull the steering lever on one side fully.
When the engine speed is raised gradually from deceleration slow (stall) to high idling, the machine must
not move.
Table 1
Brake pedal not depressed Brake pedal depressed

Conditions
Engine speed: Engine speed: Engine speed: Engine speed:
High idling Low idling High idling Low idling
• Clutch pressure: • Clutch pressure: • Clutch pressure: • Clutch pressure:

Oil pressure 0 {0} (left and right) 0 {0} (left and right) 0 {0} (left and right) 0 {0} (left and right)
(MPa {kg/cm2})
• Brake pressure: • Brake pressure: • Brake pressure: • Brake pressure:
2.3 – 2.7 {23 – 28} 2.0 – 2.6 {20 – 27} 0 {0} (left and right) 0 {0} (left and right)
(left and right) (left and right)
20-704 D575A-3 SD
TROUBLESHOOTING H-2
H-2 Machine does not turn

(Machine can travel only in a straight line)
★ HCheck the power train oil level before starting troubleshooting.

★ HWhen power train main oil pressure is normal.
Cause Remedy
1
monitor panel?
YES
Check
(See E-MODE)
• See Note 1. Is clutch disengaged? NO
YES
Defective brake (See H-1) —
3
• See Table 1. Is oil pressure in brake, clutch NO
circuit normal?
YES
Clutch disc, plate deformed or worn Replace
4
Does clutch ECMV spool move NO Replace
Defective actuation of spool
smoothly? ECMV
YES
Defective seal ring of clutch chamber Replace
Note 1
1) Raise the chassis, run the engine at low idling, and place the transmission in F3 (R3). When the steer-
ing lever on one side is pulled, the track must stop.
2) Travel in F1 (R1) with the engine at low idling. When the steering lever on one side is pulled the
machine must stop or must turn slowly.
D575A-3 SD 20-705
TROUBLESHOOTING H-2, H-13
Table 1
Steering lever not operated Steering lever operated
Conditions
Engine speed: Engine speed: Engine speed:High Engine speed:
High idling Low idling idling Low idling
• Clutch pressure: • Clutch pressure:
0 {0} (left and right) 0 {0} (left and right) right 2.3 – 2.7  right 2.0 – 2.6 
 {23 – 28}   {20 – 27} 
• Brake pressure: • Brake pressure: Right left 0{0}  left 0{0} 
2.3 – 2.7 {23 – 28} 2.0 – 2.6 {20 – 27} lever • Clutch pressure: • Clutch pressure:
(left and right) (left and right) right 0{0}  right 0{0} 
left 2.3 – 2.7  left 2.0 – 2.6 
Oil pressure  {23 – 28}   {20 – 27} 
(MPa {kg/cm2}) • Clutch pressure: • Clutch pressure:
right 0{0}  right 0{0} 
left 2.3 – 2.7  left 2.0 – 2.6 
Left  {23 – 28}   {20 – 27} 
lever • Clutch pressure: • Clutch pressure:
right 2.3 – 2.7  right 2.0 – 2.6 
 {23 – 28}   {20 – 27} 
left 0{0}  left 0{0} 
H-3 There is travel deviation

Cause Remedy
Is clutch disengaged? NO
• Note 1. Defective clutch (See H-2) —
YES
Defective brake (See H-1) —
Note 1
1) Travel in F1 (R1) with the engine at low idling. When the steering lever on one side is pulled the machine
must stop or must turn slowly.
20-706 D575A-3 SD
TROUBLESHOOTING H-4
H-4 Machine turns only in one direction (Lever operated)

Cause Remedy
1
monitor panel?
YES
Defective electrical system Check
(See E-MODE)
2
Is clutch, brake pressure of NO Replace the
• See Table 1. Defective steering ECMV
ECMV normal? ECMV
YES
3
NO
Does machine turn when clutch is Defective seal of clutch chamber Repair or
partially engaged? replace
YES
Worn clutch disc, plate, scuffing Repair or
replace
Table 1
Conditions

 {23 – 28}   {20 – 27} 
left 2.3 – 2.7  left 2.0 – 2.6 
Oil pressure  {23 – 28}   {20 – 27} 
right 0{0}  right 0{0} 
left 2.3 – 2.7  left 2.0 – 2.6 
Left  {23 – 28}   {20 – 27} 
right 2.3 – 2.7  right 2.0 – 2.6 
 {23 – 28}   {20 – 27} 
left 0{0}  left 0{0} 
D575A-3 SD 20-707
TROUBLESHOOTING H-5
H-5 Time lag is excessive

★ Check the power train oil level before starting troubleshooting
Cause Remedy
1
monitor panel?
YES
Check
(See E-MODE)
Is brake dragging? NO
YES
Brake dragging (See H-1) —
3
• 2.3 – 2.7 MPa
Is transmission main relief NO
{23 –28 kg/cm2}
pressure normal?
YES
4
• 2.3 – 2.7 MPa
Is clutch operation pressure NO
{23 –28 kg/cm2} Defective clutch ECMV Replace
normal?
YES
Clutch disc plate deformed or worm Replace
5
When transmission main relief
NO
valve is cleaned, is operation Drop in performance of pump Replace
normal?
YES Correct or
Defective main relief valve
replace
20-708 D575A-3 SD
TROUBLESHOOTING H-6
H-6 Machine travels only in one direction (Forward or in reverse)

★ Check the power train oil level before starting troubleshooting
Cause Remedy
1
monitor panel?
YES
Check
(See E-MODE)
2
• 2.3 – 2.7 MPa
Is transmission main relief NO
{23 –28 kg/cm2}
pressure normal?
YES
3
• 2.3 – 2.7 MPa Is forward or reverse clutch
{23 –28 kg/cm2} NO
operation pressure normal in
• Engine at high idling forward or reverse travel?
YES
Defective inside clutch on side that
Replace
dose not move
4
When transmission main relief
NO Drop in performance of pump Replace
valve is cleaned, is operation
normal?
YES Correct or
replace
5
NO
Does ECMV operate normally? Defective clutch ECMV Replace
YES Defective seal of clutch chamber on

Replace
side that does not move
D575A-3 SD 20-709
TROUBLESHOOTING H-7
H-7 Machine does not move. (2nd, 3rd)

Cause Remedy
1
monitor panel?
YES
Check
(See E-MODE)
Is parking brake released?
YES
3
Is brake dragging when traveling NO
• See Note 1.
in F1 (R1)?
YES
4
• 2.0 – 2.6 MPa
{20 – 27 kg/cm2} Is actuating pressure normal NO Defective clutch ECMV Replace
• Engine at high idling. when operating in 2nd, 3rd?
• See Item 2 of H-6
YES
5
• 0.6 – 0.8 MPa
Is oil pressure at torque converter NO
{6 – 8 kg/cm2} Defective inside torque converter Replace
outlet port normal?
• Engine at high idling.
YES
6
Is steering clutch pressure NO
• See Table 1. Defective steering clutch (See H-2) —
normal?
YES
Defective clutch inside transmission Replace
Note 1
1) Raise the chassis, run the engine at low idling, and place the transmission in F3 (R3).
When the steering lever on one side is pulled, the track must stop.
20-710 D575A-3 SD
TROUBLESHOOTING H-7
Table 1
Conditions
 {23 – 28}   {20 – 27} 
left 2.3 – 2.7  left 2.0 – 2.6 
Oil pressure  {23 – 28}   {20 – 27} 
right 0{0}  right 0{0} 
left 2.3 – 2.7  left 2.0 – 2.6 
Left  {23 – 28}   {20 – 27} 
right 2.3 – 2.7  right 2.0 – 2.6 
 {23 – 28}   {20 – 27} 
left 0{0}  left 0{0} 
D575A-3 SD 20-711
TROUBLESHOOTING H-8
H-8 Machine does not move in any speed range

★ HCheck the power train oil level before starting troubleshooting.
Cause Remedy
1
monitor panel?
YES
Adjust
(See E-mode)
• See Table 1. Is brake pressure normal? NO Brake dragging (See H-1) —
YES
3
• 2.3 – 2.7 MPa
Is power train main pressure NO
{23 – 28 kg/cm2}
normal?
YES
4
• 2.3 – 2.7 MPa
{23 – 28 kg/cm2} Is actuating pressure normal NO Correct or
Defective clutch ECMV
• Engine at high idling. when gear shift lever is operated? replace
• See Note 1.
YES
5
When warn valve is cleaned, NO Drop in performance of
Replace
does situation return to normal? power train pump
YES Correct or
replace
6
• 0.6 – 0.8 MPa
Is oil pressure at torque converter NO
{6 – 8 kg/cm2} Defect inside torque converter Repair
outlet port normal?
YES
7
Is steering clutch pressure NO Defective seal of steering clutch
• See Table 1 of H-2. Replace
normal? chamber
YES
Defect inside steering clutch Replace
Note 1
1) When the gearshift lever is operated, if the indicator of the oil pressure gauge drops greatly and then rises
again, the main spool is being actuated.
Table 1
Brake pedal not depressed Brake pedal depressed

Conditions
Engine speed: Engine speed: Engine speed: Engine speed:
High idling Low idling High idling Low idling

Oil pressure 0 {0} (left and right) 0 {0} (left and right) 0 {0} (left and right) 0 {0} (left and right)
(MPa {kg/cm2})
• Brake pressure: • Brake pressure: • Brake pressure: • Brake pressure:
2.3 – 2.7 {23 – 28} 2.0 – 2.6 {20 – 27} 0 {0} (left and right) 0 {0} (left and right)
(left and right) (left and right)
20-712 D575A-3 SD
TROUBLESHOOTING H-9
H-9 Torque converter overheats

Cause Remedy
Is brake dragging?
NO
YES
2
Is torque con-
• See TESTING AND NO
verter oil temper-ature sensor Defective oil temperature sensor Replace
ADJUSTING.
normal?
YES
3 NO
• 2.3 – 2.7 MPa
Is power train main pressure
{23 – 28 kg/cm2}
normal?
YES
4
• 1,650±50 rpm Is engine speed at F3 stall NO
• Engine at high idling. normal?
YES
5
• 824±25 rpm at engine speed
1800 rpm NO
Is fan speed normal?
• See TESTING AND
ADJUSTING.
YES
6
Repair
NO Defective circulation of engine cooling
• Check visually. Is core clogging?
water
YES
Clogged core Clean
Is fan belt tension correct? NO Defective belt tension Adjust
YES
8
Is wear of V-belt within service NO
Defective pulley Replace
limit?
YES
Defective belt Replace
9
Does machine stop with ope- NO
• Same as for Item 4. Brake slipping Replace
ration in Item 4?
YES
D575A-3 SD 20-713
TROUBLESHOOTING H-9
Cause Remedy
From previous page From previous page
10
Is pressure at torque converter NO
• Same as for Item 4. Defect inside torque converter Replace
inlet/outlet port normal?
YES
• Torque converter 11
Inlet port: 0.7 — 0.9 MPa
{7 — 9 kg/cm2} Does transmission output shaft NO Steering clutch slipping Replace
Outlet port: 0.6 — 0.8 MPa stop with operation in Item 4?
{6 — 8 kg/cm2}
• Engine at high idling. YES
• Transmission clutch slipping • Replace
• Increase in engine output • Adjust
12
When modulating valve is
• Remove the cover on top of NO Drop in performance of power train
cleaned, does situation return to Replace
the steering case to check. pump
normal?
YES Clean or
Defective actuation of modulating
valve replace
20-714 D575A-3 SD
TROUBLESHOOTING H-10
H-10 Abnormal noise from around hydraulic pump

★ Check the hydraulic oil level before starting troubleshooting.
Cause Remedy
1
NO
Is proper oil being used? Improper oil Replace
YES
2
Is there air inside hydraulic pump NO
suction circuit?
YES Defective seal

Tighten
Loose piping clamp
Replace
Damaged O-ring
3
NO
Is strainer clogged?
YES
Clogged strainer Clean
4 Inspect again
When hydraulic oil is strained, are NO Operate for a short time and look for (according to
metal wear particles found? any change in the condition change in

condition)
YES
Defective pump Replace
D575A-3 SD 20-715
H-11 Blade RAISE speed slow or work equipment lacks power

Note: Check for any modification of the blade.
Cause Remedy
1
• 2.9 – 3.4 MPa
Is PPC valve output pressure NO
{30 – 35 kg/cm2}
normal?
YES
2
Does cylinder extend and con- NO
Air in circuit Bleed air
tact smoothly?
YES
3
• 19.6 – 21.6 MPa Is pump discharge pressure NO
{200 – 220 kg/cm2} normal?
YES
4
• Hydraulic drift of blade: Is hydraulic drift normal when NO
See H-13 —
200 mm/15 min lever is at HOLD?
YES
• Defective actuation of check valve Replace parts
• Defective actuation of spool
5
When relief valve is adjusted, NO
• 19.6 – 21.6 MPa does pump discharge pressure Defective pump Replace
{200 – 220 kg/cm2} become normal?
YES Clean or
Defective relief valve
replace
6
• 2.9 – 3.4 MPa
{30 – 35 kg/cm2} Is PPC valve inlet pressure NO
YES
Defective PPC valve Replace
7
When PPC pump relief valve is
NO
adjusted, does condition return to Drop in performance of PPC pump Replace
normal?
YES
Defective adjustment of relief valve Adjust
20-716 D575A-3 SD
H-12 Blade pitch speed slow or blade pitch lacks power

Note: Check for any modification of the blade.
Cause Remedy
1
• 2.9 – 3.4 MPa
Is PPC valve output pressure NO
{30 – 35 kg/cm2}
normal?
YES
2
Does cylinder extend and con- NO
Air in circuit Bleed air
tact smoothly?
YES
3
• 19.6 – 21.6 MPa Is pump discharge pressure NO
{200 – 220 kg/cm2} normal?
YES
4
Is hydraulic drift of pitch normal NO
See H-14 —
when lever is at HOLD?
YES
• Defective actuation of check valve Replace parts
• Defective actuation of spool
5
• 19.6 – 21.6 MPa When relief valve is adjusted, NO
Defective pump Replace
{200 – 220 kg/cm2} does condition return to normal?
YES Clean or
Defective relief valve
replace
6
• 2.9 – 3.4 MPa
{30 – 35 kg/cm2} Is PPC valve inlet pressure NO
YES
Defective PPC valve Replace
7
When PPC pump relief valve is
NO
adjusted, does condition return to Drop in performance of PPC pump Replace
normal?
YES
Defective adjustment of relief valve Adjust
D575A-3 SD 20-717
TROUBLESHOOTING H-12, H-13
H-13 Excessive hydraulic drift of blade
Cause Remedy
1
Defective control valve
• See TESTING AND When lever is operated, does NO Replace
• Defective oil tightness of spool
ADJUSTING. downward speed become faster?
• Defective safety valve
YES
Defective cylinder, piston seal Replace
H-14 Excessive hydraulic drift of blade pitch
Cause Remedy
1
When pitch button is operated, Defective control valve
• See TESTING AND NO Replace
does downward speed become • Defective oil tightness of spool
ADJUSTING.
faster? • Defective safety valve
YES
Defective cylinder, piston seal Replace
20-718 D575A-3 SD
TROUBLESHOOTING OF MONITOR PANEL AND
ELECTRICAL SYSTEM
(M MODE)
Electricaal circuit diagram of M mode system............................................................................................. 20-806
M-1 [E0120] Short circuit in caution lamp output system is displayed ..................................................... 20-808
M-2 [E0121] Short circuit in caution buzzer system is displayed ............................................................. 20-809
M-3 [E0211] Abnormality in power train (torque converter oil temperature is displayed .......................... 20-810
M-4 [E0329] Abnormality in hydraulic oil temperature is displayed ......................................................... 20-810
M-5 [E0430] Abnormality in engine oil pressure is displayed ...................................................................20-811
M-6 [E0431] Abnormality in radiator water level is displayed ...................................................................20-811
M-7 [E0432] Abnormality in engine water temperature is displayed ........................................................ 20-812
M-8 When starting switch is turned on, monitor panel gives no display .................................................. 20-813
a) Caution module (Gauge/lamp unit) gives no display .................................................................... 20-813
b) Tachometer module (Tachometer/service meter unit) gives no display ........................................ 20-814
M-9 When starting switch is turned on, monitor panel lamps all stay lighted up and do not go out......... 20-815
a) Caution module (Gauge/lamp unit) displays all stay lighted up and do not go out ....................... 20-815
b) Tachometer module (Tachometer/service meter unit)
displays all stay lighted up and do not go out .............................................................................. 20-815
M-10 When starting switch is turned on (engine stopped), check before starting items flash ................... 20-816
a) [Radiator water level] flashes ....................................................................................................... 20-816
b) [Engine oil level] flashes ............................................................................................................... 20-817
M-11 When starting switch is turned on (engine stopped), caution items flash
(but battery charge, engine oil pressure caution do not flash) .......................................................... 20-818
a) Engine oil pressure sensor system............................................................................................... 20-818
b) Alternator system.......................................................................................................................... 20-819
M-12 When starting switch is turned on (engine stopped), caution items flash
(but there is no abnormality in checks before starting items or engine) ........................................... 20-820
a) [Battery charge] flashes ................................................................................................................ 20-820
b) [Engine oil pressure] flashes......................................................................................................... 20-821
c) [Radiator water level] flashes........................................................................................................ 20-821
d) [Engine water temperature] flashes .............................................................................................. 20-822
e) [Power train (torque converter) oil temperature] flashes............................................................... 20-823
f) [Hydraulic oil temperature] flashes ............................................................................................... 20-824
g) [Air cleaner clogging] flashes........................................................................................................ 20-825
M-13 Abnormality in caution buzzer........................................................................................................... 20-826
a) Caution item flashes but buzzer does not sound,
or buzzer does not sound for 1 second after starting switch is turned ON ................................... 20-826
b) No abnormality is displayed on monitor but buzzer sounds ......................................................... 20-826
M-14 Abnormality in caution lamp.............................................................................................................. 20-828
a) Caution item flashes but caution lamp does not flash,
or caution lamp does not light up for 2 seconds after starting switch is turned ON ...................... 20-828
b) No abnormality is displayed on monitor but caution lamp lights up .............................................. 20-828
M-15 Abnormality in engine water temperature gauge .............................................................................. 20-830
a) Engine water temperature gauge shows abnormally low temperature......................................... 20-830
b) Engine water temperature gauge gives no display (gauge does not even display one level) ...... 20-830
M-16 Abnormality in power train (torque converter) oil temperature gauge............................................... 20-832
a) Power train oil temperature gauge shows abnormally low temperature ....................................... 20-832
b) Power train (torque converter) oil temperature gauge gives no display
(gauge does not even display one level) ...................................................................................... 20-832
M-17 Abnormality in fuel level gauge......................................................................................................... 20-834
a) Fuel level gauge always display FULL ......................................................................................... 20-834
b) Fuel level gauge gives no display (gauge does not even display one level) ................................ 20-834
D575A-3 SD 20-801
M-18 Speed range display shows "- -", engine speed is not displayed...................................................... 20-836
M-19 Service meter does not advance when engine is running ................................................................ 20-836
M-20 Abnormality in service mode............................................................................................................. 20-837
a) Does not switch to service mode even when service switch is operated ..................................... 20-837
b) Stays in service mode................................................................................................................... 20-837
M-21 Night lighting on monitor panel does not light up (front lamp, working lamp are normal) ................. 20-839
a) Tachometer module lamp does not light up .................................................................................. 20-839
b) Caution module lamp does not light up ........................................................................................ 20-839
c) Switch module lamp does not light up .......................................................................................... 20-840
M-22 L.H. front lamp do not light up........................................................................................................... 20-841
a) Any one of front lamps and working lamps does not light up ...................................................... 20-841
M-23 R.H. front lamp do not light up .......................................................................................................... 20-842
M-24 L.H. working lamps do not light up.................................................................................................... 20-843
a) Any one of front lamps and working lamps does not light up ....................................................... 20-843
M-25 R.H. working lamps do not light up ................................................................................................... 20-844
20-802 D575A-3 SD

User Service
Abnormal system Nature of abnormality
code code
When GND output voltage to caution lamp has become high

Short circuit in 1. Defective caution lamp
E0120 monitor caution 2. Short circuit with power source in wiring harness between monitor panel
lamp system CN2 (7) and caution lamp 375 (2)
3. Defective monitor panel
CALL
03
When alarm buzzer GND output voltage has become high
Short circuit in 1. Defective alarm buzzer
E0121 monitor alarm 2. Short circuit with power source in wiring harness between monitor panel
buzzer system CN2 (8) and alarm buzzer 217 (2)
3. Defective monitor panel
When torque converter oil temperature caution lamp on monitor panel

Abnormality in flashes
power train (torque 1. Rise of torque converter oil temperature to about 130°C
E0211
converter) oil 2. Defective torque converter oil temperature sensor
temperature
E01 When hydraulic oil temperature caution lamp on monitor panel flashes
1. Rise of hydraulic oil temperature to about 108×C
2. Defective contact or disconnection in wiring harness between monitor panel
Abnormality in CN1 (8) – sensor 452 (1)
E0329 hydraulic oil 3. Defective hydraulic oil temperature sensor
temperature
When engine oil pressure caution lamp on monitor panel flashes

1. Lowering of engine oil pressure
2. Short circuit with chassis ground in wiring harness between monitor panel
Abnormality in CN1 (7) – sensor 301 (3)
E0430
radiator water level 3. Defective engine oil pressure sensor
CALL When radiator water level caution lamp on monitor panel flashes
1. Lowering of radiator water level (Main or dual)
2. Defective contact or disconnection in wiring harness between monitor panel
CN1 (5) – sensor DRT (2)
Abnormality in 3. Defective contact or disconnection in wiring harness between sensor DRT
E0431
engine oil pressure (1) – sensor 405 (1)
4. Defective contact or disconnection in wiring harness between sensor 405
(2) – GND
5. Defective radiator water level sensor
When engine water temperature caution lamp on monitor panel flashes

1. Rise of engine water temperature to about 108°C
Abnormality in 2. Defective engine water temperature sensor
E01 E0432 engine water
temperature
20-804 D575A-3 SD
Condition when normal Action by controller when Problem that appears on machine
Voltage between CN2 (7) and chassis 1. Sounds alarm buzzer 1. Caution lamp does not light up
: Max. 6 V (when caution lamp lights up)
Voltage between CN2 (8) and chassis 1. Lights up caution lamp 1. Alarm buzzer does not sound
: Max. 3 V (when alarm buzzer sounds)
• Resistance between 453 (1) – (2) 1. Lights up caution lamp,

At 100°C:Approx. 3.8 kΩ sounds alarm buzzer
At 90°C:Approx. 5 kΩ
• Voltage between 452 (1) (CN1 (8)) – 1. Lights up caution lamp,
chassis ground sounds alarm buzzer
When sensor is turned ON (hydraulic
oil temperature is about 104°C or
lower): 1 V max.
When sensor is turned OFF
(hydraulic oil temperature is about
108°C or higher): 20 – 30 V
• Voltage between 301 (3) (CN1 (7)) – 1. Lights up caution lamp,

When sensor is turned ON (engine is
stopped but starting switch is at ON
position): 1 V max.
When sensor is turned OFF (engine is
started): 20 – 30 V
• Voltage between DRT (2) (CN1 (5)) – 1. Lights up caution lamp,

When sensor is turned ON (radiator
water level is above LOW mark)
: 1 V max.
When sensor is turned OFF (radiator
water level is below LOW mark): 20 –
30 V
• Resistance between 402 (1) – (2) 1. Lights up caution lamp,

At 100°C:Approx. 3.8 kΩ sounds alarm buzzer
D575A-3 SD 20-805
ELECTRICAL CIRCUIT DIAGRAM OF M MODE SYSTEM
20-806 D575A-3 SD
D575A-3 SD 20-807
TROUBLESHOOTING M-1
M-1 [E0120] Short circuit in caution lamp output system is displayed

the service code displays “E”at the head. (If “P” is displayed, the condition has returned to normal.)
Cause Remedy
1
Is resistance between RMP NO
Disconnect RMP. Defective caution lamp Replace
100 400 Ω
YES
2
Disconnect RMP, CN2. Short circuit with power source in
Is voltage between CN2 (female) NO Repair or
Turn starting switch ON. wiring harness between CN2 (female)
Max. 1 V (7) and RMP (female) (2)
YES
Replace
(caution module)
M-1 Related electrical circuit diagram
20-808 D575A-3 SD
TROUBLESHOOTING M-2
M-2 [E0121] Short circuit in caution buzzer system is displayed

Cause Remedy
1
Is resistance between BZR NO Defective caution buzzer Replace
• Disconnect BZR.
(buzzer end) normal?
• Min. 200 Ω
YES
2
• Disconnect BZR, CN2. Short circuit with power source in
Is voltage between CN2 (female) NO Repair or
• Turn starting switch ON. wiring harness between CN2 (female)
• Max. 1 V (8) and BZR
YES Defective monitor panel
Replace
(caution module)
D575A-3 SD 20-809
TROUBLESHOOTING M-3, M-4
M-3 [E0211] Abnormality in power train (torque converter oil temperature

is displayed
Cause Remedy
1
Is power train (torque converter)
oil temperature caution lamp on
NO
monitor flashing?
YES
Go to M12 e). —
2
Is [E] displayed at head of service NO
Defective power train See note
code?

Replace
(caution module)
NOTE: The display on the monitor panel has returned to normal, but it shows that the power train oil tempera-
ture sensor has detected abnormal oil temperature in the past. Check the power train and remove the
cause of the abnormality.
M-4 [E0329] Abnormality in hydraulic oil temperature is displayed
Cause Remedy
1
Is hydraulic oil temperature NO
caution lamp on monitor flashing?
YES
Go to M12 f). —
2
Defective hydraulic equipment See note
code?

Replace
(caution module)
NOTE: The display on the monitor panel has returned to normal, but it shows that the hydraulic oil temperature
sensor has detected abnormal oil temperature in the past. Check the hydraulic equipment and remove
the cause of the abnormality.
20-810 D575A-3 SD
TROUBLESHOOTING M-5, M-6
M-5 [E0430] Abnormality in engine oil pressure is displayed
Cause Remedy
1
Is engine oil pressure caution NO
lamp on monitor flashing?
YES
Go to M12 b). —
2
Defective engine See note
code?

Replace
(caution module)
NOTE: The display on the monitor panel has returned to normal, but it shows that the engine oil pressure sen-
sor has detected a drop in the oil pressure in the past. Check the engine and remove the cause of the
abnormality.
M-6 [E0431] Abnormality in radiator water level is displayed
Cause Remedy
1
Is radiator water level caution NO
lamp on monitor flashing?
YES
Go to M12 c). —
2
code?

Replace
(caution module)
NOTE: The display on the monitor panel has returned to normal, but it shows that the radiator water level sen-
sor has detected a drop in the water level in the past. Check the engine and remove the cause of the
abnormality.
D575A-3 SD 20-811
TROUBLESHOOTING M-7
M-7 [E0432] Abnormality in engine water temperature is displayed
Cause Remedy
1
Is engine water temperature NO
caution lamp on monitor flashing?
YES
Go to M12 d). —
2
code?

Replace
(caution module)
NOTE: The display on the monitor panel has returned to normal, but it shows that the engine water tempera-
ture sensor has detected abnormal oil temperature in the past. Check the engine and remove the cause
of the abnormality.
20-812 D575A-3 SD
TROUBLESHOOTING M-8
M-8 When starting switch is turned on, monitor panel gives no display
a) Caution module (Gauge/lamp unit) gives no display

★ Check that circuit breaker CB2 normal before starting troubleshooting.
(If it is blown, check for a short circuit with the ground in the wiring harness related to it.)
Cause Remedy
1
Turn starting switch ON. Is voltage between CN1 (1) and NO
20 30 V (2) normal?
YES
Replace
(caution module)
2
Turn starting switch ON. Is voltage between CN1 (1) and NO Repair or
(1) fuse 12

Repair or
replace
(2) chassis ground
D575A-3 SD 20-813
TROUBLESHOOTING M-8
b) Tachometer module (Tachometer/service meter unit) gives no display

★ Check that fuse 5 and circuit breaker CB2 are normal before starting troubleshooting.
(If they are blown, check for a short circuit with the ground in the wiring harness related to them.)
Cause Remedy
1
• Turn starting switch ON. Is voltage between T01 (7) and NO
• 20 – 30 V (2) normal?
YES
2
• Turn starting switch ON. Is voltage between T01 (1) and NO Repair or
wiring harness between T01 (female)
• 20 – 30 V (2) normal? replace
(1) – fuse 12
Replace
(caution module)
3
• Turn starting switch ON. Is voltage between T01 (7) and NO Repair or
wiring harness between T01 (female)
(7) – fuse 1
wiring harness between T01 (female) Repair or
(2) – chassis ground replace
M-8 b) Related electrical circuit diagram
20-814 D575A-3 SD
TROUBLESHOOTING M-9
M-9 When starting switch is turned on, monitor panel lamps all stay
lighted up and do not go out
a) Caution module (Gauge/lamp unit) displays all stay lighted up and do not go out
Cause Remedy

Replace
(caution module)
b) Tachometer module (Tachometer/service meter unit) displays all stay lighted up and do not go out
Cause Remedy

Replace
(tachometer module)
D575A-3 SD 20-815
TROUBLESHOOTING M-10
M-10 When starting switch is turned on (engine stopped), check before

starting items flash
a) [Radiator water level] flashes

★ Check that the radiator water level is normal before starting troubleshooting.
Cause Remedy
1
• Connect short connector to
Does radiator water level caution NO
405 (female).
lamp go out? Check sensor
according to
YES STANDARD
Defective radiator water level sensor
system VALUE
TABLE,
then replace
2
NO Repair or
• Disconnect 405. (female) (2) and chassis ground wiring harness between 405 (female)
replace
• Max. 1 Ω normal? (2) and chassis ground
YES
3
• Turn starting switch OFF. Is resistance between CN1 Defective contact or disconnection in
NO Repair or
• Disconnect CN1. (female) (5) and chassis ground wiring harness between CN1 (female)
replace
• Max. 1 Ω normal? (5) – 405 (female) (2)
Replace
(caution module)
20-816 D575A-3 SD
b) [Engine oil level] flashes

★ Check that the engine oil level is normal before starting troubleshooting.
Cause Remedy
1
Does engine oil level caution NO
404 (female).
lamp go out? Check sensor
according to
YES STANDARD
Defective engine oil level sensor
system VALUE
TABLE,
then replace
2
NO Repair or
• Disconnect 404. (female) (2) and chassis ground wiring harness between 404 (female)
replace
• Max. 1 Ω normal? (2) – chassis ground
YES
3
NO wiring harness between CN1 (female) Replace
• Disconnect CN1.
Replace
(caution module)
D575A-3 SD 20-817
M-11 When starting switch is turned on (engine stopped), caution items

flash (but battery charge, engine oil pressure caution do not flash)
★ Check both the engine oil pressure system and alternator system.
a) Engine oil pressure sensor system
Cause Remedy
1 Check sensor
according to
Turn starting switch OFF. Is resistance between 403
NO STANDARD
Disconnect 403. (sensor side)and chassis ground Defective engine oil pressure sensor
VALUE
Min. 1 Ω normal?
TABLE, then
YES replace
2
Turn starting switch OFF. Is resistance between CN1 Defective contact or disconnection in
NO Repair or
Disconnect CN1. (female) (7) and chassis ground wiring harness between CN1 (female)
replace
Min. 1 Ω normal? (7) 403

Replace
(caution module)
20-818 D575A-3 SD
b) Alternator system
Cause Remedy
1
• Disconnect 174. Is voltage between 174
NO Replace
• Turn starting switch ON. (alternator) (1) and chassis Defective alternator
• Max. 1 V ground normal?
YES
2
• Disconnect CN1. Is voltage between CN1 (female) NO
• Turn starting switch ON. (4) and chassis ground normal?
• Max. 1 V
Replace
(caution module)
3
• Disconnect T01.
Is voltage between T01 (female) NO
• Max. 1 V
YES
Replace
(tachometer module)
4 Short circuit with power source in

• Disconnect CN1, 220. wiring harness between CN1 (female) Repair or
Is voltage between CN1 (female) NO (4) – T01 (female) (4) – ANR – 103
• Turn starting switch ON. replace
(4) and chassis ground normal? (female) (2) – 104 (female) (2) – 220
• Max. 1 V
(male) (2)
YES
Defective diode (220) Replace
D575A-3 SD 20-819
M-12 When starting switch is turned on (engine stopped), caution items

flash (but there is no abnormality in checks before starting items or
engine)
a) [Battery charge] flashes
Cause Remedy
1
• Disconnect 174.
Is voltage between 174
• Start engine. NO Replace
(alternator side) and chassis Defective alternator
• Run at half throttle or above.
ground normal?
• 20 – 30 V
YES
2
• Disconnect CN1.
• Start engine. Is voltage between CN1 (female) NO
• Run at half throttle or above. (4) and chassis ground normal?
• 20 – 30 V
Replace
(caution module)
3
• Disconnect CN1, T01. Defective contact or disconnection in
• Start engine. Is voltage between CN1 (female) NO Repair or
• Run at half throttle or above. (1) and chassis ground normal? replace
(4) – 174
• 20 – 30 V
YES
Replace
(tachometer module)
20-820 D575A-3 SD
b) [Engine oil pressure] flashes

★ Check that the engine oil pressure is normal before starting troubleshooting.
Cause Remedy
1
Disconnect 403. Does engine oil pressure caution NO
Start engine. lamp go out?
Check senso
according to
YES
STANDARD
Defective engine oil pressure sensor
VALUE
TABLE,
2 then replace
Turn starting switch OFF. Is resistance between CN1 Short circuit with chassis ground in
NO Repair or
Disconnect CN1, 403. (female) (7) and chassis ground wiring harness between CN1 (female)
replace
Min. 1 M Ω normal? (7) 403
YES
Replace
(caution module)
c) [Radiator water level] flashes
Cause Remedy
Go to M-10 a)
D575A-3 SD 20-821
TROUBLESHOOTING M12
d) [Engine water temperature] flashes

★ Check that the engine water temperature is normal before starting troubleshooting.
Cause Remedy
1
Is engine water temperature NO Defective monitor panel
• Start engine. Replace
gauge in level 7 range (Max.)? (caution module)
YES
2
• Disconnect LE32. Does engine water temperature NO
• Start engine. caution lamp go out?
YES
3
Does engine water temperature NO Defective monitor panel Repair or
402 (female).
caution lamp go out? (caution module) replace
• Start engine.
YES Check sensor
according to
Defective engine water temperature STANDARD
sensor VALUE
TABLE,
then replace
M-12 d) Related electrical circuit diagram
20-822 D575A-3 SD
e) [Power train (torque converter) oil temperature] flashes

★ Check that the power train (torque converter) oil temperature is normal before starting troubleshooting.
Cause Remedy
1
Is engine water temperature NO Defective monitor panel Replace
• Start engine.
gauge in level 7 range (Max.)? (caution module)
YES
2
Does power train oil temperature NO Defective monitor panel
453 (female). Replace
caution lamp go out? (caution module)
• Start engine.
YES Check sensor
according to
Defective power train oil temperature STANDARD
sensor VALUE
TABLE,
then replace
M-12 e) Related electrical circuit diagram
D575A-3 SD 20-823
f) [Hydraulic oil temperature] flashes

★ Check that the hydraulic oil temperature is normal before starting troubleshooting.
Cause Remedy
1
• Connect CN452 (female) (1)
to chassis ground. Does hydraulic oil temperature NO
• Start engine. caution lamp go out? Check sensor
YES according to
Defective hydraulic oil temperature STANDARD
sensor VALUE
TABLE,
then replace
2
NO Repair or
• Disconnect CN1. (female) (8) and chassis ground wiring harness between CN1 (female)
replace
YES
Replace
(caution module)
M-12 f) Related electrical circuit diagram
20-824 D575A-3 SD
g) [Air cleaner clogging] flashes

★ Check that the air cleaner is not clogged before starting troubleshooting.
Cause Remedy
1
• Disconnect 401, then
Does air cleaner clogging caution NO
connect wiring harness end.
lamp go out?
• Start engine. Check sensor
YES according to
Defective air cleaner clogging sensor STANDARD
VALUE
TABLE,
then replace
2
Is resistance between 401 (2) and NO Repair or
• Disconnect 401. wiring harness between 401 (2) –
• Max. 1 Ω chassis ground
YES
3
NO
• Disconnect CN1. (female) (9) and chassis ground wiring harness between CN1 (female) Replace
• Max. 1 Ω normal? (9) – 401 (1)
YES
Replace
(caution module)
M-12 g) Related electrical circuit diagram
D575A-3 SD 20-825
M-13 Abnormality in caution buzzer

★ Check that any service code is not displayed. (If any one is displayed, check according to it.)
★ The alarm buzzer sounds for all caution items except the battery charge.
★ Even if there is an abnormality in the battery charge, the alarm buzzer does not sound.
a) Caution item flashes but buzzer does not sound, or buzzer does not sound for 1 second after start-
ing switch is turned ON
★ Check that circuit breaker CB2 is normal before starting troubleshooting.
(If it is blown, check for short circuit with the ground in the wiring harness related to it.)
Cause Remedy
1
• Disconnect CN2, then
Does buzzer sound when CN2
connect (female) (8) to NO
chassis ground.
are connected?
Replace
(caution module)
2
• Disconnect BZR. Defective contact or disconnection in
Is voltage between BZR (2) and NO Repair or
• Turn starting switch ON. wiring harness between BZR (2) – fuse
• 20 – 30 V 10
YES
3
Is resistance between BZR (1) NO Repair or
• Disconnect BZR, CN2. wiring harness between CN2 (female)
and CN2 (female) (8) normal? replace
• Max. 1 Ω (8) and BZR (1)
YES
Defective caution buzzer Replace
b) No abnormality is displayed on monitor but buzzer sounds
Cause Remedy
1
• Disconnect CN2. Does buzzer stop when CN2 is NO
• Turn starting switch ON. disconnected?
YES
Replace
(caution module)
2
• Turn starting switch OFF. Is resistance between CN2 Short circuit with chassis ground in
NO wiring harness between BZR and Repair or
• Disconnect BZR, CN2. (female) (8) and chassis ground
replace
• Min. 1 M Ω normal? CN2 (female) (8)
YES
Defective caution buzzer Replace
20-826 D575A-3 SD
D575A-3 SD 20-827
M-14 Abnormality in caution lamp

★ Check that any service code is not displayed. (If any one is displayed, check according to it.)
a) Caution item flashes but caution lamp does not flash, or caution lamp does not light up for 2 sec-
onds after starting switch is turned ON
★ Check that circuit breaker CB2 is normal before starting troubleshooting.
(If it is blown, check for short circuit with the ground in the wiring harness related to it.)
Cause Remedy
1
• Disconnect CN2, then
Does caution lamp light up when
connect (female) (8) to NO
CN2 (female) (7) and chassis
chassis ground.
ground are connected?
(caution module) Replace
2
• Disconnect RMP. Defective contact or disconnection in
Is voltage between RMP (female) NO Repair or
• Turn starting switch ON. wiring harness between RMP (female)
• 20 – 30 V (1) – fuse 10
YES
3
• Turn starting switch OFF. Is resistance between RMP Defective contact or disconnection in
NO Repair or
• Disconnect RMP, CN2. (female) (2) and CN2 (female) (7) wiring harness between CN2 (female)
replace
• Max. 1 Ω normal? (7) and RMP (female) (2)
YES
Defective caution lamp Replace
b) No abnormality is displayed on monitor but caution lamp lights up
Cause Remedy
1
• Disconnect CN2. Does caution lamp go out when NO
• Turn starting switch ON. CN2 is disconnected?
Replace
YES
(caution module)
2
NO Repair or
• Disconnect RMP, CN2. (female) (7) and chassis ground wiring harness between RMP (female)
replace
• Min. 1 M Ω normal? (2) and CN2 (female) (7)
YES
Defective caution lamp Replace
20-828 D575A-3 SD
D575A-3 SD 20-829
M-15 Abnormality in engine water temperature gauge

★ Check that the engine water temperature is normal before starting troubleshooting. (If not check the
engine.)
a) Engine water temperature gauge shows abnormally low temperature
Cause Remedy
1
• Disconnect E32. Does gauge display become NO
• Turn starting switch ON. normal?
YES
2

NO
402. Does gauge display go out?
• Turn starting switch ON. Check sensor
according to
YES STANDARD
Defective engine water temperature
sensor VALUE
TABLE, then
replace
3
NO Repair or
• Disconnect CN1 and 402. (female) (2) and CN1 (female) (2) wiring harness between CN1 (female)
replace
YES
4
NO Repair or
• Disconnect 402, CN2. (female) (1) and CN2 (female) (1) wiring harness between CN2 (female)
replace
Replace
(caution module)
b) Engine water temperature gauge gives no display (gauge does not even display one level)
Cause Remedy
1
• Disconnect E32.
Does gauge display appear?
NO
YES
Defective engine controller
2
Replace
• Disconnect 402. NO
according to
YES Defective engine water temperature STANDARD
sensor VALUE
TABLE,
then replace
3 Short circuit with chassis ground in
• Turn starting switch OFF. Is resistance between CN2 wiring harness between CN2 (female)
NO Repair or
• Disconnect 402 and CN2. (female) (1) and chassis ground (1) – E32 (female) (5) – 402 (female) replace
YES
Replace
(caution module)
20-830 D575A-3 SD
D575A-3 SD 20-831
M-16 Abnormality in power train (torque converter) oil temperature gauge

★ Check that the power train (torque converter) oil temperature is normal before starting troubleshooting. (If
not check the power line.)
★ Before carrying out troubleshooting, check that all the related connectors are properly connected.
a) Power train oil temperature gauge shows abnormally low temperature
Cause Remedy
1
453. Does gauge display go out? NO
Check sensor
according to
YES STANDARD
Defective power train oil temperature
VALUE
sensor
TABLE,
then replace
2
• Turn starting switch OFF. Is resistance between 453 Defective contact or disconnection in Repair or
• Disconnect 453, CN1. NO wiring harness between CN1 (female)
(female) (2) and CN1 (female) (2) replace
YES
3 Defective contact, disconnection, or

• Turn starting switch OFF. Is resistance between 453 short circuit with power source in Repair or
NO
• Disconnect 453, CN2. (female) (1) and CN2 (female) (2) wiring harness between CN2 (female) replace
b) Power train (torque converter) oil temperature gauge gives no display (gauge does not even display
one level)
Cause Remedy
1
• Disconnect 453.
NO
according to
YES Defective power train oil temperature STANDARD
VALUE
sensor
TABLE, then
replace
2
NO Repair or
• Disconnect 453, CN2. (female) (2) and chassis ground wiring harness between CN2 (female)
replace
• Min. 1 M Ω normal? (2) – 453 (female) (1)
Replace
(caution module)
20-832 D575A-3 SD
D575A-3 SD 20-833
M-17 Abnormality in fuel level gauge

★ Check that there is ample fuel before starting troubleshooting.
★ Before carrying out troubleshooting, check that all the related connectors are properly connected.
a) Fuel level gauge always display FULL
Cause Remedy
1
• Disconnect 423.
Does gauge display go out?
NO
according to
YES STANDARD
Defective fuel level sensor VALUE
TABLE,
then replace
2
NO wiring harness between CN2 (female) Repair or
• Disconnect 423, CN2. (female) (3) and chassis ground
replace
• Min. 1 M Ω normal? (3) – 423 (female) (1)
YES
Defective monitor panel Replace
(caution module)
b) Fuel level gauge gives no display (gauge does not even display one level)
Cause Remedy
1
423. Does gauge display show FULL? NO
according to
YES STANDARD
Defective fuel level sensor VALUE
TABLE,
then replace
2
• Disconnect 423, CN1. NO wiring harness between CN1 (female)
Repair or
(female) (2) and CN1 (female) (2)
• Max. 1 Ω replace
normal? (2) – 423 (female) (2)
YES
3 Defective contact, disconnection, or

• Turn starting switch OFF. Is resistance between 423 short circuit with power source in
NO Repair or
• Disconnect 423, CN2. (female) (1) and CN2 (female) (3) wiring harness between CN2 (female) replace
YES
Replace
(caution module)
20-834 D575A-3 SD
D575A-3 SD 20-835
TROUBLESHOOTING M18, M-19
M-18 Speed range display shows “– –”, engine speed is not displayed
Cause Remedy
Abnormality in network system Go to N-3
M-19 Service meter does not advance when engine is running

Cause Remedy
1
Is sand timer mark dsplayed on NO Go to M-12 a) —
• Start engine.
service meter module?
YES
Replace
(tachometer module)
20-836 D575A-3 SD
M-20 Abnormality in service mode

a) Does not switch to service mode even when service switch is operated
Cause Remedy
1
Is resistance between T01
• Disconnect T01.
NO
• Turn service switch ON.
normal?
• Max. 1 Ω
2
Is resistance between SMW (1) NO
• Turn service switch ON. Defective service switch Replace
and SMW (3) normal?
• Max. 1 Ω
YES
3
Is resistance between SMW (3) NO Repair or
• Turn service switch ON. wiring harness between SMW (3) and
and T01 (female) (5) normal? replace
• Max. 1 Ω T01 (female) (5)
Repair or
wiring harness between SMW (1) –
replace
chassis ground
b) Stays in service mode
Cause Remedy
1
Is resistance between T01
• Disconnect T01. NO
• Turn service switch OFF.
normal?
• Min. 1 M Ω
Replace
(caution module)
2
Is resistance between SMW (1) NO Defective service switch Replace
• Turn service switch ON.
• Min. 1 M Ω and SMW (3) normal?
Repair or
wiring harness between SMW (female)
replace
(3) and T01 (female) (5)
D575A-3 SD 20-837
20-838 D575A-3 SD
M-21 Night lighting on monitor panel does not light up (front lamp, work-
ing lamp are normal)
★ Check the lamps visually to confirm that there is no disconnection before starting troubleshooting. (If any
lamp is broken, replace it.)
★ Check that fuse 10 is normal. (If it is broken, check the circuit related to it for short circuit with chassis
ground.)
a) Tachometer module lamp does not light up
Cause Remedy
• Disconnect TO1. 1
• Turn starting switch ON. Is voltage between TO1 (6) and NO
• Turn on head lamp and rear
lamp switches. chassis ground normal?
• 20 – 30 V YES
2
• Disconnect TO1.
Is resistance between TO1 (2) NO Disconnection in wiring harness Repair or
and chassis ground normal? between TO1 (2) – GND003 replace
• Max. 1 Ω
YES
Defective tachometer module Replace
• Disconnect M11. 3
• Turn starting switch ON. Is voltage between M11 (female) NO Repair or
between RPS6 – M11 (1) or between
(1) and chassis ground normal? FPS6 – M11 (1) or defective diode G1 replace
lamp switches.
or G1
• 20 – 30 V YES
between M11 (1) – TO1 (6) replace
b) Caution module lamp does not light up
Cause Remedy
• Disconnect CN4. 1
• Turn starting switch ON. Is voltage between CN4 (1) and NO
lamp switches. chassis ground normal?
• 20 – 30 V YES
2
• Disconnect CN4.
Is resistance between CN4 (2) NO Disconnection in wiring harness Repair or
and chassis ground normal? between CN4 (2) – GND003 replace
• Max. 1 Ω
YES
Defective caution module Replace
lamp switches.
or G1
• 20 – 30 V YES
D575A-3 SD 20-839
c) Switch module lamp does not light up
Cause Remedy
• Disconnect SO1, SO2. 1

• Turn starting switch ON. Is voltage between SO1 (10), NO
• Turn on head lamp and rear SO2 (1) and chassis ground
lamp switches. normal?
• 20 – 30 V YES
2
• Disconnect SO1, SO2. Is resistance between SO1 (2),
• Turn starting switch OFF. SO2 (2) and chassis ground
between SO1 (2), SO1 (1) – GND003 replace
• Max. 1 Ω normal?
YES
Defective switch module Replace
lamp switches.
or G1
• 20 – 30 V YES
20-840 D575A-3 SD
M-22 L.H. front lamp do not light up

★ Check that all bulbs are normal. (If any one is broken, replace it.)
★ Check that fuse breaker CB8 are normal. (If breaker is broken, check the circuit related to it for short circuit
with chassis ground.)
a) Any one of front lamps and working lamps does not light up
Cause Remedy
1
• Disconnect M30. Is resistance between M30 (male) NO
Defective head lamp switch Replace
• Turn head lamp switch ON. (F) and (E) (D) normal?
• Max. 1 Ω
YES
2
• Turn starting switch ON. Is voltage between M30 (E) (D) NO Repair or
wiring harness between breaker CB8 –
• 20 – 30 V and chassis ground normal? replace
M30 (female) (F)
YES
3
• Turn starting switch ON. Defective contact or disconnection in
• Turn head lamp switch ON. wiring harness between M30 (female)
• 20 – 30 V (3) – 221 (female) (1), 222 (female) (1)
YES
Breakage of bulb Replace
D575A-3 SD 20-841
M-23 R.H. front lamp do not light up

★ Check that breaker CB9 are normal. (If breaker is broken, check the circuit related to it for short circuit with
chassis ground.)
Cause Remedy
1
Defective head lamp switch Replace
• Turn head lamp switch ON. (A) and (B) (C) normal?
• Max. 1 Ω
YES
2
• Turn starting switch ON. Is voltage between M30 (B) (C) NO Repair or
wiring harness between breaker CB9 –
M30 (female) (F)
YES
3
• Turn head lamp switch ON. wiring harness between M30 (female)
• 20 – 30 V (3) – 223 (female) (1), 224 (female) (1)
YES
20-842 D575A-3 SD
M-24 L.H. working lamps do not light up

★ Check that fuse FB8 are normal. (If fuse is broken, check the circuit related to it for short circuit with chassis
ground.)
Cause Remedy
1
Disconnect M30. Is resistance between M30 (male) NO
Defective rear lamp switch Replace
Turn rear lamp switch ON. (F) and (K) normal?
Max. 1 Ω
YES
2
Turn starting switch ON. Is voltage between M30 (K) and NO Repair or
wiring harness between fuse FB8
M30 (female) (N)
YES
3
Turn starting switch ON. Defective contact or disconnection in
Is voltage between 222 (1) and NO Repair or
Turn rear lamp switch ON. wiring harness between M30 (female)
20 30 V (3) 222 (female) (1)
YES
D575A-3 SD 20-843
M-25 R.H. working lamps do not light up

★ Check that fuse FB7 are normal. (If fuse is broken, check the circuit related to it for short circuit with chassis
ground.)
Cause Remedy
1
Defective rear lamp switch Replace
• Turn rear lamp switch ON. (G) and (H) (J) normal?
• Max. 1 Ω
YES
2
• Turn starting switch ON. Is voltage between M30 (H) (J) NO Repair or
wiring harness between fuse FB7 –
M30 (female) (G)
YES
3
• Turn rear lamp switch ON. wiring harness between M30 (female)
• 20 – 30 V (3) – 242 (female) (1), 243 (female) (1)
YES
20-844 D575A-3 SD
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL ....................... 30- 3 PTO, TORQUE CONVERTER

PRECAUTIONS WHEN CARRYING Removal ......................................................30- 54
OUT OPERATION........................................... 30- 4 Installation ...................................................30- 56
SPECIAL TOOL LIST....................................... 30- 7 Disconnection ..............................................30- 57
ENGINE OIL COOLER Connection ..................................................30- 58
Removal........................................................ 30-20 PTO
Installation..................................................... 30-21 Disassembly ................................................30- 59
FUEL INJECTION PUMP Assembly .....................................................30- 62
Removal........................................................ 30-21 TORQUE CONVERTER
Installation..................................................... 30-23 Disassembly ................................................30- 66
AFTER-COOLER CORE Assembly .....................................................30- 70
Removal and Installation............................... 30-24 TORQFLOW TRANSMISSION
NOZZLE HOLDER Removal ......................................................30- 75
Removal and Installation............................... 30-25 Installation ...................................................30- 76
CYLINDER HEAD Disassembly ................................................30- 77
Removal........................................................ 30-26 Assembly .....................................................30- 84
Installation..................................................... 30-28 STEERING CASE
HYDRAULIC COOLER Removal ......................................................30- 94
Removal and Installation............................... 30-30 Installation ...................................................30- 95
RADIATOR Disassembly ................................................30- 96
Removal........................................................ 30-31 Assembly .....................................................30-100
Installation..................................................... 30-33 STEERING CLUTCH
FAN DRIVE SUPPORT Disassembly ................................................30-109
Removal........................................................ 30-34 Assembly ..................................................... 30-110
Installation..................................................... 30-36 STEERING BRAKE
FAN DRIVE PULLEY (FAN END) Disassembly ................................................ 30-111
Removal and Installation............................... 30-37 Assembly ..................................................... 30-113
Disassembly.................................................. 30-37 TORQUE CONVERTER VALVE
Assembly ...................................................... 30-38 Removal ...................................................... 30-118
FAN DRIVE PULLEY (ENGINE END) Installation ................................................... 30-119
Removal........................................................ 30-40 Disassembly ................................................30-120
Installation..................................................... 30-41 Assembly .....................................................30-122
Disassembly.................................................. 30-41 TRANSMISSION CONTROL VALVE
Assembly ...................................................... 30-42 Removal and Installation .............................30-124
DAMPER Disassembly ................................................30-125
Removal........................................................ 30-43 Assembly .....................................................30-126
Installation..................................................... 30-45 POWER TRAIN PUMP
Disassembly.................................................. 30-45 Removal and Installation .............................30-127
Assembly ...................................................... 30-46 TRANSMISSION LUBRICATION PUMP
POWER TRAIN Removal and Installation .............................30-127
Removal........................................................ 30-48 SCAVENGING PUMP
Installation..................................................... 30-52 Removal and Installation .............................30-128
D575A-3 SD 30-1
!
FINAL DRIVE WORK EQUIPMENT ASSIST, CONTROL
Removal...................................................... 30-128 PUMP
Installation................................................... 30-129 Removal and Installation .............................30-209
Disassembly................................................ 30-130 BLADE VALVE
Assembly .................................................... 30-135 Removal and Installation .............................30-210
TRACK FRAME Disassembly ................................................30-212
Removal...................................................... 30-145 Assembly ..................................................... 30-214
Installation................................................... 30-147 MAIN RELIEF VALVE
RECOIL SPRING, TUBE Disassembly and Assembly.........................30-216
Removal and Installation............................. 30-148 BLADE LIFT CYLINDER
Disassembly................................................ 30-149 Removal and Installation .............................30-217
Assembly .................................................... 30-153 BLADE PITCH CYLINDER
IDLER YOKE CYLINDER Removal and Installation .............................30-218
Disassembly................................................ 30-156 HYDRAULIC CYLINDER
Assembly .................................................... 30-157 Disassembly ................................................30-219
IDLER Assembly ..................................................... 30-221
Disassembly................................................ 30-158 BLADE PPC VALVE
Assembly .................................................... 30-159 Removal ..................................................... 30-223
TRACK ROLLER Installation ...................................................30-224
Removal...................................................... 30-161 Disassembly ................................................30-224
Installation................................................... 30-162 Assembly ..................................................... 30-225
Disassembly................................................ 30-163 BLADE
Assembly .................................................... 30-164 Removal ......................................................30-226
BOGIE Installation ...................................................30-227
Removal...................................................... 30-166 Disassembly ................................................30-228
Installation................................................... 30-167 Assembly ..................................................... 30-229
Disassembly................................................ 30-167 POTENTIOMETER
Assembly .................................................... 30-169 Removal ..................................................... 30-231
TRACK SHOE Installation ...................................................30-232
Checking before removal ............................ 30-172 OPERATOR’S COMPARTMENT FRAME
Removal...................................................... 30-172 Removal ......................................................30-232
Removal (when there is abnormality Installation ...................................................30-234
inside track frame) .................................... 30-174 CAB
Installation................................................... 30-176 Removal ......................................................30-235
Disassembly................................................ 30-177 Installation ...................................................30-236
Assembly .................................................... 30-181 ROPS
PRESS-FITTING JIG DIMENSION Removal ......................................................30-236
TABLE FOR LINK PRESS ............................. 30-195 Installation ...................................................30-237
FIELD DISASSEMBLY OF ONE LINK COUNTERWEIGHT FRAME
Disassembly................................................ 30-196 Removal and Installation .............................30-237
Assembly .................................................... 30-197 BLADE CYLINDER SUPPORT
MASTER LINK Removal ......................................................30-238
Disassembly................................................ 30-199 Installation ...................................................30-239
Assembly .................................................... 30-200
ADJUSTING TRACK SHOE TENSION ......... 30-202
PIVOT SHAFT
Removal and Installation............................. 30-203
EQUALIZER BAR
Removal...................................................... 30-204
Installation................................................... 30-205
SEGMENT TEETH
WORK EQUIPMEMT PUMP
30-2 D575A-3 SD
!
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
METHOD OF USING MANUAL

1. When removing or installing unit assemblies
When removing or installing a unit assembly, the order of work and techniques used are given for the
removal operation; the order of work for the installation operation is not given.
Any special techniques applying only to the installation procedure are marked , and the same
mark is placed after the relevant step in the removal procedure to indicate which step in the installation
procedure it applies to.
(Example)
REMOVAL OF ASSEMBLY...............Title of operation
.....................................................................Precautions related to safety when carrying out the
operation
1. X X X X (1).....................................................Step in operation
★..................................................................Technique or important point to remember when remov-
ing XXXX (1).
2. (2): ................................................ .......Indicates that a technique is listed for use
during installation
3. assembly (3)
.............................................................Quantity of oil or water drained
INSTALLATION OF ASSEMBLY .......Title of operation

• Carry out installation in the reverse order to removal.
..........................................................Technique used during installation
★ .................................................................Technique or important point to remember when install-
ing (2).
• Adding water, oil ........................................Step in operation
★ ................................................................Point to remember when adding water or oil
............................................................Quantity when filling with oil and water
2. General precautions when carrying out installation or removal (disassembly or assembly) of units are given
together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow these precautions
when carrying out the operation.
3. Listing of special tools

For details of the description, part number, and quantity of any tools (A1, etc.) that appear in the opera-
tion procedure, see the SPECIAL TOOLS LIST given in this manual.
D575A-3 SD 30-3
!
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general pre-
cautions given below when carrying out the operation.]
1. Precautions when carrying out removal work
• If the coolant contains antifreeze, dispose of it correctly.
• After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
• When draining oil, prepare a container of adequate size to catch the oil.
• Confirm the match marks showing the installation position, and make match marks in the necessary places
before removal to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when discon-
necting the connectors. Do not pull the wires.
• Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
• Check the number 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 enter-
ing after removal.
★ Precautions when handling piping during disassembly
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
Nominal number Plug (nut end) Sleeve nut (elbow end) Use the two items below as a set
02 07376-50210 07221-20210 (Nut), 07222-00210 (Plug)
03 07376-50315 07221-20315 (Nut), 07222-00312 (Plug)
04 07376-50422 07221-20422 (Nut), 07222-00414 (Plug)
05 07376-50522 07221-20522 (Nut), 07222-00515 (Plug)
06 07376-50628 07221-20628 (Nut), 07222-00616 (Plug)
10 07376-51034 07221-21034 (Nut), 07222-01018 (Plug)
12 07376-51234 07221-21234 (Nut), 07222-01219 (Plug)
1) Hoses and tubes using sleeve nuts

Nominal number Flange (hose end) Sleeve head (tube end) Split flange
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
2) Split flange type hoses and tubes

3) If the part is not under hydraulic pressure, the following corks can be used.
Dimensions (mm)
Nominal number Part Number
D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
30-4 D575A-3 SD
!
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING
2. Precautions when carrying out installation work

• Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
• Install the hoses without twisting or interference.
• Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pins and lock plates securely.
• When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion
with 2 – 3 drops of adhesive.
• When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no
dirt or damage, then coat uniformly with gasket sealant.
• Clean all parts, and correct any damage, dents, burrs, or rust.
• Coat rotating parts and sliding parts with engine oil.
• When press fitting parts, coat the surface with anti-friction compound (LM-P).
• After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
• When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
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 idling.
2. Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the cyl-
inder 100 mm from the end of its stroke.
3. Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4. After doing this, run the engine at normal speed.
★ When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation

• If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine
to circulate the water through the system. Then check the water level again.
• If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run
the engine to circulate the oil through the system. Then check the oil level again.
• If the hydraulic equipment has been removed for repair, always bleed the air from the system after reassem-
bling the parts.
★ For details, see TESTING AND ADJUSTING, Bleeding air.
• Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
D575A-3 SD 30-5
!
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST

Nature of work Symbol Part No. Part Name Q’ty Remarks
790-401-1200 Lifting tool 1
1 —
Removal, installation of A 790-401-1210 Shackle 2
engine assembly
Centering of engine and
2 791-820-1020 Centering tool 2
power train
790-101-5201 Push tool kit (B) 1
• 790-101-5241 • Plate 1
1 Press fitting of oil seal
• 790-101-5221 • Grip 1
• 01010-51225 • Bolt 1
790-101-5401 Push tool kit (C) 1
• 790-101-5471 • Plate 1
• 790-101-5421 • Grip 1
• 01010-51240 • Bolt 1
Disassembly, assembly of
fan drive pulley assembly AA 790-101-5201 Push tool kit (C) 1
(fan end)
• 790-101-5261 • Plate 1
3 Press fitting of bearing
• 790-101-5221 • Grip 1
• 01010-51225 • Bolt 1
790-101-5401 Push tool kit (C) 1
• 790-101-5441 • Plate 1
4 Press fitting of bearing
• 790-101-5421 • Grip 1
• 01010-51240 • Bolt 1
5 791-803-1110 Plate 1 Press fitting of shaft
790-101-5401 Push tool kit (C) 1
• 790-101-5491 • Plate 1
• 790-101-5421 • Grip 1
• 01010-51240 • Bolt 1
790-101-5401 Push tool kit (C) 1
• 790-101-5471 • Plate 1
2 Press fitting of pulley
bearing
• 790-101-5421 • Grip 1
fan drive pulley assembly AB • 01010-51240 • Bolt 1
(engine end)
796-426-1120 Push tool 1
790-441-1820 Adapter 1
791-775-1140 Screw 1
3 01580-03024 Bolt 1 Press fitting of shaft
01643-33080 Washer 1
790-101-4000 Puller (490KN (50 ton)) 1
790-101-1102 Pump 1
D575A-3 SD 30-7
!

791-812-1100 Installer 1
• 790-101-2460 • Adapter 1
• 790-101-2520 • Screw 1
• 790-201-2860 • Spacer 1
Removal, installation of Press fitting of damper
damper assembly AC • 790-201-2250 • Plate 1 bearing
• 790-101-2540 • Washer 1
• 790-112-1180 • Nut 1
790-101-4200 Puller (294KN (30 ton)) 1
790-101-1102 Pump 1
790-501-2001 Engine repair stand 1
torque converter assembly B 790-901-5110 Bracket 1 —
790-901-3030 Plate 1
Assembly of PTO assembly C • 791-813-1121 Pin 1 Press fitting of idler gear
• 790-101-2300 Push-puller 1
• 790-101-2310 • Block 1
• 790-101-2360 • Plate 1
• 02215-11622 • Nut 2 Removal of input shaft
1 bearing
• 790-438-1110 • Screw 2
Disassembly, assembly of 790-101-2450 Adapter 2

fan transmission assembly D
791-101-2102 Puller (294KN (30 ton) 1
790-101-1102 Pump 1
Removal, installation of
2 791-815-1010 Push tool 1 snap ring
3 790-201-2860 Spacer 1 Press fitting of bearing
Checking of clutch
4 799-301-1600 Oil leak tester 1 actuation pressure
Removal, installation of final E 791-827-1130 Lifting tool 1 —
drive assembly
791-827-1140 Shackle 1
791-827-1700 Remover 1
• 791-827-1310 • Block 1
• 791-827-1720 • Plate 1
Disassembly, assembly of • 791-520-4140 • Screw 1 Removal of hub

final drive assembly F 1
• 791-775-1140 • Screw 2
• 791-775-1150 • Adapter 2
• 01803-13034 • Nut 2
• 01644-13009 • Washer 2
30-8 D575A-3 SD
!

• 04530-11222 • Eyebolt 2
• 01010-52075 • Bolt 4
1 • 01643-32060 • Washer 4 Removal of hub
790-101-2102 Puller (294KN (30 ton)) 1
790-101-1102 Pump 1
2 791-827-1151 Installer 1 Installation of floating

seal
Installation of floating
3 791-827-1180 Installer 1 seal
791-827-1600 Push tool 1
• 791-827-1610 • Plate 1
• 791-827-1620 • Sleeve 1
• 790-434-1060 • Screw 1
Press fitting of hub
4 • 01010-51255 • Bolt 6 bearing
• 01580-03024 • Nut 1
• 01634-33080 • Washer 1
790-101-4000 Puller (490KN (50 ton)) 1
790-101-1102 Pump 1
Disassembly, assembly of 791-827-1800 Installer 1

final drive assembly F
• 791-827-1720 • Plate 1
• 791-827-1810 • Pusher 1
• 791-520-4140 • Screw 1
• 791-112-1180 • Nut 1
Press fitting of hub
5 • 01644-12408 • Washer 1 bearing inner race
• 04530-11222 • Eyebolt 4
• 01010-52075 • Bolt 4
• 01643-32060 • Washer 4
790-101-4000 Puller (490KN (30 ton) 1
790-101-1102 Pump 1
791-827-1300 Installer 1
• 791-827-1310 • Block 1
• 791-827-1320 • Plate 1
• 791-650-1240 • Spacer 1 Press fitting of hub
6 bearing outer race
• 792-900-1530 • Screw 1
• 205-46-62160 • Bolt 1
• 01582-03024 • Nut 4
• 01643-33080 • Washer 4
D575A-3 SD 30-9
!

790-101-4000 Puller (490KN (50 ton)) 1 Press fitting of hub
6 bearing outer race
790-101-1102 Pump 1
791-827-1400 Remover 1
• 791-827-1410 • Sleeve 1
• 790-434-1040 • Adapter 1
• 790-434-1060 • Screw 1
7 Removal of carrier pin
• 01580-03024 • Nut 1
• 01643-33080 • Washer 1
790-101-4000 Puller (490KN (50 ton)) 1
790-101-1102 Pump 1
790-827-1500 Installer 1
• 791-827-1510 • Sleeve 1
• 791-827-1520 • Adapter 1
• 790-434-1060 • Screw 1
8 • 01010-52055 • Bolt 2 Press fitting of carrier pin
• 01580-03024 • Nut 1
• 01643-33080 • Washer 1
final drive assembly F 790-101-4000 Puller (490KN (50 ton)) 1
790-101-1102 Pump 1
791-822-1200 Remover & Installer 1
• 791-822-1210 • Adapter 1
• 791-822-1220 • Plate 1
• 791-822-1230 • Plate 1
• 790-101-2510 • Block 2
• 790-101-2520 • Screw 1
• 790-101-2540 • Washer 1
• 790-101-2560 • Nut 4 Removal press fitting of
6 No.1 pinion, gear
• 790-101-2570 • Washer 2
• 790-101-2620 • Leg 2
• 790-101-2630 • Leg 2
• 790-101-2730 • Adapter 4
• 791-112-1180 • Nut 1
• 01252-31650 • Bolt 4
• 01252-31235 • Bolt 8
• 01643-32060 • Washe 2
30-10 D575A-3 SD
!
Disassembly, assembly of 790-101-3800 Puller (490KN (50 ton)) 1 Removal, press fitting of
final drive assembly F 9 No. 1 pinion, gear
790-101-1102 Pump 1
791-822-1200 Remover and Installer 1
• 791-822-1210 • Adapter 1
• 791-822-1220 • Plate 1
• 791-822-1230 • Plate 1
• 790-101-2510 • Block 2
• 790-101-2520 • Screw 1
• 790-101-2540 • Washer 1
• 790-101-2560 • Nut 4
• 790-101-2570 • Washer 2 Removal, press fitting of
1
• 790-101-2620 • Leg 2 output shaft bearing
• 790-101-2630 • Leg 2
• 790-101-2730 • Adapter 4
• 791-112-1180 • Nut 1
• 01252-31650 • Bolt 4
• 01252-31235 • Bolt 8
• 01643-32060 • Washer 2
Disassembly, assembly of 790-101-3800 Puller (490KN (50 ton)) 1
steeing clutch, G
brake assembly 790-101-1102 Pump 1
791-822-1700 Push tool 1
• 791-822-1210 • Adapter 1
• 790-201-2870 • Spacer 1
• 792-900-1520 • Plate 1
• 790-101-2520 • Screw 1 Press fitting of brake
2 shaft bearing inner race
• 790-101-2540 • Washer 1
• 791-112-1180 • Nut 1
• 01252-31650 • Bolt 4
• 790-101-2102 Puller (294KN (30 ton)) 1
• 790-101-1102 Pump 1
791-822-1010 Lifting tool 1 Removal of brake
3 assembly
01010-52070 Bolt 2
Removal, Installation of
4 791-822-1020 Wrench 1 round nut for holding
brake shaft
791-822-1400 Lifting tool 1 Removal of clutch
5 assembly
• 791-822-1410 • Lifting tool 1
D575A-3 SD 30-11
!

• 791-822-1420 • Adapter 1
5 • 01010-51680 • Bolt 2 Removal of clutch
assembly
• 01306-11025 • Set screw 1
791-822-1300 Removal & Installer 1
• 791-822-1310 • Adapter 2
• 791-822-1320 • Push tool 1
• 791-822-1210 • Adapter 1
• 790-101-2620 • Leg 2
• 790-101-2310 • Block 1
• 790-101-2360 • Plate 2
6 • 790-101-2560 • Nut 2 Removal, press fitting of
clutch assembly flange
• 01643-32060 • Washer 2
• 790-101-2520 • Screw 1
• 791-112-1180 • Nut 1
• 01643-33080 • Washer 1
• 01252-31650 • Bolt 4
Disassembly, assembly of 790-101-3800 Puller (294KN (30 ton)) 1

steeing clutch, brake
assembly 790-101-1102 Pump 1
G
7 Removal of center shaft
01010-51640 Bolt 4
791-822-1600 Cage assembly 1
• 791-822-1520 • Plate 1
• 791-822-1530 • Bracket 3
• 791-822-1540 • Bracket 3
8 Assembly of clutch disc
• 01010-31235 • Bolt 6
• 01643-11232 • Washer 6
• 04020-00820 • Pin 3
• 04530-00815 • Eyebolt 3
791-822-1500 Cage assembly 1
• 791-822-1510 • Plate 1
• 791-822-1530 • Bracket 3
9 • 791-822-1540 • Bracket 3 Assmbly of brake disc
• 01010-31235 • Bolt 6
• 01643-11232 • Washer 6
• 04020-00820 • Pin 3
30-12 D575A-3 SD
!

9 • 04530-00815 • Eyebolt 2 Assembly of brake disc
01017-51220 Bolt 4
10 01580-11210 Nut 4 Releasing brake
01643-31232 Washer 4
790-201-2870 Spacer 1 Press fitting of center
11
790-201-2670 Plate 1 shaft bearing inner race
steeing clutch, brake 790-201-2440 Plate 1
assembly G 12 Press fitting of outer race
790-201-2690 Plate 1
791-822-1250 Spacer 1 Press fitting of bevel
13
790-201-2690 Plate 1 pinion bearing inner race
791-822-1240 Plate 1
Press fitting of bevel
14 790-201-2480 Plate 1 pinion cage, bearing outer
race
790-201-2690 Plate 1
1 790-401-1200 Lifting tool 1 engine assembly
791-822-1100 Centering tool 1
• 791-822-1110 • Cover 1
• 791-822-1120 • Sleeve 1
• 791-822-1130 • Sleeve 1
Removal, Installetion of
power train assembly H • 791-822-1150 • Ring 1 Centering of final drive
2 and steering joint
• 791-822-1160 • Plate 1
• 791-503-1060 • Gauge 1
• 791-503-1190 • Magnet stand 1
• 01010-50814 • Bolt 5
• 01010-51220 • Bolt 8
791-685-8501 Compressor (B) 1
791-635-3160 Extension 1
791-830-1281 Guide 1
01252-31255 Bolt 2 Disassembly, assembly
3 of recoil spring
791-830-1290 Spacer 1
recoil spring, tube assembly 1 791-830-1340 Spacer 1
790-101-1600 Cylinder (686KN (70 ton)) 1
790-101-1102 Pump 1
791-830-1221 Push tool 1
Press fitting of coil bush-
2 790-101-5421 Grip 1 ing
01010-51240 Bolt 1
D575A-3 SD 30-13
!

791-830-1231 Push tool 1
Disassembly, assembly of I 3 790-101-5421 Grip 1 Assembly of dust seal
recoil spring, tube assembly
01010-51240 Bolt 1
791-830-1201 Push tool 1
• 791-822-1270 • Screw 1
• 790-210-2880 • Spacer 1
Disassembly, assembly of 1 • 01580-04536 • Nut 1 Press fitting of idler yoke

idler yoke J
• 01643-34512 • Washer 1
790-101-4100 Puller (980KN (100 ton)) 1
790-101-1102 Pump 1
2 791-830-1261 Spacer 1 Removal of idler yoke
791-850-1100 Remover & Installer 1
• 791-850-1110 • Bracket 1
• 791-850-1120 • Plate 1
• 790-438-1110 • Screw 1
• 791-112-1180 • Nut 2
1 • 790-101-3300 • Bearing puller 1 Removal, press fitting of
center pin bushing
• 790-101-2510 • Block 1
• 01643-32780 • Washer 1
• 04530-01018 • Eyebolt 2
790-101-4000 Puller (490KN (50 ton)) 1
790-101-1102 Pump 1
Replacement of equalizer 791-850-1200 Remover 1

K
bar • 791-850-1130 • Sleeve 1
• 791-850-1140 • Sleeve 1
• 792-900-1530 • Screw 1
Removal of side pin
2 • 791-650-1240 • Spacer 2 spherical bushing
• 01582-13024 • Nut 2
• 01643-33080 • Washer 2
790-101-4000 Puller (490KN (50 ton)) 1
790-101-1102 Pump 1
791-850-1300 Installer 1
• 791-850-1310 • Plate 1 Press fitting of side pin
3 spherical bushing
• 791-850-1140 • Sleeve 1
• 791-775-1140 • Screw 1
30-14 D575A-3 SD
!

• 791-650-1240 • Spacer 2
• 01582-13024 • Nut 2
Replacement of equalizer Press fitting of side pin
bar K 3 • 01643-33080 • Washer 2 spherical bushing
790-101-4000 Puller (490KN (50 ton)) 1
790-101-1102 Pump 1
791-831-1100 Installer 1
• 791-831-1120 • Plate 1
• 791-831-1130 • Shaft 2
• 791-831-1140 • Plate 1
• 791-831-1150 • Plate 1
• 791-831-1160 • Pin 1
• 791-831-1170 • Shaft 3
• 791-850-1180 • Plate 1
• 791-850-1190 • Plate 1
Removal, installation of Presss fitting of shaft
pivot shaft assembly L • 791-831-1240 • Plate 1 seal assembly
• 790-101-2520 • Screw 1
• 790-101-2540 • Washer 1
• 791-112-1180 • Nut 1
• 01010-30820 • Bolt 3
• 01010-30816 • Bolt 6
• 01580-01613 • Nut 3
• 04530-01222 • Eyebolt 2
790-101-4200 Puller (294KN (30 ton)) 1
790-101-1102 Pump 1
1 Raising support
01010-32450 Bolt 4
blade lift support assembly M 791-861-1170 Bracket 2
2 791-661-180 Bolt 2 Installation of support
01580-03629 Nut 2
790-830-1100 Push tool 1
• 791-830-1110 • Plate 1
• 791-830-1120 • Plate 1
Assembly of bogie N 1 Press fitting of bushing
• 790-434-1050 • Screw 1
• 01644-12408 • Washer 1
• 01580-12419 • Nut 1
D575A-3 SD 30-15
!

790-101-2102 Puller (294KN (30 ton)) 1
1 Press fitting of bushing
790-101-1102 Pump 1
Assembly of bogie N 2 791-830-1150 Shaft 1 Assembly of bogie
Installation of floating
3 791-830-1140 Installer 1 seal

seal
791-830-1300 Push tool 1
• 791-830-1310 Plate 1
• 791-830-1320 Rod 2
Disassembly, assembly of O • 790-101-2510 Block 1
idle assembly
2 • 790-101-2570 Washer 2 Presss fitting of bushing
• 01580-01613 Nut 2
• 01643-31645 Washer 2
790-101-2102 Puller (294KN (30 ton)) 1
790-101-1102 Pump 1
791-830-1250 Push tool 1
1 Removal of bushing
Disassembly, assembly of 790-201-2680 Plate 1
track roller assembly P 2 791-830-1240 Plate 1 Press fitting of bushing

seal
1 790-411-1010 Wrench 1 round nut
carrier roller assembly Q
seal
1 790-502-1003 Cylinder repair stand 1 —
2 790-720-1000 Expander 1 —
Disassembly, assembly of 796-720-1730 Ring 1
hydraulic cylinder assembly R For blade Com-
07281-03209 Cramp 1 pitch cylinder pres-
3 sion of
796-720-1720 Ring 1 For blade lift piston
cylinder ring
07281-02429 Cramp 1
Disassembly, assembly of S 791-872-1110 Stand 2 —
blade assembly
Removal, installation of track
flame assembly T 790-827-1120 Lifting tool 1 —

790-401-1761 Adapter 1
Removal, installation of track U 790-401-1540 Shackle 2 —
roller assembly
790-401-1740 Bar 1
790-401-1750 T-bolt 2
30-16 D575A-3 SD
!

Removal of pin plug of oil X 791-646-7531 Remover 1 —
sealed track link
Cleanling f pin oil sealed
track link Y 791-660-7460 Brush 1 For cleaning pin
791-646-7900 Push tool 1 For large plug

Z 790-434-1220 Bar 1 For large plug
Installetion of pin plug of oil 790-434-1210 Guide 1 For large plug

sealed track link 791-932-1110 Push tool 1 For small plug
KA 791-646-7523 Bar 1 For small plug
791-646-7590 Guide 1 For small plug
Installetion of seal of oil KB 791-832-1110 Push tool 1 For F3 type seal
sealed track link
Checking air tightness of oil KC 790-701-3000 Checker 1 —
sealed track link
Filling oil seald track link with
oil KD 791-646-8002 Lubricator 1 —
791-832-1250 Bracket 1 —
1 791-832-1260 Plate 1 —
01010-52050 Bolt 2 —
791-832-1210 Frame 1 —
2 04530-11628 Eyebolt 1 —
791-832-1280 Adapter 1 —
791-832-1270 Bracket 1 —
3
01010-51495 Bolt 1 —
790-101-4500 Cylinder 1 1,960KN (200 ton)
4
790-101-1102 Pump 1 —
791-832-1220 Plate 1 —
Field disassembly of one link KE 791-832-1230 Shaft 2 —
5 791-832-1240 Nut 2 —
04530-11628 Eyebolt 1 —
791-832-1310 Adapter 1 —
791-832-1320 Guide 1 —
791-832-1340 Extension 2 —
791-832-1350 Pusher 1 —
6
791-832-1360 Pusher 1 —
01320-41030 Screw 5 —
791-832-1370 Pusher 1 —
790-101-2102 Puller 1 294KN (30 ton) (long)
7
790-101-1102 Pump 1 —
D575A-3 SD 30-17
!

791-832-1430 Adapter 1
1 —
791-832-1440 Adapter 1
2 791-832-1460 Guide 1 —
791-832-1210 Frame 1 —
791-832-1220 Plate 1 —
791-832-1230 Shaft 2 —
791-832-1240 Nut 2 —
04530-11628 Eyebolt 2 —
3 791-832-1310 Adapter 1 —
791-832-1410 Extension 1 —
791-832-1420 Guide 1 —
791-832-1440 Adapter 1 —
790-101-4500 Cylinder 1 1,960KN (200 ton)
790-101-1102 Pump 1 —
791-832-1210 Frame 1 —
791-832-1220 Plate 1 —
791-832-1230 Shaft 2 —
Field assembly of one link KF 791-832-1240 Nut 2 —
04530-11628 Eyebolt 2 —
791-832-1310 Adapter 1 —
4
791-832-1330 Guide 1 —
791-832-1410 Extension 1 —
791-832-1430 Adapter 1 —
791-832-1450 Adapter 1 —
790-101-4500 Cylinder 1 —
790-101-1102 Pump 1 —
5
790-101-1102 Pump 1 —
6 791-832-1380 Guide 1 —
791-832-1210 Frame 1 —
791-832-1220 Plate 1 —
791-832-1230 Shaft 2 —
7
791-832-1240 Nutr 2 —
04530-11628 Eyebolt 2 —
791-832-1280 Adapter 1 —
30-18 D575A-3 SD
!

791-832-1310 Adapter 1 KIT
791-832-1330 Guide 1 —
Field assembly of one link KF 7 01320-01030 Screw 1 —
790-101-4500 Cylinder 1 —
790-101-1102 Pump 1 —
791-832-1200 Removal & Installer 1 —
Disassembly, assembly of 790-101-1102 Pump 1 —

track link KG
790-101-4500 Cylinder 1 1,960KN (200 ton)
D575A-3 SD 30-19
!
DISASSEMBLY AND ASSEMBLY ENGINE OIL COOLER
REMOVAL OF ENGINE OIL 7. Remove cover (13).

★ Remove the cover and element as an assem-
COOLER ASSEMBLY bly from the engine oil cooler assembly.
• Remove the engine from the machine before

removing or installing the engine oil cooler
assembly.
1. Remove engine assembly.

For details, see REMOVAL OF ENGINE ASSEM-
BLY..
2. Remove exhaust manifold cover (1).
3. Disconnect hose (2).
4. Remove tubes (3), (4), and (5).
8. Remove oil cooler element (14).

★ Remove 8 mounting bolts from each element
before removing the element.
5. Remove mounting bolts (6), (7), (8), (9), (10),

and (11).
★ Sling the engine oil cooler assembly.
★ Remove a total of 20 bolts (11) at the top and
bottom.
6. Lift off engine oil cooler assembly (12).
Engine oil cooler assembly : 102 kg
30-20 D575A-3 SD
➀
DISASSEMBLY AND ASSEMBLY ENGINE OIL COOLER, FUEL INJECTION PUMP
INSTALLATION OF ENGINE REMOVAL OF FUEL

OIL COOLER ASSEMBLY INJECTION PUMP ASSEMBLY
(BOTH LEFT AND RIGHT)
• Carry out installation in the reverse order to
removal.
1. Link
1) Cut seal and remove center bolt (6).
2) Loosen locknut (7), and remove stud (8).
★ Coat the O-ring with engine oil, assemble it 3) Remove cover (9).
to the tube, and take care not to damage it,
when installing the tube.
★ Coat the O-ring with engine oil, assemble it

to the tube, and take care not to damage it,
when installing the tube.
Mounting bolt :
66.19 ± 7.35 Nm {6.75 ± 0.75 kgm}
Mounting bolt :
66.19 ± 7.35 Nm {6.75 ± 0.75 kgm}
4) Remove link (10).
Gasket (both surfaces) :

Gasket sealant (LG-6)
Mounting bolt :
31.4 ± 3.04 Nm {3.2 ± 0.31 kgm}
2. Remove engine hood.

For details, see REMOVAL OF RADIATOR
ASSEMBLY.
3. Remove air cleaner and muffler assembly.

For details, see REMOVAL OF CYLINDER
HEAD ASSEMBLY.
D575A-3 SD 30-21
➀
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
4. Close fuel supply valve. • Fuel injection pump for right bank
• Fuel injection pump for left bank 1) Remove fuel injection pipe (7).
1) Remove fuel injection pipe (1). 2) Disconnect hose (8) and tube (9).
2) Disconnect lubrication hose (2) and air hose 3) Disconnect lubrication tube (10).
(3).
3) Disconnect fuel control rod (4).
4) Disconnect fuel hose (11).
4) Disconnect fuel hose (5).
5) Remove fuel injection pump assembly (12).
5) Remove fuel injection pump assembly (6).

★ Remove the mounting bolts, move to the
rear, then lift up.
★ Remove the mounting bolts, move to the
rear, then lift up.
Fuel injection pump (without gover-
Fuel injection pump (without gover- nor) : 30 kg
nor) : 47 kg
30-22 D575A-3 SD
➀
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
NSTALLATION OF FUEL 3) Pass stud (8) through tap hole in housing

(11) and turn it until it reaches the end
INJECTION PUMP ASSEMBLY (approx. 14 mm with 7 turns).
(BOTH LEFT AND RIGHT) 4) When stud (8) reaches the end, turn it back
approx. 2 turns.
• Carry out installation in the reverse order to ★ The stud will move 4 mm and the center
removal. of the fulcrum of the link will move 2 mm
forward.
5) Tighten locknut (7) temporarily.
Sleeve nut :
22.06 ± 2.45 Nm {2.25 ± 0.25 kgm}
★ Align the spline of the coupling and install,

then align the line on the body and tighten
the mounting bolts.
★ Adjust the fuel injection timing and the fuel

injection amount for the left and right banks.
For details, see TESTING AND ADJUST-
ING.
6) Fit O-ring on link, fit gasket and install cover
(9).
• Install the link as follows. 7) Fit washer and tighten center bolt (6).
1) Insert pin at tip of link (10) in joint of both Center bolt :
racks. 53.9 ± 19.6 Nm {5.5 ± 2 kgm}
2) Pull link (10) towards injection pump and
pass stud (8) through nut inside link (approx.
4 turns).
★ Adjust the difference between the left and

right exhaust temperatures.
ING.
D575A-3 SD 30-23
➀
DISASSEMBLY AND ASSEMBLY AFTER-COOLER CORE
REMOVAL OF 6. Remove cover assemblies (9) and (10).
AFTER-COOLER CORE
ASSEMBLY
1. Remove air cleaner assembly and muffler
assembly.
For details, see REMOVAL OF CYLINDER
HEAD ASSEMBLY.
2. Remove connector (1), tubes (2), and connec-

tors (3).
Remove 2 connectors (3), one each at the top
and bottom.
3. Remove tube (4). 7. Remove cores (11) and (12) from cover assem-
blies (9) and (10).
4. Remove connector (5), tubes (6), and connec-

tors (7).
★ Remove 2 connectors (7), one each at the
top and bottom. INSTALLATION OF
5. Remove tube (8).
AFTER-COOLER CORE
ASSEMBLY
removal.
• Refilling with water

Add water through water filler to the specified
level.
★ Run the engine to circulate the water through
the system. Then check the water level
again.
30-24 D575A-3 SD
➀
DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER
REMOVAL OF NOZZLE 5. Remove nozzle holder assembly (5).
HOLDER ASSEMBLY
1. Remove fuel injection pipe (1) of nozzle holder to
be removed.
INSTALLATION OF NOZZLE
2. Remove spill hose (2). HOLDER ASSEMBLY
removal.
Sleeve nut :
22.06 ± 2.45 Nm {2.25 ± 0.25 kgm}
★ Tighten the mounting bolts of the head cover

in the order given in the diagram..
Mounting bolt :
31.87 ± 2.45 Nm {3.25 ± 0.25 kgm}
3. Remove joint (3).
4. Remove head cover (4). Nozzle holder mounting bolt :

26.97 ± 2.45 Nm {2.75 ± 0.25 kgm}
D575A-3 SD 30-25
➀
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
REMOVAL OF CYLINDER 5) Remove air cleaner and muffler assembly

(7).
HEAD ASSEMBLY ★ Raise the air cleaner slightly, pull out the
intake connector, then remove to the
1. Drain coolant. front of the machine.
2. Remove engine hood. Air cleaner, muffler assembly : 610 kg

ASSEMBLY.
3. Remove engine side cover.
4. Air cleaner, muffler assembly

1) Disconnect tube (1) and hose (2).
5. Remove left and right exhaust manifold covers

(8).
2) Disconnect rods (3) and (4).
3) Remove pipe (5)..

4) Remove plate (6).
30-26 D575A-3 SD
➀
6. Remove exhaust manifold (9). 9. Remove joint (12), then remove head cover (13).
10. Remove nozzle holder (14).
11. Remove rocker arm assembly (15).

★ Loosen locknut (16), then loosen adjustment
screw (17) 2 – 3 turns.
7. Remove fuel injection tube (10).
8. Remove spill hose (11).
12. Disconnect tube (18).
D575A-3 SD 30-27
➀
13.Remove rocker arm housing (19). INSTALLATION OF CYLINDER

★ Remove pin (20), put a bar in contact with
portion , then tap in the direction of the
HEAD ASSEMBLY
arrow to move pipe (21) to side.
removal.
★ Tighten the exhaust manifold in the following

order and to the following torque.
i) Install in the order A → B → C given in
Figs. 1 and 2.
14. Remove push rod (22).
15. Remove crosshead (23).
16. Remove cylinder head assembly (24).

★ Remove the head bolts, then use lifting tool
to remove.
Cylinder head assembly : 40 kg ii) Tighten in the order given in Figs. 3 and
4.
30-28 D575A-3 SD
➀
★ Adjust the valve clearance.

ING, Adjusting valve clearance.
Rocker arm, screw, locknut :
67.7 ± 9.8 Nm {6.9 ± 1.0 kgm}
Rocker arm housing mounting bolt :

98 ± 4.9 Nm {10 ± 0.5 kgm}
Mounting bolt: ★ Check that the push rod is fitted properly into
1st step : 49 ± 9.8 Nm {5 ± 1 kgm} the cam follower.
2nd step :
83.4 ± 4.9 Nm {8.5 ± 0.5 kgm}
★ Adjust the crosshead as follows.
i) Loosen the locknut and turn the adjust-
ment screw back.
Sleeve nut : ii) Hold down the top of the crosshead
22.06 ± 2.45 Nm {2.25 ± 0.25 kgm} lightly and screw in the adjustment
screw.
iii) When the adjustment screw contacts the
valve stem, tighten a further 20°.
★ Tighten the mounting bolts of the head cover iv) Tighten the locknut to hold in position.
in the order given in Fig. 5.
Llocknut : 54.9 ± 3.9 Nm {5.6 ± 0.4 kgm}
★ Tighten the cylinder head bolts in the order

given in Fig. 6.
Mounting bolt :
31.87 ± 2.45 Nm {3.25 ± 0.25 kgm}
Nozzle holder mounting bolt :

26.97 ± 2.45 Nm {2.75 ± 0.25 kgm} Bolt thread, seat surface :
Anti-friction compound (LM-P)
★ Check that the ball of the adjustment screw

is fitted properly into the socket of the push
rod.
Rocker arm mounting bolt :
98.1 ± 4.9 Nm {10 ± 0.5 kgm}
D575A-3 SD 30-29
➀
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD, HYDRAULIC COOLER
Cylinder head bolt : REMOVAL OF HYDRAULIC

Unit: Nm (kgm)
COOLER ASSEMBLY
Order Tightening torque
1. Remove fan drive support assembly.
1st pass 78.5 ± 14.7 Nm (8.0 ± 1.5)
For details, see REMOVAL OF FAN DRIVE
2nd pass 230.5 ± 14.7 Nm (23.5 ± 1.5) SUPPORT ASSEMBLY.
3rd pass 382.5 ± 14.7 Nm (39.0 ± 1.5) 2. Disconnect cooler inlet hose (1).
4th pass 495.2 ± 14.7 Nm (50.5 ± 1.5)
3. Disconnect cooler outlet hoses (2) and (3).
4. Remove cooler assemblies (4) and (5).

• Refilling with water
Add water through water filler to the specified Hydraulic cooler assembly : 45 kg
level.
the sy stem. Then check the water level
again.
INSTALLATION OF
HYDRAULIC COOLER
ASSEMBLY
removal.
30-30 D575A-3 SD
➀
DISASSEMBLY AND ASSEMBLY RADIATOR
REMOVAL OF RADIATOR 4. Remove covers (3), (4) and (28).

ASSEMBLY 5. Disconnect wiring connector (5).
1. Drain coolant. 6. Disconnect ether hose (6).
2. Open undercover (1).
★ Raise the drawbar from the front of the radia-
tor and remove the mounting bolts.
★ Put protective material at the corner under
the radiator.
Undercover (under radiator) : 540 kg
7. Remove engine hood (7).

★ Sling the engine hood and remove the
mounting bolts.
Engine hood : 250 kg
3. Remove guard (2).

★ Sling the guard and remove the mounting
bolts.
D575A-3 SD 30-31
➀
8. Remove covers (8) and (29). 13. Disconnect wiring (15).

★ Remove the connector and clamp, and dis-
9. Remove clamps (9), (10) and (30), then remove connect from the radiator.
bracket (11) and (12).
14. Disconnect hoses (16), (17), and (18).
10. Move together with tube (13) away from notched
portion of radiator top cover, and move to outside
of machine.
11. Repeat above Steps 8 – 10 to disconnect tube

on opposite side.
15. Remove shutter plate (19).
12. Remove radiator top cover (14) together with

guard.
★ Sling the cover and remove the mounting
bolts.
Radiator top cover : 210 kg
16. Disconnect radiator outlet tube (20).
17. Remove hose (21) together with flange.
18. Remove plate (22).
19. Remove shutter plate (23).
30-32 D575A-3 SD
➀
20. Remove left and right cushions (24). INSTALLATION OF

RADIATOR ASSEMBLY
removal.
• Adjusting radiator guard

1. Securing radiator guard
1) With radiator guard raised, adjust with bolts
(2) so that clearances a and b are 0.
2) Measure clearance C, then insert shims of
dimension C + 1.5 mm.
21. Remove left and right pins (25).
22. Remove mounting bolts of left and right brackets

(26).
3) Remove bolts (2), then tighten mounting

bolts (3).
23. Lift off radiator assembly (27).

Radiator assembly : 890 kg
D575A-3 SD 30-33
➀
DISASSEMBLY AND ASSEMBLY RADIATOR, FAN DRIVE SUPPORT
• Refilling with water REMOVAL OF FAN DRIVE

Add water through water filler to the specified
level. SUPPORT ASSEMBLY
the system. Then check the water level 1. Drain hydraulic oil.
again. Hydraulic tank : Approx. 300

★ Raise the drawbar from the front of the radia-
tor and remove the mounting bolts.
★ Put protective material at the corner under
the radiator.
Undercover (under radiator) : 540 kg
3. Remove engine hood and top cover.

For detail, see REMOVAL OF RADIATOR
ASSEMBLY.
4. Disconnect fan pulley grease hose (2).

Remove the hose clamp tightened together with
the wiring.
30-34 D575A-3 SD
➀
DISASSEMBLY AND ASSEMBLY FAN DRIVE SUPPORT
5. Sling radiator grill (3), then remove mounting 8. Disconnect hydraulic cooler inlet hose (6).
bolts, and remove.
9. Disconnect hydraulic cooler return hose (7).
Radiator grill (each) : 390 kg
10. Remove oil cooler cushion bracket (11).

6. Sling fan (4), then remove mounting bolts, and
remove.
Fan : 130 kg
11. Remove bolt , then disconnect universal joint

(12).
7. Remove shroud (5) and bracket (10).
D575A-3 SD 30-35
➀
DISASSEMBLY AND ASSEMBLY FAN DRIVE SUPPORT
12. Remove brackets (8) and (9). INSTALLATION OF FAN DRIVE

13. Sling fan drive support assembly (10), then SUPPORT ASSEMBLY
remove mounting bolts, and move approx. 50
mm to outside. • Carry out installation in the reverse order to
removal.
Before removing the mounting bolts, use 2
guide bolts (length: approx. 100 mm) in ★ When installing the fan drive support assem-
the support mounting bolt holes to prevent bly, insert the shaft and be extremely careful
the fan drive support assembly from tipping not to damage the fan pulley oil seal.
over to the front.
Fan pulley oil seal lip :
Grease (G2-LI)
• Refilling with oil (hydraulic tank)

Add oil through oil filler to the specified level.
★ Run the engine to circulate the oil through
the system. Then check the oil level again.
14. Raise universal joint with lever block, then move

fan drive support assembly to outside and
remove.
★ When removing the fan drive support assem-
bly, be careful not to damage the oil seal at
the fan pulley portion.
Fan drive support assembly : 85 kg
30-36 D575A-3 SD
➀
DISASSEMBLY AND ASSEMBLY FAN DRIVE PULLEY
REMOVAL OF FAN DRIVE DISASSEMBLY OF FAN DRIVE

PULLEY ASSEMBLY PULLEY ASSEMBLY
(FAN END) (FAN END)
1. Remove fan drive support assembly. 1. Flange
For details, see REMOVAL OF FAN DRIVE Remove mounting bolts, then remove flange (1).
SUPPORT ASSEMBLY.
2. Remove grease hose (1).
2. Cover assembly
1) Remove mounting bolts, then remove cover
assembly (2).
3. Sling fan drive pulley assembly (2), and remove 2) Disassembly of cover assembly
mounting bolts, then remove from support (3). i) Remove snap ring (3), then remove
bearing (4).
Fan drive pulley assembly : 30 kg
ii) Remove oil seal (5) from cover (6).
INSTALLATION OF FAN DRIVE

PULLEY ASSEMBLY
(FAN END)
removal.
• Greasing
Pump in grease (G2-LI) to the bearing portion of
the fan drive pulley.
D575A-3 SD 30-37
➀
3. Shaft ASSEMBLY OF FAN DRIVE

1) Remove snap ring (7).
2) Using push tool , remove shaft (8) and oil PULLEY ASSEMBLY
seal (9) from cage (10). (FAN END)
.
1. Using tool AA4, press fit bearings (11) and (12)
to cage (10).
2. Oil seal
Using tool AA2, install oil seal (9) to cage (10).
Lip of oil seal : Grease (G2-LI)
3) Remove bearing (11) from shaft (8).
4. Bearing
Remove bearing (12) from cage (10).
3. Shaft
Set tool AA5 to bearing portion, then use
push tool to press fit shaft (8).
4. Snap ring
Install snap ring (7).
30-38 D575A-3 SD
➀
5. Cover assembly 6. Flange

1) Assembly of cover assembly Install flange (1).
i) Using tool AA1, install oil seal (5) to
cover (6). 7. Greasing
ii) Using tool AA3, press fit bearing (4) to After assembling, rotate fan pulley by hand and
cover (6). pump in grease (G2-LI) through nipple (13).
iii) Install snap ring (3). ★ Check that grease comes out from portion R.
2) Fit O-ring and install cover assembly (2).

Fill at least 80% of the hatched por
tion with grease (G2-LI).
D575A-3 SD 30-39
➀
REMOVAL OF FAN DRIVE 4. Loosen V-belt tension adjustment bolt (3), and
remove V-belt (4).
PULLEY ASSEMBLY ★ Loosen adjustment bolt (3) to a point where
(ENGINE END) the V-belt comes out of the groove in the pul-
ley. Do not disconnect the bolt completely.
1. Remove engine hood assembly.
ASSEMBLY.
Engine hood assembly : 250 kg
2. Remove pulley cover (1).
5. Disconnect grease hose (5).

★ Disconnect the related hose clamps.
3. Raise universal joint and retainer mounting bolts

of cover (2), then move together with universal
joint towards front.
★ When moving the universal joint, remove the
grease nipple of the fan pulley portion (front
end).
6. Sling fan drive pulley assembly (6), then remove

mounting bolts (7), and remove from engine.
Fan drive pulley assembly : 120 kg
30-40 D575A-3 SD
➀
INSTALLATION OF FAN DRIVE DISASSEMBLY OF FAN DRIVE

PULLEY ASSEMBLY PULLEY ASSEMBLY
(ENGINE END) (ENGINE END)
• Carry out installation in the reverse order to 1. Pulley
removal. Remove pulley (1) from case assembly (2).
2. Cover
Remove cover (3).
★ Turn adjustment bolt (3) to adjust so that
dimension a is 36 ± 3 mm, then tighten lock- 3. Snap ring
nut (8). Remove snap ring (4).
• Greasing 4. Shaft
Pump in with grease (G2-LI) to the fan drive pul- 1) Using push tool , pull out shaft (5).
ley (front, rear). 2) Remove grease hose (6) from shaft (5).
D575A-3 SD 30-41
➀
5. Cover assembly ASSEMBLY OF FINAL DRIVE

1) Remove cover assembly (7).
2) Remove oil seal (8) from cover (9). PULLEY ASSEMBLY
(ENGINE END)
1. Bearings
Using tool AB2, press fit bearings (10) and (11)
to case (12).
Fill at least 80% of the hatched portion
with grease (G2-LI).
6. Bearings
Remove bearings (10) and (11) from case (12).
2. Cover assembly
1) Using tool AB1, install oil seal (8) to cover
(9).
2) Fit O-ring and install cover assembly (7) to

case.
30-42 D575A-3 SD
➀
DISASSEMBLY AND ASSEMBLY FINAL DRIVE PULLEY, DAMPER
3. Shaft REMOVAL OF DAMPER

1) Install grease hose (6) to shaft (5).
2) Using tool AB3, press fit shaft (5) to case ASSEMBLY
bearing portion.
1. Open undercover.
4. Snap ring For details, see REMOVAL OF SCAVENGING
Install snap ring (4). PUMP ASSEMBLY.
Undercover : 140 kg
2. Drain oil.
Damper oil : Approx. 2.4
3. Remove oil filler (1).
5. Cover
Fit O-ring and install cover (3).
6. Pulley
Install pulley (1) to case assembly (2).
7. Greasing
After installing fan drive pulley assembly to 4. Remove universal joint assembly (2).
engine, pump in grease (G2-LI) again. ★ Sling the universal joint assembly, then
remove the mounting bolts, and remove the
universal joint.
Universal joint : 65 kg
D575A-3 SD 30-43
➀
DISASSEMBLY AND ASSEMBLY DAMPER
5. Remove holder (5). 8. Damper assembly

1) Sling damper assembly (9) and set guide
6. Remove coupling (6). bolts in position.
★ Use the mounting bolt holes to install the
guide bolts.
2) Remove mounting bolts (10) and lift off
damper assembly.
★ When removing the damper assembly,
install nuts to the guide bolts, and be
careful not to let the damper assembly fly
off.
Damper assembly : 80 kg
7. Cover assembly
1) Sling cover assembly (7).
2) Remove mounting bolts (8), take out forcing
screws, screw into tap holes , , and ,
and remove cover assembly.
★ Use guide bolts and nuts and be careful not
to let the cover assembly fly off.
Cover assembly : 90 kg
30-44 D575A-3 SD
➀
INSTALLATION OF DAMPER DISASSEMBLY OF DAMPER

ASSEMBLY ASSEMBLY
• Carry out installation in the reverse order to 1. Set damper assembly on block .
removal.
2. Remove mounting bolts (1), and use forcing
screws to remove flange (2).
Mounting bolt :
18.6 ± 7.8 Nm {1.9 ± 0.8 kgm}
Universal joint bolt :

176.5 ± 19.6 Nm {18 ± 2.0 kgm}
Holder mounting bolt :

Thread tightener (LT-2)
Holder mounting bolt :
549.2 ± 58.8 Nm {56 ± 6 kgm}
3. Remove shaft (3).
Install cover (7) as follows. 4. Remove rubber (4).

i) Set cover (7) in mounting position with guide
bolt. 5. Using forcing screws , remove flange (5) from
ii) Press fit bearing (8) with tool AC. body (6).
When installing the damper assembly, fit guide 6. Remove seals (7) from flanges (2) and (5).
bolts at the top and bottom of the damper.
When installing damper assembly (9), fill 50% of
the clearance at portion “a” with grease (G2-LI)
(approx. 55 g).
• Refilling with oil

★ Add engine oil through the oil filler to the
specified level.
D575A-3 SD 30-45
➀
• Disassembly of damper cover assembly ASSEMBLY OF DAMPER

7. Remove bearing (8) and oil seal (9) from cover ASSEMBLY
(10).
1. Install seals (7) to flanges (2) and (5).
8. Remove oil seal (11) from retainer (12). ★ Install the seals with the lip facing the inside
as shown in the diagram.
2. Align bolt holes and install flange (5) to body (6).

Mating surface of flange :
★ Check that there are no dents, rust, grease,

oil, or water on the mating surface, then coat
the surfaces of both the flange and body with
gasket sealant.
★ Coat to a thickness of 0.1 – 0.2 mm and
leave for 2 – 3 minutes to dry before install-
ing.
30-46 D575A-3 SD
➀
3. Set flange and body assembly on block , and 7. Using push tool , press fit oil seal (11) to
set shaft (3) in position. retainer (12).
Press fitting surface of oil seal :
4. Assemble rubber (4).
★ Coat the inside surface of the
retainer with gasket sealant and
wipe off any gasket sealant that is
pushed out.
When assembling the rubber, coat the

whole surface of the rubber, the outside
circumference of the shaft, and the
inside circumference of the body with
grease (G2-LI).
After assembling the rubber, fill approx.

8. Using push tool , press fit bearing (8) to cover
50 % of th e cl ea ra nce (1 6 pl a ce s)
(10).
between the shaft and body with grease
(G2-LI) (approx. 350 g).
5. Install flange (2).

Mating surface of flange :
★ Check that there are no dents, rust, grease,
oil, or water on the mating surface, then coat
the surfaces of both the flange and body with
gasket sealant.
★ Coat to a thickness of 0.1 – 0.2 mm and
leave for 2 – 3 minutes to dry before install-
ing.
6. Tighten mounting bolts (1).
D575A-3 SD 30-47
➀
DISASSEMBLY AND ASSEMBLY DAMPER, POWER TRAIN
9. Using push tool , press fit oil seal (9) to REMOVAL OF POWER TRAIN
cover (10).
ASSEMBLY
Press fitting surface of oil seal:
Gasket sealant (LG-1) 1. Remove operatorís compartment frame assem-
★ Coat the inside surface of the cover bly.
with gasket sealant and wipe off any For details, see REMOVAL OF OPERATORíS
gasket sealant that is pushed out. COMPARTMENT FRAME ASSEMBLY.
Lip of oil seal : Grease (G2-LI) 2. Draining oil, fuel
Hydraulic tank : Approx. 300
Power train oil pan : Approx. 345
Fuel tank : Approx. 2,100
3. Remove alternator wiring (1) and wiring clamp

(2), and disconnect wiring (3).
4. Remove support (4).

★ Sling the support and remove the mounting
bolts.
Support : 85 kg
30-48 D575A-3 SD
➀
DISASSEMBLY AND ASSEMBLY POWER TRAIN
5. Remove bracket (5). 9. Remove rear cover.

★ Before removing the mounting bolts, make a
line at the top and side of the bracket. 10. Remove elbow (31) of fuel tank.
★ Disconnect the hose clamp, then sling the
bracket and remove the mounting bolts.
11. Disconnect breather hose (9) and fuel tank drain

hose (10).
6. Disconnect air conditioner compressor hose (6). ★ Close the drain valve at the tank end before
disconnecting the fuel tank drain hose.
7. Remove step (7).
12. Disconnect rod (11), and remove lever assembly

(12).
8. Remove bracket (8).
13. Remove suction tube (13).
★ Fit a blind plug or tape to prevent any dirt or
dust from entering the steering case.
14. Disconnect hoses (14) and (15).
D575A-3 SD 30-49
➀
15. Open undercover. 19. Disconnect work equipment assist pump outlet
For details, see REMOVAL OF SCAVENGING hose (19).
PUMP ASSEMBLY.
20. Disconnect control pump outlet hose (20).
16. Remove universal joint assembly (16).
★ Sling from above the machine, then remove
the mounting bolts.
Universal joint assembly : 65 kg
21. Disconnect hose (21) between torque converter

and cooler.
17. Remove damper oil filler (17) together with

bracket.
22. Disconnect hose (22) between power train pump

and filter.
★ Disconnect hose (22) to make it possible to
fit eyebolts.
18. Disconnect hydraulic pump outlet hose (18).
30-50 D575A-3 SD
➀
23. Remove control pump (32).

★ Remove from bolt (33).
2) To prevent interference, remove bolt at

front and adjustment bolt at rear.
24. Gear coupling

1) Remove plugs (23) and (24) of gear coupling
and drain oil.
Gear coupling : Approx. 1.5
2) Remove mounting bolts (25) of cover.

3) Move gear (26) towards final drive.
★ Remove the gear after removing the
power train assembly.
3) Using tool H1, lift off power train assembly

(30).
★ Check the number and thickness of the
shims at the mount, and keep in a safe
place.
Power train assembly : 7,000 kg
25. Power train assembly

1) Tighten adjustment bolts and , then
remove mount bolts (27) and (28).
★ Before removing the mount bolts, check
the misalignment to the left and right at
the front and rear. Make marks on the
mount.
★ If the power train is to be used again as it
is , there is no need to remove position-
ing plate (29).
D575A-3 SD 30-51
➀
INSTALLATION OF POWER 2. Rear mount

1) Tighten the cushion with adjustment bolts
TRAIN ASSEMBLY to adjust so that clearance b is 1 mm on both
the left and right, then tighten bolt (28) to
• Carry out installation in the reverse order to hold in position.
removal. 2) Remove bolt .
Mounting bolt :
1,520 ± 392 Nm {155 ± 40 kgm}
★ Install temporarily, and tighten fully after
installing the operatorís compartment frame
assembly.
★ After connecting the hose, open the valve at

the fuel tank end..
• Method of adjusting power train mount block

1. Front mount
1) Tighten the cushion with adjustment bolt
(01016-52090) to adjust so that clearance a
is 1 mm on both the left and right, then
tighten bolt (27) to hold in position.
2) Remove bolt ,.
• Assembly of power train assembly
1) Replace power train assembly as assem-
bly.
2) Replace steering case.
3) Replace torque converter case.
4) Replace mount of torque converter case.
5) Replace transmission case.
6) Replace power train mount block.
7) Replace power train mount rubber bush-
ing.
30-52 D575A-3 SD
➀
If the above parts have been replaced, center the • Refilling with oil
final drive input shaft as follows. ★ Add oil through the oil filler to the specified
i) Assemble the shims that were removed and level.
install the power train assembly.
★ Remove the gear coupling. Gear coupling : Approx. 1.5
ii) Set tool H2 between the shafts. (fill from plug (23))
iii) Rotate tool H2 and measure the radial runout
(up, down, front, rear).
★ Radial runout : Within 1 mm
★ Change the shim thickness to adjust the
up-down misalignment.
Move the power train to adjust the front-
to-rear misalignment.
iv) After completing the centering, adjust the

block. For details, see the above
METHOD FOR ADJUSTING POWER TRAIN
MOUNT BLOCK. Tighten positioning plate
(29) and remove tool H2.
v) Raise the power train assembly, assemble

the gear coupling, and install again.
★ Be careful not to to hit the positioning
plate strongly.
D575A-3 SD 30-53
➀
DISASSEMBLY AND ASSEMBLY PTO, TORQUE CONVERTER
REMOVAL OF PTO, TORQUE 9. Disconnect central pressure detection hose (8)

and solenoid connector.
CONVERTER ASSEMBLY ★ Fit tags to distinguish the mounting position
of the hoses.
1. Remove power train assembly.
For details, see REMOVAL OF POWER TRAIN 10. Disconnect solenoid connector (9).
ASSEMBLY.
2. Set power train assembly (1) on block hori-

zontally.
3. Remove step (2).
4. Remove V-belt cover (3).
11. Disconnect torque converter oil temperature sen-

sor connector (10), and remove wiring clamp.
12. Disconnect central pressure detection hose (11)

and remove hose clamp.
13. Disconnect hydraulic oil temperature sensor con-

nector (12) and remove wiring clamp.
5. Remove belt, then remove air conditioner com-
pressor assembly (4) together with bracket.
6. Disconnect wiring (5).
7. Remove belt, then remove alternator assembly

(6).
8. Remove bracket (7).
14. Remove transmission lubrication pump outlet

tube (13) and inlet tube (14).
30-54 D575A-3 SD
➀
15. Disconnect hose (15), and remove block (16). 24. Remove lubrication pump assembly (25).
★ Sling the pump assembly, then remove the
16. Remove control pump filter assembly (17). mounting bolts.
Lubrication pump assembly : 25 kg
25. Remove power train pump assembly (26).

mounting bolts.
Power train pump assembly : 45 kg
17. Disconnect scavenging pump hose (18).
18. Disconnect control pump outlet hose (19).
19. Remove power train pump outlet hose (20).
26. Remove work equipment assist and control

pump assembly (27).
• Sling the pump assembly, then remove the
mounting bolts.
Work equipment assist, control pump
assembly : 47 kg
27. Remove hydraulic pump assembly (28).

mounting bolts.
Hydraulic pump assembly : 50 kg
20. Remove hydraulic pump inlet tube (21).
21. Remove work equipment assist pump inlet tube

(22).
22. Remove power train pump inlet tube (23).
23. Remove tube (24).
D575A-3 SD 30-55
➀
28. Remove filter assembly (29). INSTALLATION OF PTO,

Filter assembly : 50 kg TORQUE CONVERTER
ASSEMBLY
removal.
Transmission input shaft seal ring :

Grease (G2-LI)
★ Using a lever block, raise the PTO and
torque converter assembly horizontally, align
the spline of the shaft at the steering case
end, and install.
29. Remove left and right mount assemblies (30).

★ Sling the mount assemblies, then remove the
mounting bolts.
Mounting cap (1 pc) : 30 kg
30. Remove PTO and torque converter assembly

(31).
★ Sling the PTO and torque converter assem-
bly, then remove the mounting bolts.
★ Using a lever block, raise the PTO and
torque converter assembly horizontally, then
lift off.
PTO, torque converter assembly :
1,200 kg
30-56 D575A-3 SD
➀
DISCONNECTION OF PTO, 4. Remove snap ring (8), then remove spacer (9).
TORQUE CONVERTER
ASSEMBLY
1. Coupling assembly
1) Remove coupling assembly (1).
2) Remove snap ring (2), then remove cap (3)
from coupling (4).
5. Remove mounting bolts, and using eyebolts ,

sling PTO assembly.
6. Using forcing screws, remove PTO assembly

(10).
PTO assembly : 300 kg
2. Retainer assembly
1) Screw in forcing screws and remove retainer
assembly (5).
2) Remove oil seal (6) from retainer.
3. Remove shims (7).

shims, and keep in a safe place.
D575A-3 SD 30-57
➀
CONNECTION OF PTO, 4) Assemble the selected thickness of shim and

tighten the retainer assembly to the specified
TORQUE CONVERTER tightening torque.
ASSEMBLY
removal.
Adjust the clearance of the taper roller bearing

as follows.
1) Set retainer assembly to housing, then
tighten 6 mounting bolts uniformly in turn to
9.8 Nm (1 kgm).
2) Using feeler gauge, measure clearance a
between retainer and housing.
★ Measure at 4 places (A, B, C, D) around
the circumference and take the average Retainer mounting bolt thread :
value as clearance a. Thread tightener (LT-2)
3) Select shim thickness. Retainer mounting bolt :
★ Shim thickness = 66.19 ± 7.35 Nm (6.75 ± 0.75 kgm)
Clearance a – (0 – +0.05 mm)
★ The shim is a split type, so be careful to ★ Assemble as shown in the diagram on the
check that the thickness and number of right so that the shim is not at the same posi-
shims is the same on the left and right. tion as the retainer tap hole.
★ Standard shim thickness: 0.15, 0.20, 0.5
mm

O-ring : Grease (G2-LI)
Press-fitting surface of oil seal :
When coating with gasket sealant, coat
the inside surface of the hole in the hous-
ing thinly, and wipe off any gasket seal-
ant that is pushed out.
★ Check that the snap ring is fitted securely in

the groove.
★ When assembling the PTO assembly, coat

portion P of the shaft with anti-friction com-
pound (LM-P).
30-58 D575A-3 SD
➀
DISASSEMBLY AND ASSEMBLY PTO
DISASSEMBLY OF PTO 4. Drive shaft assembly (for power train pump)

1) Screw in forcing screws, and using eyebolts,
ASSEMBLY remove drive shaft assembly (9).
1. Outer race, sleeve

1) Remove ring (1), then remove outer race (2).
2) Remove sleeve (3).
2) Disassemble drive shaft assembly.

i) Remove snap ring (10).
ii) Use a suitable tool to hold outside cir-
cumference of cage (16), then push out
2. Strainer shaft (11) to remove.
Remove strainer (4).
3. Scavenging pump assembly

1) Remove pump assembly (5).
iii) Remove snap ring (13), then remove

bearing (12) from cage (16).
2) Disassemble pump drive shaft.

ii) Knock out shaft (7) and remove.
iii) Remove bearing (8).
D575A-3 SD 30-59
➀
3) Remove snap ring (14), then remove inner 6. Drive shaft assembly
race (15) from shaft (11). 1) Screw in forcing screws, and using eyebolts,
4) Remove snap ring (17), then remove bearing remove drive shaft assembly (24).
(18) from case (3).
2) Disassemble drive shaft assembly.

5. Alternator drive shaft assembly
ii) Use a suitable tool to hold outside cir-
1) Remove housing (19), then remove drive
cumference of cage (26), then push out
shaft (20).
shaft (27) to remove.
2) Remove oil seal (21) from housing (19).

3) Remove snap ring (22), then remove bearing
(23) from shaft (20).
30-60 D575A-3 SD
➀
iv) Remove snap ring (30), then remove 2) Remove mounting bolts, then remove shaft
inner race (31) from shaft (27). (40) and gear (41).
(33) from case (3).
3) Remove snap ring (42), then remove inner

race (43) from shaft (40).
7. Idler shaft, gear assembly
1) Remove cage assembly.
ii) Using puller , remove cage assembly
(35) together with bearing (37).
★ The inner race of bearing (37) will
come off from the shaft.

(45) from case (3).

D575A-3 SD 30-61
➀
ASSEMBLY OF PTO
5) Fit shaft (40) to gear (41) and tighten bolts.
ASSEMBLY
Mounting bolt :
★ Clean all parts, and check for dirt or damage. Thread tightener (LT-2)
★ Coat the sliding surfaces of all parts with engine Mounting bolt :
oil before installing. 277.04 ± 31.87 Nm {28.25 ± 3.25 kgm}
1. Idler gear, shaft assembly

1) Using push tool, press fit bearing (45) to
case (3).
2) Install snap ring (44).

cage (35).
3) Using push tool, press fit inner race (43) to

shaft (40), then install snap ring (42).
8) Install cage as follows.

i) Raise PTO case horizontally.
ii) Put tool C in contact with hole at torque
converter case end, and adjust with a
4) Set idler gear (41) to case. crane to lower both case and tool to
★ Set with the inside stepped portion facing ground.
the cage. ★ Leave the crane as it is.
30-62 D575A-3 SD
➀
iii) Fit O-ring and set cage (35) to shaft (36). v) Using push tool, press fit shaft (27) to
iv) Press fit inner race of bearing (37) to inner race of bearing (28) installed to
shaft (36), and install cage (35). cage.
★ Rotate the shaft while press fitting. vi) Install snap ring (25).
v) Install snap ring (34). ★ Drop a small amount of engine oil on
the bearing and rotate at least 10
times.
2. Drive shaft assembly (for hydraulic pump)

1) Using push tool, press fit bearing (33) to 3) Fit O-ring, and using eyebolts, install drive
case (3), and install snap ring (32). shaft assembly (24).
2) Assemble drive shaft as follows.
i) Using push tool, press fit inner race (31)
to shaft (27).
ii) Install snap ring (30).
iii) Using push tool, install bearing (28) to

cage.
iv) Install snap ring (29).
D575A-3 SD 30-63
➀
3. Alternator drive shaft 4. Drive shaft assembly (for power train pump)
1) Using push tool, press fit bearing (23) to 1) Using push-puller, install bearing (18) to case
shaft (20), and install snap ring (22). (3), then install snap ring (17).
2) Using push tool, press fit oil seal (21) to 2) Assemble drive shaft assembly.
housing (19). i) Using push tool, press fit inner race (15)
to shaft (11).
Press-fitting portion of oil seal (at
ii) nstall snap ring (14).
housing end) :
iii) Using push tool, press fit bearing (12) to

cage (16).
3) Install alternator drive shaft (20).
★ Align the spline with the hydraulic pump
drive shaft, and press fit the bearing to
the case.
4) Fit O-ring and install housing (19).
★ Be careful not to damage the oil seal lip.
★ Drop a small amount of engine oil on the
bearing and rotate at least 10 times.
v) Using push tool, press fit shaft (11) to

inner race of bearing (12) installed to
cage.
vi) Install snap ring (10).
★ Drop a small amount of engine oil on
the bearing and rotate at least 10
times.
30-64 D575A-3 SD
➀
2) Fit O-ring and install pump assembly (5).

3) Fit O-ring, and using eyebolts, install drive
shaft assembly (9). 6. Fit O-ring and install strainer (4).
5. Scavenging pump assembly 7. Sleeve, outer race

1) Install pump drive shaft. 1) Install sleeve (3) to case.
i) Using push tool, press fit bearing (8) to ★ Expand fit the sleeve.
case (3). 2) Using push tool, install outer race (2).
ii) Set shaft (7) to bearing (8). 3) Install ring (1).
iii) Push inner race of bearing (8) and press

fit shaft (7) to bearing, then install snap
ring (6).
D575A-3 SD 30-65
➀
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
DISASSEMBLY OF TORQUE 3) Disassemble lock-up clutch and drive case

assembly as follows.
CONVERTER ASSEMBLY i) Remove seal ring (5), and using forcing
screws, remove input shaft (6).
1. Torque converter assembly
Set torque converter assembly (1) to tool B.
ii) Remove snap ring (7), then remove plate

(8).
2. Torque converter valve assembly
Remove mounting bolts, and using eyebolts , iii) Using puller , disconnect press-fitting
remove valve assembly (2). portion of bearing, then remove turbine
(9).
3. Lock-up clutch, drive case assembly

1) Leaving 2 mounting bolts (3) in position,
remove other mounting bolts, then set with iv) Using eyebolts , remove housing and
input shaft at top and remove remaining 2 piston assembly (10).
mounting bolts. ★ When removing the assembly, sup-
2) Using eyebolts , remove lock-up clutch port the piston assembly by hand to
and drive case assembly (4). prevent it from falling.
v) Remove piston (11) from housing (12).
30-66 D575A-3 SD
➀
vi) Remove seal rings (13) and (14). 4. Stator assembly

Remove snap ring (20), then remove stator
assembly (21).
★ If race (22) and stator (23) are to be sepa-
rated, remove the bolt at this point.
vii) Using push tool , remove bearing (15)

from housing (16).
5. Pump assembly
1) Remove pump assembly (24).
viii) Remove 2 discs (17) and 1 plate (18) in

turn from drive case (19).
★ Store the discs and plates in a flat
place to prevent them from becoming
distorted. 2) Remove mounting bolts, then remove
retainer (25).
3) Tap with a plastic hammer to remove bearing
and guide assembly (26) from pump.
4) Remove bearing (27) from guide (28).
D575A-3 SD 30-67
➀
6. Stator clutch housing 9. Pin

Remove mounting bolts, then remove stator Remove pin (34).
clutch housing (29).
10. Gear
Remove snap ring (35), then remove inner gear
(36).
11. Piston assembly

1) Remove piston assembly (37) from case
(38).
7. Spring
Remove spring (30).
8. Discs, plate, spring

Remove spring (31), 2 discs (32), and 1 plate
(33).
★ Store the discs and plate in a flat place to
prevent them from becoming distorted. 2) Remove seal rings (39) and (40).
12. Stator shaft, shaft assembly

1) Remove mounting bolts (41).
30-68 D575A-3 SD
➀
2) Tap stator shaft and shaft assembly (42) with 6) Disassemble stator shaft assembly as fol-
a plastic hammer, and remove from case lows.
(38). i) Remove seal ring (51).
★ When removing the stator shaft assem- ii) Remove snap ring (52).
bly, set the case in the position shown in iii) Using push tool , remove bearing (53)
the diagram to remove. from stator shaft (54).
4) Using push tool , remove shaft assembly
(44) from stator shaft assembly (45).
5) Disassemble shaft assembly as follows.

i) Remove snap ring (46), then remove
inner race (47).
ii) Remove seal ring (48).
iii) Remove bushing (49) from shaft (50).
D575A-3 SD 30-69
➀
ASSEMBLY OF TORQUE 2) Tap stator shaft assembly (45) with a plastic

hammer to press fit bearing to case.
CONVERTER ASSEMBLY
★ Clean all parts, and check for dirt or damage.
★ Put drops of engine oil on the rotating parts of

the bearing and rotate several times.
★ Check that the snap ring is fitted securely in the

groove.
★ Coat the seal ring thinly with grease (G2-LI).
1. Case
Set case (38) to tool B.
3. Shaft assembly
1) Assemble shaft assembly as follows.
i) Install bushing (49).
★ Expand fit the bushing.
ii) Using push tool , press fit inner race
(47) and secure with snap ring (46).
iii) Install seal ring (48) to shaft (50).
2. Stator shaft assembly

1) Assemble stator shaft assembly as follows.
i) Using push tool , press fit bearing (53)
and secure with snap ring (52).
ii) Install seal ring (51) to stator shaft (54).
2) Install shaft assembly (44).

★ Use 2 guide bolts (Thread dia.=10mm,
Pitch=1.25mm, Length=60mm), align the
oil holes, and install the shaft assembly.
3) Tighten mounting bolts temporarily.
30-70 D575A-3 SD
➀
5) Tighten mounting bolts (41) fully. 2) Install piston assembly (37) to case (38).
Mounting bolt : Contact surface of seal ring :
Thread tightener (LT-2) Grease (G2-LI)
Mounting bolt :
5. Gear
66.19 ± 7.35 Nm {6.75 ± 0.75 kgm}
Install inner gear (36) and secure with snap ring
(35).
6. Pin
Install pin (34).
4. Piston assembly
1) Install seal rings (40) and (39).
7. Discs, plate, spring

Install plate (33), discs (32), and spring (31).
8. Spring
Install spring (30).
★ The seal ring must be installed facing in

the correct direction. Install with the side
receiving the pressure facing the case.
D575A-3 SD 30-71
➀
9. Stator clutch housing 4) Install pump assembly (24).

Align with dowel pin, fit stator clutch housing ★ When installing the pump assembly, be
(29), then tighten with mounting bolts. extremely careful not to damage the seal
★ Check that the spring is fitted securely in the ring assembled to the shaft.
hole in the piston and housing.
Mounting bolt :
Mounting bolt :
110.32 ± 12.26 Nm {11.25 ± 1.25 kgm}
11. Stator assembly

1) Assemble race (22) to stator (23), and
tighten mounting bolts.
Mounting bolt :
10. Pump assembly Mounting bolt :
1) Using push tool, press fit bearing (27) to 110.32 ± 12.26 Nm {11.25 ± 1.25 kgm}
guide (28).
2) Fit stator assembly (21) and secure with
★ Put drops of engine oil on the bearing
snap ring (20).
portion, then rotate 10 times.
2) Set bearing and guide assembly (26) to
pump, and tap with a plastic hammer to
press fit bearing.
3) Install retainer (25).
Mounting bolt :
Mounting bolt :
66.19 ± 7.35 Nm (6.75 ± 0.75 kgm)
30-72 D575A-3 SD
➀
12. Lock-up clutch, drive case assembly iv) Install seal rings (14) and (13).
1) Assemble lock-up clutch and drive case
i) Set turbine (9) to block .
v) Install piston (11) to housing (12).

When installing, be careful not to dam-
age the seal ring.
ii) Using eyebolts, set drive case (19) to tur-
vi) Using eyebolts , install housing and
bine.
piston assembly (10).
When installing, support the piston
assembly by hand to prevent it from fall-
ing.
Mounting bolt :
Mounting bolt :
110.32 ± 12.26 Nm {11.25 ± 1.25 kgm}
iii) Install 2 discs (17) and 1 plate (18) in

turn.
D575A-3 SD 30-73
➀
vii) Using push tool , press fit bearing

(15).
viii) Fit plate (8) and secure with snap ring
(7).
13. Torque converter valve assembly

Fit gasket, and using eyebolts , install valve
assembly (2).
★ Tighten the mounting bolts uniformly in turn.
viii) Using eyebolts, fit input shaft (6) and Mounting bolt :
tighten with mounting bolts. 49.0 ± 4.9 Nm {5.0 ± 0.5 kgm}
Mounting bolt :
Mounting bolt :
277.04 ± 31.87 Nm {28.25 ± 3.25 kgm}
ix) Install seal ring (5) to input shaft.
14. Torque converter assembly

Remove torque converter assembly (1) from tool
B.
2) Using eyebolts , set lock-up clutch and

drive case assembly (4) to pump.
★ Fit guide bolts (Thread dia.=10mm,
Pitch=1.5mm, Length=60mm) to the
drive case, and set to the pump.
3) Tighten mounting bolts (3).
Mounting bolt :
Mounting bolt :
53.9 ± 4.9 Nm {5.5 ± 0.5 kgm}
30-74 D575A-3 SD
➀
DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION
REMOVAL OF TORQFLOW 5. Disconnect hose (5), and remove hose clamp.
TRANSMISSION ASSEMBLY 6. Disconnect wiring connectors (6) and (7), and

remove wiring (8).
1. Remove PTO and torque converter assembly. ★ Fit tags to distinguish the mounting position
For details, see REMOVAL OF PTO, TORQUE of the connectors.
CONVERTER ASSEMBLY.
2. Remove cover (1), and disconnect speed sensor

connector for bevel gear.
7. Disconnect 4 transmission central pressure

detection hoses (9).
★ Fit tags to distinguish the mounting position
of the hoses.
3. Disconnect steering central pressure detection
hoses (2). 8. Remove central pressure detection bracket (10).
of the hoses.
4. Disconnect wiring connectors (3) and (4).

of the connectors.
9. Remove filter assemblies (11) and (12).

Filter assembly (11) : 35 kg
Filter assembly (12) : 35 kg
D575A-3 SD 30-75
➀
10. Remove transmission assembly (13). INSTALLATION OF

★ Sling the transmission assembly, and
remove the mounting bolts. TORQFLOW TRANSMISSION
★ Using a lever block, lift off the transmission ASSEMBLY
assembly horizontally.
Transmission assembly : 2,400 kg
removal.
★ Using a lever block, raise the transmission

horizontally, then align the spline of the bevel
gear and install.
30-76 D575A-3 SD
➀
DISASSEMBLY OF TORQ- 5. Tie bolts

1) Remove cage mounting bolts (6).
FLOW TRANSMISSION 2) Remove tie bolts (7).
ASSEMBLY
DISASSEMBLY
Precautions when disassembling
1) To prevent mistakes when assembling the parts,
make match marks and check the mounting
direction before removing.
2) Store the discs and plates in a flat place to pre-
vent them from becoming distorted.
1. Cover
Remove cover.
2. Control valve assembly 6. Front housing

Remove control valve assembly. Using eyebolts , remove front housing (8).
For details, see REMOVAL OF TRANSMISSION
CONTROL VALVE ASSEMBLY (ECMV ASSEM-
BLY).
3. Sleeve
Using forcing screws, remove sleeve (3).
7. Input shaft, No. 1 carrier assembly

Using eyebolts , remove input shaft and No. 1
carrier assembly (9).
4. Case
1) Set input shaft of transmission assembly (4)
at top, and set on block.
2) Using eyebolts , remove case (5).
D575A-3 SD 30-77
➀
★ Portion of bearing (10) will come out. 10. No. 1 housing assembly
1) Using eyebolts , remove No. 1 housing
assembly (16).
2) Remove piston (17) from housing.
8. No. 1 clutch disc, plate, spring

Remove disc (11), plate (12), and springs (13)
and (14).
11. Plate
Screw in forcing screws and remove plate (18).
12. Ring gear for No. 1 carrier

1) Remove ring gear (19) for No. 1 carrier.
2) Remove snap ring (20) from ring gear.
9. No. 1 ring gear

Remove No. 1 ring gear (15).
13. Guide pins, spring

Remove guide pins (22) and (23), and spring
(24).

Remove disc (25), plate (26), and spring (27).
30-78 D575A-3 SD
➀
15. No. 2 ring gear 18. Plate

Remove No. 2 ring gear (28). Remove plate (36).
16. No. 2 housing assembly 19. No. 2, 3 carrier assembly

1) Using eyebolts , remove No. 2 housing Using eyebolts , remove No. 2 and 3 carrier
assembly (29). assembly (37).
2) Remove piston (30) from housing.
20. No. 3 ring gear

17. No. 3 clutch disc, plate, springs 1) Remove plate (38).
Remove disc (32), plate (33), and springs (34) 2) Remove No. 3 ring gear (39).
and (35). 3) Remove snap ring (40) from ring gear.
D575A-3 SD 30-79
➀
21. No. 3 housing assembly 25. No. 4 housing assembly

1) Using eyebolts , remove No. 3 housing 1) Using eyebolts , remove No. 4 housing
assembly (43). assembly (53).
2) Remove piston (44) from housing. 2) Remove piston (54) from housing.
22. Guide pins, spring 26. No. 4 sun gear

Remove guide pins (45) and (46), and spring Remove No. 4 sun gear (55).
(47). Be careful not to get your fingers caught.

Remove disc (48), plate (49), and spring (50).
27. No. 5 clutch, No. 4 sun gear assembly

Using puller , pull out
No. 5 clutch and No. 4 carrier assembly (56),
24. No. 4 ring gear then using eyebolts to remove.
Remove No. 4 ring gear (52). ★ The maximum tensile force of the 2 12mm
bolts is approx. 157 kN (16 ton), so do not
apply any load greater than this.
30-80 D575A-3 SD
➀
28. Output shaft assembly DISASSEMBLY OF INPUT SHAFT, NO. 1

1) Screw in forcing screws, and using eyebolts CARRIER ASSEMBLY
, remove output shaft (60).
1. Retainer (outside)
1) Remove snap ring (66), then remove spacer
(67).
2) Using tool D1, remove retainer (70) together
with bearings (68) and (69).
3) Remove bearing (68) from retainer (70).
2) Disassemble output shaft assembly.

ii) Use a suitable tool to hold cage (62),
then push out shaft (65), and remove
cage (62) from shaft.
bearing (64). 2. Retainer (inside)
Screw in forcing screws and remove retainer
(70).
D575A-3 SD 30-81
➀
3. No. 2 sun gear 5. No. 1 sun gear

1) Turn over input shaft and No. 1 carrier 1) Remove snap ring (85).
assembly, and put block in contact with car- 2) Remove No. 1 sun gear (86).
rier.
3) Remove No. 2 sun gear (74).
4) emove snap ring (75).
6. Bearing
Remove bearing (87) from input shaft (76).
4. No. 1 carrier assembly

1) Push out input shaft (76), and remove No. 1
carrier assembly (77) from shaft.
★ Lay cardboard under the shaft.
DISASSEMBLY OF NO. 2, 3 CARRIER

ASSEMBLY
1. Bearing, No. 3 sun gear

2) Push No. 3 sun gear (89) from inside, and
2) Disassemble No. 1 carrier assembly. remove bearing and collar assembly (90)
i) Push out shaft (79) and ball (80) and and No. 3 sun gear (89).
remove.
ii) Remove thrust washer (81) and gear
(82) from carrier.
iii) Remove bearing (84) from gear (82).
30-82 D575A-3 SD
➀
2. Planetary gear iv) Remove piston (103).

1) Pull out shaft (96), and remove together with v) Remove snap ring (104), then remove
ball (91). bearing (105).
2) Remove thrust washer (92) and gear (93) vi) Remove snap ring (106), then push bear-
from carrier (94). ing (107) and remove together with collar
3) Remove bearing (95) from gear (93). (108).
DISASSEMBLY OF NO. 5 CLUTCH 2. Lift off hub (109).

ASSEMBLY
3. Remove disc (110), plate (111), and spring (112).
1. Housing, piston assembly
1) Remove mounting bolts, then using eyebolts
, remove housing assembly (97).
4. Disassemble drum and No. 4 carrier assembly

as follows.
2) Disassemble housing and piston assembly 1) Remove snap ring (113).
as follows. 2) Pull out shaft (114) to direction of ball (115),
i) Push tool D2 with press, compress then remove gear (116), bearing (117), and
spring (99), and remove snap ring (98). thrust washer (118).
ii) Return press slowly and extend spring.
iii) Remove spacer (101) and spring (99).
D575A-3 SD 30-83
➀ ➀
ASSEMBLY OF TORQFLOW 2. Hub

Fit seal ring and set hub (109) to drum and No. 4
TRANSMISSION ASSEMBLY carrier assembly.
★ Clean all parts thoroughly (especially the oil 3. Discs, plates, springs
holes), and check for dents, dirt or damage. Install discs (110), plates (111), and springs
Coat the sliding surfaces of all parts with engine (112).
oil before installing. ★ No. of discs: 9
★ Install the seal ring with the side receiving the ★ No. of plates: 8
pressure facing the housing. Coat with grease ★ No. of springs: 9
(G2-LI) and be careful to install uniformly.
4. Housing, piston assembly

ASSEMBLY OF NO. 5 CLUTCH 1) Assemble housing and piston assembly as
ASSEMBLY follows.
i) Using push tool, press fit bearing (105) to
1. Drum, No. 4 carrier assembly housing.
Assemble No. 4 carrier assembly as follows. ii) Install snap ring (104).
1) Assemble bearing (117) to gear (116).
2) Put thrust washers (118) in contact on both
sides, and set in carrier.
3) Fit ball (115), then push shaft (114) from
drum end and install.
30-84 D575A-3 SD
➀
iii) Using push tool, press fit bearing (107) to 2) Using eyebolts , align outside teeth of pis-
housing (102). ton with drum, then install housing and piston
iv) Fit dowel pin and install collar (108) to assembly (97).
housing (102).
Mounting bolt :
v) Install snap ring (106).
Mounting bolt :
110.32 ± 12.26 Nm {11.25 ± 1.25 kgm}
vi) Fit seal ring and install piston (103) to

housing (102).
Seal ring : Grease (G2-LI)
vii) Set spring (99) and spacer (101) to pis-

ton (100).
★ Assemble the spring in the direction
shown in the diagram.
viii) Push tool D2 with press, compress
spring (99), and install snap ring (98).
ix) Loosen press slowly and remove tool.
D575A-3 SD 30-85
➀
ASSEMBLY OF NO. 2, 3 CARRIER 2. No. 3 sun gear

ASSEMBLY Assemble No. 3 sun gear (89).
1. Planetary gear 3. Bearing, collar

1) Assemble bearing (95) to No. 3 gear (93), 1) Using push tool, press fit bearing (97) to col-
put thrust washers (92) in contact on both lar (87).
sides, and set in carrier (94). 2) Press fit bearing and collar assembly (90) to
2) Set shaft (96) with ball hole facing top and carrier (87).
push in from below. 3) Install snap ring (88).
★ The top of the bearing will fall inside and
the shaft will catch, so insert the shaft
from below.
3) Repeat procedure in Step 1) to set No. 2
gear (93) in carrier.
ASSEMBLY OF INPUT SHAFT, NO. 1

CARRIER ASSEMBLY
1. Bearing
1) Support input shaft (76) to prevent it from
falling over.
2) Shrink fit bearing (87) to input shaft.
★ Shrink-fitting temperature :
100°C for approx. 30 minutes
4) Push up shaft to a point where ball hole can

be seen.
5) Fit ball (91) and install shaft.
30-86 D575A-3 SD
➀
DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMSSION
2. No. 1 sun gear 2) Raise No. 1 carrier assembly (77) and install
1) Install No. 1 sun gear (86) to input shaft. to input shaft (76).
Set with the protruding end facing the bear-
ing.
4. No. 2 sun gear

2) Install No. 2 sun gear (74).
3. No. 1 carrier assembly 3) Install snap ring (73).
1) Assemble No. 1 carrier assembly.
i) Assemble bearing (84) to gear (82).
ii) Fit thrust washers (81) to both ends and
set to carrier.
iii) Fit ball (80), then push shaft (79) and
install.
5. Retainer (inside)
1) Turn over input shaft and No. 1 carrier.
2) Fit seal ring and install retainer (71) to No. 1
carrier (72).
Mounting bolt :
iv) Turn over carrier assembly, then using
push tool, install bearing (78). Mounting bolt :
110.32 ± 12.26 Nm {11.25 ± 1.25 kgm}
D575A-3 SD 30-87
➀
6. Retainer (outside) ASSEMBLY

retainer (70). 1. Output shaft assembly
1) Assemble output shaft assembly as follows.
i) Using push tool, press fit bearing (64) to
cage (62).
ii) Install snap ring (61).
2) Install retainer (70) to retainer (71).

★ The outer race of the bearing is press fit-
ted.
iii) Using tool D3, press fit cage (62) to out-

put shaft (65).
★ Push the inner race of the bearing.
7. Bearing
1) Press fit bearing (68).
2) Fit spacer (67) and install snap ring (66).
30-88 D575A-3 SD
➀
2) Fit seal ring, then using eyebolts , install 3. No. 4 sun gear
output shaft assembly (60) to housing (59). Install No. 4 sun gear (55).
★ Be careful not to get your fingers caught.
Mounting bolt :
Mounting bolt :
110.32 ± 12.26 Nm {11.25 ± 1.25 kgm}
4. No. 4 housing assembly

1) Fit seal ring and install piston (54) to hous-
ing.
2. No. 5 clutch, No. 4 carrier assembly
★ Be careful not to get the seal ring caught.
Using eyebolts , set No. 5 clutch and No. 4
2) Using eyebolts , install No. 4 housing
carrier assembly (56) to output shaft, then using
assembly (53).
tool D3 and No. 4 sun gear, install.
5. No. 4 ring gear

★ Press fit bearings (58) and (57) at 2 places Install No. 4 ring gear (52).
and .
6. Guide pins
Install guide pins (46) and (45).
D575A-3 SD 30-89
➀
7. No. 4 clutch discs, plates, springs 9. Sleeve

Install discs (48), plates (49), and springs (47) Install sleeve (42).
and (50). ★ Install the sleeve with the side with the slit
★ No. of discs: 4 facing down.
★ No. of plates: 3
★ Free length of spring: 56.9 mm
10. No. 3 ring gear

8. No. 3 housing assembly 2) Align with outside teeth of No. 4 carrier and
1) Fit seal ring and install piston (44) to No. 3 install No. 3 ring gear (39).
housing. 3) Install plate (38).
Seal ring : Grease (G2-LI) Mounting bolt :
★ Be careful not to get the seal ring caught.
2) Using eyebolts , install No. 3 housing Mounting bolt :
assembly (43). 110.32±12.26 Nm{11.25±1.25 kgm}
30-90 D575A-3 SD
➀
11. No. 2, 3 carrier assembly 14. No. 2 housing assembly

Using eyebolts , install No. 2 and 3 carrier 1) Fit seal ring and install piston (30) to hous-
assembly (37). ing.
★ Mesh the inside teeth of the collar with the
output shaft, and the No. 3 sun gear with the
output shaft and No. 3 planetary gear. ★ Be careful not to get the seal ring caught.
2) Using eyebolts , install No. 2 housing
assembly (29).
12. Plate
Fit seal ring and install plate (36).
Mounting bolt : Thread tightener (LT-2) 15. No. 2 ring gear
Mounting bolt : Install No. 2 ring gear (28).
110.32 ± 12.26 Nm {11.25 ± 1.25 kgm} ★ Overall length of ring gear : 144 mm
★ Mesh the inside teeth with the No. 2 plane-
tary gear.
16. Guide pins

Install guide pins (23) and (22).
13. No.3 clutch discs, plates, springs

Install discs (32), plates (33), and springs (34)
and (35).
★ No. of discs: 5
★ Free length of spring: 68.8 mm
D575A-3 SD 30-91
➀
17. No. 2 clutch discs, plates, springs 20. No. 1 housing assembly
Install discs (25), plates (26), and springs (24) 1) Fit seal ring and install piston (17) to hous-
and (27). ing.
★ No. of discs: 9 Seal ring : Grease (G2-LI)
★ No. of plates: 8 ★ Be careful not to get the seal ring caught.
★ Free length of spring: 168 mm 2) Using eyebolts , install No. 1 housing
assembly (16).
18. Ring gear for No. 1 carrier

1) Install snap ring (20). 21. No. 1 ring gear
2) Align with outside teeth of No. 2 carrier, and Install No. 1 ring gear (15).
install ring gear (19) for No. 1 carrier. ★ Mesh the inside teeth with the outside teeth
of the No. 1 carrier.
19. Plate
Install plate (18).
Mounting bolt : Thread tightener (LT-2)
Mounting bolt :
110.32 ± 12.26 Nm {11.25 ± 1.25 kgm}
22. No. 1 clutch discs, plates, springs

Install discs (11), plates (12), and springs (13)
and (14).
★ No. of discs: 8
★ Free length of spring: 133 mm
30-92 D575A-3 SD
➀
23. Input shaft, No. 1 carrier assembly 25. Tie bolts

Using eyebolts , install input shaft and No. 1 1) Tighten tie bolts (7).
carrier assembly (9).
Tie bolt :
372.7 ± 19.6 Nm {38 ± 2 kgm}
2) Install cage mounting bolts (6).
Mounting bolt :
Mounting bolt :
110.32±12.26 Nm{11.25±1.25 kgm}
★ Portion of bearing (10) is press fitted to

the No. 2 carrier.
26. Checking piston stroke

Using tool D4, check stroke of each piston.
Unit: mm
Piston Standard stroke
R 10.2
F 11.0
3 4.8
24. Front housing 2 4.0
Using eyebolts , install front housing (8). 1 8.9
D575A-3 SD 30-93
➀
DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION, STEERING CASE
27. Case REMOVAL OF STEERING

Fit O-ring, and using eyebolts , install case
(5). CASE ASSEMBLY
★ Tighten the bolts from below.
1. Remove power train assembly.
Mounting bolt : For details, see REMOVAL OF POWER TRAIN
549.2 ± 58.8 Nm {56 ± 6 kgm} ASSEMBLY.
2. Set power train assembly (1) horizontally on

block .
28. Control valve

1) Set transmission assembly (4) facing side.
2) Fit O-ring and install sleeve (3).
3. Remove step (2).
4. Remove suction tube (3).
3) Install control valve assembly.

For detail, see INSTALLATION OF TRANS-
MISSION CONTROL VALVE ASSEMBLY.
(ECMV ASSEMBLY)
29. Cover
Install cover.
30-94 D575A-3 SD
➀
DISASSEMBLY AND ASSEMBLY STEERING CASE
6. Disconnect pressure detection hose (5).

★ Remove the related clamps at the same
time.
of the hoses.

of the connectors.
8. Remove breather hose (8).
INSTALLATION OF STEERING
CASE ASSEMBLY
removal.
★ Using a lever block, raise the steering case

assembly horizontally, then align with the
9. Remove strainer (9). spline of the transmission shaft and install.
Strainer : 85 kg
10. Remove steering case assembly (10).

★ Sling the steering case assembly, then
remove the mounting bolts.
★ Using a lever block, raise the steering case
assembly horizontally.
Steering clutch, brake assembly :
3,400 kg
D575A-3 SD 30-95
➀
DISASSEMBLY OF STEERING 5. Clutch assembly

1) Remove plate (5) and shim (6).
CASE ASSEMBLY ★ Check the number and thickness of
shims (6), and keep in a safe place.
1. Lift off steering control valve assembly (1). ★ Make match marks on the taper serration
Steering control valve assembly : 60 kg portion.
2. Remove oil filler (2).
2) Using tool G6, pull out clutch assembly (7)

from shaft.
3. Remove lubrication tube (3). After removing the press-fitting portion,
be careful not to let the clutch assembly
fall from the shaft.
4. Brake assembly
1) Leave 1 mounting bolt each at left, right, and
bottom, and remove other mounting bolts.
2) Set tool G3 to tap hole at top of brake
assembly (4), remove remaining bolts, then
remove brake assembly.
30-96 D575A-3 SD
➀
3) Set tool G5 to clutch assembly (7), and 2) Using forcing screws, pull out bevel pinion
remove clutch assembly from shaft. assembly, then lift off.
★ When removing the clutch assembly, be ★ Pull the bevel pinion assembly out
careful not to damage the discs and slightly, remove top and bottom split
plates. shims (9), and keep the shims in sets for
each position.
When installing tool G5 to the clutch
assembly, be careful not to let it fall from
the shaft.
Ti g h t e n t h e l o ck b o l ts o f to o l G5
securely.
• Repeat the procedure in Steps 4 and 5 and
remove the brake and clutch assembly on
the opposite side.
3) Disassemble bevel pinion assembly as fol-

lows.
i) Remove plate (10) and shims (11).
★ Check the number and thickness of
the shims, and keep in a safe place.
ii) Set bevel pinion assembly on block ,

6. Bevel pinion assembly
then use bearing forcing screws and
1) Remove mounting bolts of bevel pinion
remove pinion gear (12) and inner bear-
assembly (8), and install guide bolt .
ing (13).
D575A-3 SD 30-97
➀
iii) Remove bearing inner (15) from bevel 9. Remove clamp, then remove pipe (19).
pinion cage (14).
10. Remove flange (20).
★ The flange is a top and bottom split type, and
one part is secured by a dowel pin, so tap
with a plastic hammer to remove it.
iv) Remove bearing outer races (16) and

(17) from bevel pinion cage.
11. Bevel gear, shaft assembly

1) Sling shaft, then use forcing screws to
remove left bearing cage assembly (21).
★ Pull the bearing cage assembly out
slightly, remove top and bottom split
shims (22), and keep the shims in sets
for each position.
7. Remove valve seat (18) from case assembly.
8. Remove bracket (32) and shims (33).

★ When removing the bracket, be careful not to
damage rotating sensor (34) of the bevel
gear.
30-98 D575A-3 SD
➀
2) Set tool G7 to bevel gear and shaft assembly 5) Disassemble bevel gear and shaft assembly
(23) and sling. as follows.
i) Remove O-rings (25) from bevel gear
and shaft assembly (23).
ii) Using bearing puller, remove bearing
(26).
iii) Remove collar (31), then remove seal
ring (27).
3) Using forcing screws, remove right bearing

cage assembly (24).
★ Pull the bearing cage assembly out
slightly, remove top and bottom split
shims (25), and keep the shims in sets
for each position.
★ Check the number and thickness of the iv) Remove nut (28), and set push tool to
shims, and keep in a safe place. bevel gear (29).
v) Push bevel gear and remove bearing
(30) and bevel gear (29) from shaft.
Wh e n r e m o v i n g t h e b e a r i n g , b e
extremely careful not to let the shaft fall
over.
★ After removing the bevel gear, set it on a
block to protect it from damage.
★ Check that there is no abnormality in the
bearing.
4) Remove bevel gear and shaft assembly (23).
D575A-3 SD 30-99
➀
12. Remove outer race (31) from bearing cage ASSEMBLY OF STEERING
assemblies (21) and (24).
CASE ASSEMBLY
1. Using tool G12, press fit outer race (31) to bear-
ing cages (24) and (21).
2. Bevel gear, shaft assembly

1) Using guide bolt , install shims (25)
)removed during disassembly) and bearing
cage assembly (24) to right side of steering
case.
★ Standard shim thickness : 2.5 mm
Mounting bolt :
277.04 ± 31.87 Nm {28.25 ± 3.25 kgm}
30-100 D575A-3 SD
➀
2) Assemble bevel gear and shaft assembly as ★ Assemble the tip of the bevel gear
follows. and shaft assembly securely into the
i) Install bevel gear (29) to shaft. bearing cage on the right side of the
ii) Using tool G11, press fit bearing (30) to case.
shaft with press.
4) Using a push tool, fit stopper to bevel

gear and shaft assembly (23) as shown
iii) Assemble seal rings (27) to shaft.
in Fig., then sling with wire from holes in
★ Be careful not to damage the seal
top of case.
ring when assembling.
5) With above condition, remove tool G7.
iv) Assemble collar (31).
★ Be careful not to damage the seal
ring when assembling.
3) Set tool G7 to bevel gear and shaft assembly

(23) and assemble in steering case.
D575A-3 SD 30-101
➀
6) Assemble bearing cage assembly (21) to 4. Bevel pinion assembly

bevel gear and shaft assembly, then assem- 1) Assemble bevel pinion assembly as follows.
ble shim (22) (removed during disassembly), i) Using tool G14, press fit bearing outer
and install bearing cage assembly. race (16) to bevel pinion cage (14).
★ Standard shim thickness : 2.5 mm ii) Using tool G14, press fit bearing outer
race (17) to bevel pinion cage (14).
Mounting bolt :
★ After press fitting, check that there is
277.04 ± 31.87 Nm {28.25 ± 3.25 kgm}
no clearance at portion a of the outer
★ After installing bearing cage assembly race and cage in Steps 1) and 2).
(21), remove stopper installed to the
bevel gear and shaft assembly on the
opposite side.
iii) Using tool G13, press fit bearing (13) to

pinion gear (12).
★ After press fitting, check that there is
3. Adjusting preload no clearance at portion b of the
Fit push-pull scale to tip of bevel gear teeth, bearing and pinion gear.
then measure rotating torque of bevel gear and
shaft.
Measure without meshing the bevel pinion.
★ Standard value for rotating torque :
5.00 – 6.96 Nm {0.51 – 0.71 kgm}
(at top of bevel gear teeth:
26.5 – 37.3 N {2.7 – 3.8 kg})
★ If the measurement is not within the standard
value, adjust the shim thickness as follows.
If value is HIGH, add shims
If value is LOW, remove shims
★ Rotate the bevel gear 2 – 3 times before
measuring the rotating torque.
30-102 D575A-3 SD
➀
iv) Assemble bevel pinion cage assembly vii) Install dial gauge , rotate bevel pinion
(14) to pinion gear assembly (12). cage assembly (14) slowly, and read
value shown on dial gauge.
• Adjusting preload ★ Rotate the bevel pinion cage assem-
v) Install bearing inner race (15), insert bly thoroughly, then carry out mea-
shim (11) 1.5 mm (standard clearance surements at 4 places around the
1.0 + 0.5 mm), and tighten inner race circumference.
with plate (10).
★ Tightening torque when press fitting
inner race :
24.5 ± 4.9 Nm {2.5 ± 0.5 kgm}
viii) Raise bevel pinion cage assembly (14)

as shown in the diagram on the right, and
read value on dial gauge , in
same way as in Step vii).
★ The difference between dial gauge
readings and is clearance
in the axial direction.
vi) Remove plate (10) and shim (11).
D575A-3 SD 30-103
➀
ix) Calculate thickness of shim (11) as fol- 5. Adjusting tooth contact, backlash
lows, then insert shim and install plate 1) Adjusting backlash
(10). Put the probe of dial gaugee at right
angles in contact with the tip of the bevel
Shim thickness = 1.5 mm (thickness of gear teeth. Hold the bevel pinion in position,
shim assembled in Step v)) – Clearance and read the measurement when the bevel
± 0.025 mm gear is moved forward and backward.
★ After adjusting the preload, check ★ Standard value for backlash :
that the rotating torque at the tip of 0.36 – 0.46 mm
the bevel pinion teeth is less than ★ Measure at a minimum of three points on
38.64 N {3.94 kg}. opposite sides.
2) Using guide bolt , assemble bevel pinion • If the result of the inspection shows that
assembly (8). t h e c o r r e c t b a c kl a s h i s n o t b e i n g
★ When assembling the bevel pinion obtained, adjust as follows.
assembly, leave a clearance to assemble • If backlash is too small
the shim. Adjust the shim thickness at the bevel
3) Remove guide bolt, assemble shim (9) pinion end to move the bevel pinion in
(removed during disassembly), then install direction A, or adjust the shim thickness
bevel pinion assembly (8). at the bearing cage of the bevel gear
★ Standard shim thickness : 1.55 mm shaft to move the bevel gear in direction
B.
Mounting bolt :
277.04 ± 31.87 Nm {28.25 ± 3.25 kgm}
30-104 D575A-3 SD
➀
• If backlash is too large 2) Adjusting tooth contact

Adjust the shim thickness at the bevel Testing
pinion end to move the bevel pinion in i) Coat the tooth face of the bevel pinion
direction A (the opposite direction from A lightly with red lead (minium). Rotate the
above), or adjust the shim thickness at bevel gear forward and backward and
the bearing cage of the bevel gear shaft inspect the pattern left on the teeth.
to move the bevel gear in direction B (the ii) The center of tooth contact f should be in
opposite direction from B above). the center of the tooth height and at a
★ When adjusting the shim thickness at the position 40 – 60% of the tooth length
bearing cage of the bevel gear shaft, do from the small end, and the width of con-
not change the preload of the bearing. tact e should be 30 – 75% of the tooth
Adjust by moving shims between the length.
bearing cage and the bevel pinion. In addition, there should be no strong
Always keep the same total thickness of contact at addendum a or dedendum b
shims. (tip or root of the gear teeth) or at small
end d or big end c.
★ If the gears are adjusted to this pattern,
the tooth contact will be correct when
load is applied.
D575A-3 SD 30-105
➀
Adjustment ii) If bevel pinion is too close to center line

If the result of the inspection shows that the of bevel gear.
correct tooth contact is not being obtained, Contact is at the big end of the convex
adjust again as follows. tooth face of the bevel gear and the small
i) If bevel pinion is too far from center line end of the concave tooth face.
of bevel gear. • Correct the tooth contact as follows.
Contact is at the small end of the convex Adjust the thickness of the shims at the
tooth face of the bevel gear and at the bevel pinion to move the bevel pinion in
big end of the concave tooth face. direction A (the opposite direction from A
• Correct the tooth contact as follows. above).
Adjust the thickness of the shims at the Or adjust the thickness of the shims at
bevel pinion to move the bevel pinion in the bearing cage of the bevel gear shaft
direction A. to move the bevel gear in direction B (the
Or adjust the thickness of the shims at opposite direction from B above), then
the bearing cage of the bevel gear shaft check the tooth contact pattern and
to move the bevel gear in direction B, backlash again.
then check the tooth contact pattern and
backlash again.
★ When adjusting the movement in or out

of the bevel gear, do not change the pre-
load of the bearing. Adjust by moving
shims between the bearing cage and the
bevel pinion. Always keep the same total
thickness of shims.
30-106 D575A-3 SD
➀
6. Install flange (20). 10. Clutch assembly

★ Align correctly with the dowel pin hole and 1) Install O-rings (25) to bevel gear and shaft
install. assembly (24).
★ Be careful not to damage the O-ring
7. Fit O-rings to pipes (19) and install to flange (20). when assembling, and coat with grease.
★ Be careful not to damage the O-ring when
assembling, and install the clamp securely.
2) Set tool G5 in position, raise clutch assembly

(7), and assemble in steering case.
8. Install speed sensor, bracket, and shims as fol- ★ Be careful not to damage O-ring (25)
lows. assembled to the shaft, and assemble
1) Set so that ridge of bevel gear tooth is hori- the clutch assembly.
zontal. ★ Tighten the lock bolt of tool G5 securely.
2) Install speed sensor (34) to bracket (32).
3) Without assembling shim (33), install bracket
and measure clearance at point where
speed sensor and bevel gear teeth are in
light contact.
4) Remove bracket, insert shim (thickness =
clearance measured in Step 3) + 2
shims), then tighten bracket temporarily.
Thickness of 1 shim : 0.5 mm
5) Insert feeler gauge from hole in top of steer-
ing case, and check that clearance is
0.75 – 1.5 mm, then tighten bolts of bracket
fully.
9. Install valve seat (18) to case.

Be careful not to damage the O-ring when install-
ing.
D575A-3 SD 30-107
➀
3) Set tool G6 in position and press fit clutch 11. Set tool G3 to brake assembly (4), then assem-
assembly (7). ble to clutch assembly and install.
★ Press fitting force of clutch assembly : ★ Install tool G3 to the tap hole at the top of the
294 – 392 kN {30 – 40 ton} brake assembly.
★ When installing the brake assembly, align the
Press-fitting surface : spline portion of the clutch assembly and
Anti-friction compound (LM-P) brake drum, then push in the brake assembly.
4) Remove tool G6, assemble shim (6) • If it is impossible to assemble the brake
(removed during disassembly), and install assembly to the clutch assembly, do not
plate (5). try to force it in. Check the alignment of
★ Standard shim thickness : 3 mm the tooth groove of the clutch assembly,
and if there is any abnormality, correct
Mounting bolt : the problem. For details, see DISAS-
277.04 ± 31.87 Nm {28.25 ± 3.25 kgm} SEMBLY OF CLUTCH ASSEMBLY.
★ Adjusting method of shim (6) ★ Assemble the O-ring of the mounting surface
i) Measure stepped difference of the brake assembly, and be careful not to
between end face of shaft and clutch damage it when installing the brake assem-
assembly. bly.
★ Mesured stepped difference :
3 ± 0.5 mm • Repeat the procedure in Steps 9) and 10) to
ii) Adjust shim thickness to – (0.1 – install the brake assembly and clutch assem-
0.2) mm and assemble. bly on the opposite side.
12. Install lubrication tube (3).
30-108 D575A-3 SD
➀
DISASSEMBLY AND ASSEMBLY STEERING CASE, STEERING CLUTCH
13. Install oil filler (2). DISASSEMBLY OF STEERING

14. Install steering control valve assembly (1). CLUTCH ASSEMBLY
1. Remove retainer (1).
2. Remove belleville springs (2).

★ No. of belleville springs: 3
3. Lift off piston (3).
4. Remove seal ring (4) from piston (3).
D575A-3 SD 30-109
➀
DISASSEMBLY AND ASSEMBLY STEERING CLUTCH
5. Remove plate (5) from piston (3). ASSEMBLY OF STEERING

CLUTCH ASSEMBLY
1. Assemble seal ring (9) to clutch flange (8).
★ Be extremely careful not to damage the seal
ring when assembling, and coat with grease
(G2-LI).
2. Set tool G8 to clutch flange (8), then assemble

plates (7) and discs (6) in turn.
★ Check that there is no dirt or damage to the
mating surface of the discs and plates.
★ Coat the mating surface of the discs and the
plates w ith engine oil (EO30-CD) and
assemble.
6. Remove discs (6) and plates (7) from flange (8). ★ No. of discs: 8
★ No. of discs: 8 ★ No. of plates: 7
★ Keep the discs and plates in a safe place to
protect them from damage.
7. Remove seal ring (9) from clutch flange (8).
3. Install plate (5) to piston (3).
4. Assemble seal ring (4) to piston (3).

★ Be extremely careful not to damage the seal
ring when assembling, and coat with grease
(G2-LI).
30-110 D575A-3 SD
➀
DISASSEMBLY AND ASSEMBLY TEERING CLUTCH, STEEERING BRAKE
5. Raise piston (3) and assemble to clutch flange DISASSEMBLY OF STEERING

(8).
★ Be careful not to damage the seal ring when BRAKE ASSEMBLY
assembling the piston.
1. Remove plate (1) and shims (2).
★ Check the number and thickness of shims
(2), and keep in a safe place.
6. Assemble belleville springs (2).

★ Be careful to assemble the belleville spring
facing in the correct direction.
★ No. of belleville springs: 3 2. Set tool G1 in position, and remove gear cou-
pling (3).
7. Install retainer (1), and remove tool G8. ★ Press-fitting load of gear coupling :
Mounting bolt : 294 – 392 KN {30 – 40 ton}
277.04 ± 31.87 Nm {28.25 ± 3.25 kgm}
3. Remove cage (4) and O-ring from gear coupling.
4. Remove cover (5), then remove oil seal (6) and

O-ring.
D575A-3 SD 30-111
➀
DISASSEMBLY AND ASSEMBLY STEERING BRAKE
5. Remove lock washer, then remove plate (7). 8. Disconnect drum (12) and shaft (13).
9. Remove seal ring (14) from shaft (14).

★ Be careful not to damage the seal ring when
removing.
6. Using tool G4, remove nut (8).
10. Remove bearing inner (15) from shaft (13).
7. Drum, shaft assembly

1) Raise brake assembly approx. 100 mm, then
set wooden block under brake assembly.
2) Set push-puller in position, then pull out
drum and shaft assembly (10).
3) Remove bearing inner race (11).
★ The plate is under pressure from the
belleville spring, so loosen the bolts slowly.
30-112 D575A-3 SD
➀
12. Remove discs (17), plate (18), and wave springs ASSEMBLY OF STEERING
(19).
★ No. of discs: 9 BRAKE ASSEMBLY
★ No. of wave springs: 9 1. Assemble belleville springs (22) to brake flange
(23).
13. Remove cage (20), piston (21), and belleville

spring (22) from brake flange (23). ★ Assemble the 4 belleville springs as shown
★ Be careful not to damage piston rings (24) in the diagram.
and (25) when removing.
2. Install piston ring (25) to piston (21), and assem-

14. Remove bearing outer race (26) from cage (20). ble to brake flange.
D575A-3 SD 30-113
➀
★ Align the position of piston tap hole and 4. Assemble piston ring (24) to cage (20), and
brake release tap hole in brake flange install to brake flange (23).
when assembling the piston. ★ Coat the sliding surface of the seal ring with
There is also danger that the 3rd belleville grease. (G2-LI)
spring from the bottom may come out of ★ When installing cage (20), be careful not to
position, so be careful when assembling. damage piston rings (24) and (25).
Mounting bolt :
277.04 ± 31.87 Nm {28.25 ± 3.25 kgm}
★ Be careful of the direction of the lip when

installing the seal ring. Be careful not to
damage the seal ring when assembling, and 5. Using tool G10 through brake release tap hole in
coat the sliding surface with grease after brake flange (23), tighten piston (21) and com-
installing. press belleville spring (22).
★ Be careful not to damage the seal ring when ★ Install 4 brake release bolts G10 on diago-
assembling, and after installing the seal ring, nally opposite sides.
coat the sliding surface with grease.
3. Press fit bearing outer races (26) to cage (20).

★ After press fitting, check that there is no
clearance at portion “a”.
30-114 D575A-3 SD
➀
6. Set tool G9 to brake flange (23), and assemble

discs (17), plates (18), and wave springs (19).
9. Assemble seal ring (14) to shaft (13).

★ Be careful not to damage the seal ring when
assembling, and coat the sliding surface with
★ No. of discs: 9 grease.
★ No. of wave springs: 9 10. Install shaft (13) to drum (12).
★ Coat the mating surface of the discs and
plates with engine oil (EO30-CD). Mounting bolt :
★ Check that there is no dirt or damage to the 539.4 ± 49.0 Nm {55 ± 5 kgm}
mating surface of the discs and plates.
7. Install plate (16).

★ After installing the plate, remove tool G9.
11. Raise brake assembly (9) and assemble to drum

and shaft assembly (10).
★ Be careful not to damage seal ring (14) when
assembling the brake assembly to the drum
8. Press fit bearing inner race (15) to shaft (13). assembly.
After press fitting the inner race, check that there
is no clearance at portion “b”.
★ Measure dimension A of the shaft.
Standard value : 205.79 ± 0.4 mm
★ Measure dimension B (set height) of the
inner race of the bearing.
Standard value:
+0.458
TIMKEN bearing : 89.305 --0.050
D575A-3 SD 30-115
➀
12. Press fitting of bearing inner race. 13. Install plate (7), and lock bolt with lock washer.
1) Use bolt G10 to keep brake released.
2) Using tool G2, press fit bearing inner race
(11).
3) Measure dimension C, and check that rela-
tionship between dimensions A and B mea-
sured in Step 8 is as follows.
C = (A – B) ± 0.3 mm
★ Bend the lock washer perpendicularly

against one face of the bolt.
4) Using tool G4, install nut (8).

Nut : 981 ± 245 Nm {100 ± 25 kgm}
5) Remove bolt .
★ After removing the bolt, install blind plugs
securely in 4 places.
14. Press fit oil seal (6) to cover (5), and install O-
ring.
30-116 D575A-3 SD
➀
15. Install cover (5). ★ Adjusting shim (2)

1) Measure stepped difference between
shaft and gear coupling (mounting sur-
face of plate).
Standard stepped difference :
3 ± 0.5 mm
2) Adjust shim to a thickness of – (0.1 –
0.2)mm.
16. Gear coupling

1) Assemble O-ring and cage (4) to gear cou-
pling (3).
2) Using tool G1, press fit gear coupling (3).
Press-fitting surface of gear coupling

: Anti-friction compound (LM-P)
18. Check face runout and radial runout of gear cou-
★ Press-fitting force of gear coupling :
pling.
294 – 392 kN {30 – 40 ton}
• Position for checking face runout :
Portion
• Position for checking radial runout :
Portion
• Runout limit : Within 0.08 mm
17. Assemble shim (2) (removed during disassem-

bly), and install plate (1).
★ Standard shim thickness : 3 mm
Mounting bolt :
277.04 ± 31.87 Nm {28.25 ± 3.25 kgm}
D575A-3 SD 30-117
➀
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER VALVE
REMOVAL OF TORQUE 8. Lift off torque converter valve assembly (10).
CONVERTER VALVE
ASSEMBLY
1. Open cover and remove steps (1) and (2).
2. Disconnect filter inlet hose (3).
3. Disconnect pressure detection hose (4), and 3

relief valve outlet and inlet hoses (5).
4. Remove tube (6) between transmission pump

and filter.
5. Lift off filter assembly (7) together with seat.

★ Remove 6 mounting bolts marked ▲.
Torque converter valve ass'y : 35 kg
6. Disconnect solenoid valve wiring connector (8).
7. Disconnect 3 pressure detection hoses (9).
30-118 D575A-3 SD
➀
INSTALLATION OF TORQUE
CONVERTER VALVE
ASSEMBLY
removal.
Mounting bolt :
49.0 ±4.9 Nm {5.0 ± 0.5 kgm}
★ Tighten the mounting bolts uniformly in turn.

Run the engine to circulate the oil through the
system. Then check the oil level again.
D575A-3 SD 30-119
➀
DISASSEMBLY OF TORQUE
CONVERTER VALVE
ASSEMBLY
1. Disassembly of lock-up valve
1) Remove solenoid valve assembly (1).
2) Remove cover (2), then remove spring (3).
3) Remove cover (4), then remove piston (5).
4) Pull out spool (6).
2. Disassembly of torque converter relief valve

1) Remove cover (7), then remove spring (8).
2) Remove cover (9), them remove valve (10),
and springs (11) and (12).
3. Disassembly of main relief valve

1) Remove cover (14), then remove shim (15)
and spring (16).
2) Remove cover (17), then remove valve (18),
spring (19), and valve (20).
4. Disassembly of stator clutch modulating valve

1) Remove cover (22), then remove piston (23)
and spring (24).
2) Remove ring (25) from body.
5) Remove shim (31) from spool.
5. Disassembly of lock-up clutch modulating

valve
1) Remove cover (32), then remove piston (33)
and spring (34).
2) Remove ring (35) from body.
5) Remove spool (41) and shim (42) from spool
(40).
30-120 D575A-3 SD
➀
D575A-3 SD 30-121
➀
ASSEMBLY OF TORQUE CON- 5. Assembly of lock-up valve

1) Assemble spool (6).
VERTER VALVE ASSEMBLY 2) Assemble piston (5) in cover (4), then fit O-
ring and install cover.
★ Clean all parts, and check for dirt or damage. 3) Assemble spring (3).
Coat the sliding surfaces of all parts with engine 4) Fit O-ring and install cover (2).
oil before installing. 5) Fit O-ring and install solenoid valve assem-
★ Assemble valves (39) and (37), (29) and (27), bly (1).
(20) and (18), and (12) and (10) as shown in the
diagram with the hole in the center of the valve
assembled on the inside of the spool.
1. Assembly of lock-up clutch modulating valve

1) Set shim (42) to spool (41), then assemble to
spool (40).
3) Assemble valve (39), spring (38), and valve
(37) to spool, then fit O-ring and install cover
(36).
4) Assemble ring (35) to body.
5) Assemble spring (34).
6) Assemble piston (33) to cover (32), then fit
O-ring and install cover.
2. Assembly of stator clutch modulating valve

1) Assemble shim (31) to spool (30).
2) Assemble shim (30).
(26).
4) Assemble ring (25) to body.
6) Assemble piston (23) to cover (22), then fit
O-ring and install cover.
3. Assembly of main relief valve

(17).
4) Assemble shim (15) to cover (14), then fit O-
ring and install cover.
4. Assembly of torque converter relief valve

(9).
4) Fit O-ring and install cover (7).
30-122 D575A-3 SD
➀
D575A-3 SD 30-123
➀
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE
REMOVAL OF TRANSMISSION
CONTROL VALVE ASSEMBLY
(ECMV ASSEMBLY)
Stop the machine on level ground, lower the
work equipment completely to the ground, then
apply the parking brake.
1. Remove cover.
3. Remove ECMV assembly (3).
INSTALLATION OF
TRANSMISSION CONTROL
VALVE ASSEMBLY
(ECMV ASSEMBLY)
removal.
★ Before removing the ECMV assembly, clean

the area around the valve thoroughly and be
careful not to let any dirt get in.
ECMV assembly mounting bolt :

30.89 ± 3.43 Nm {3.15 ± 0.35 kgm}
30-124 D575A-3 SD
➀
DISASSEMBLY OF TRANSMISSION CONTROL VALVE

ASSEMBLY (ECMV ASSEMBLY)
• Before removing the ECMV assembly from the 2) Remove solenoid valve (15).
transmission assembly, clean the area around ★ Carry out masking to prevent any dirt or
the ECMV thoroughly, and prevent any dirt from dust from getting inside from the mating
getting inside the transmission assembly or surface of the solenoid valve.
ECMV.
• After removing the parts, be careful not to dam-
age them and keep them in a safe place.
1. Remove plate (2) from valve body (1).

★ When disassembling the valve during the proce-
d u r e b e l o w, ch e ck th a t t h e v a l v e mo v e s
smoothly.
2. Flow detection valve

1) Using bolt (Thread dia.= 8mm, Pitch=
1.25mm), pull out plug (3), then remove
spring (4), valve (5), and spring (6).
2) Pull out connectors (7) and (8) from bracket,
then remove fill switch (9) and bracket (10).
3. Pressure control valve

1) Remove spring (11), shim (12), piston (13),
and valve (14).
Start engine and retract piston rod fully.
★ Check the number and thickness of
shims (12), and keep in a safe place.
D575A-3 SD 30-125
➀
ASSEMBLY OF 3. Inspecting ECMV oil pressure

Inspect ECMV oil pressure.
TRANSMISSION CONTROL For details, see TESTING AND ADJUSTING,
VALVE ASSEMBLY Inspecting ECMV oil pressure.
(ECMV ASSEMBLY)
4. Adjusting ECMV oil pressure
★ If the pressure control parts have been disas- • If the result of the check shows that the oil
sembled or removed, always check the oil pres- pressure is not within the standard value,
sure. use shim (12) to adjust the oil pressure.
Coat the sliding surfaces of all parts with engine Amount of adjustment Approx.
oil before installing. for 1 shim 0.019 MPa
(thickness: 0.2 mm) {0.19 kg/cm2}
1. Pressure control valve

1) Assemble valve (14) in body (1). ★ Adjust the oil pressure as follows.
★ Push with your finger from both ends of To INCREASE pressure, INCREASE shim
the body to check that the valve moves thickness
smoothly. ★ To DECREASE pressure, DECREASE shim
2) Fit O-ring to solenoid valve (15) and install to thickness
body. ★ Install the shims securely, and be careful not
to drop them inside the valve.
Mounting bolt : ★ After adjusting with shims, check the oil pres-
13.24 ± 1.47 Nm {1.35 ± 0.15 kgm} sure again.
3) Assemble piston (13) in valve (14).
★ Check that the piston moves smoothly.
4) Assemble shim (12) and spring (11) to valve
(14), then fit O-ring and install to body.
• Standard number of shims: 3
• Standard thickness of shim: 0.6 mm
(Thickness of 1 shim: 0.2 mm)
★ If valve body (1), spring (11), piston (13), valve
(14), and solenoid valve (15) are all used again,
assemble the same number of shims that was
removed during disassembly.
★ If any of the above parts is replaced, assemble
the standard shim.
★ When replacing solenoid valve (15), remove
plate (2) and check that spring (11) is assembled
securely.
2. Flow detector valve

1) Assemble valve (5) to body.
★ Push with your finger from both ends of
the body to check that the valve moves
smoothly.
2) Assemble spring (6) and fit O-ring to body,
then install fill switch (9) and bracket (10).
Mounting bolt :
30.89 ± 3.43 Nm {3.15 ± 0.35 kgm}
3) Assemble spring (4) and fit O-ring to plug (3),
then install to body.
4) Install plate (2) to body.
Mounting bolt :
30.89 ± 3.43 Nm {3.15 ± 0.35 kgm}
5) Install connectors (7) and (8) to bracket.
30-126 D575A-3 SD
➀
POWER TRAIN PUMP,
DISASSEMBLY AND ASSEMBLY TRANSMISSION LUBRICATION PUMP
REMOVAL OF POWER TRAIN REMOVAL OF TRANSMISSION

PUMP ASSEMBLY LUBRICATION PUMP
ASSEMBLY
1. Remove step (1).
★ Open the cover, then remove the step. 1. Remove step (1).
★ Open the cover and remove the step.

2. Remove clamp and disconnect hose (2).
3. Disconnect hydraulic pump outlet hose (3).
3. Remove pump outlet tube (3) and inlet tube (4).
4. Disconnect 2 power train pump outlet hoses (4).
4. Lift off transmission lubrication pump assembly
5. Disconnect power train pump inlet tube (5). (5).
6. Lift off power train pump assembly (6). Transmission lubrication pump assembly :
25 kg
Power train pump assembly : 45 kg
INSTALLATION OF
INSTALLATION OF POWER TRANSMISSION LUBRICATION
TRAIN PUMP ASSEMBLY
PUMP ASSEMBLY
removal. • Carry out installation in the reverse order to
removal.
Add oil through oil filler to the specified level. • Refilling with oil
Run the engine to circulate the oil through the Add oil through oil filler to the specified level.
system. Then check the oil level again. Run the engine to circulate the oil through the
D575A-3 SD 30-127
➀
DISASSEMBLY AND ASSEMBLY SCAVENGING PUMP, FINAL DRIVE
REMOVAL OF SCAVENGING REMOVAL OF FINAL DRIVE

PUMP ASSEMBLY ASSEMBLY
1. Drain oil from power train oil pan. 1. Remove track shoe assembly.
For details, see REMOVAL OF TRACK SHOE
Power train oil pan : Approx. 345
ASSEMBLY.
2. Raise chassis with jack and set stands under
★ Support with the transmission jack and front and rear of frame.
remove the mounting bolts.
Undercover (center) : 140 kg
4. Remove scavenging pump assembly (3).
3. Drain oil from final drive case.

Final drive case : Approx. 160 (each)
INSTALLATION OF
SCAVENGING PUMP
ASSEMBLY
removal.
• Refilling with oil (power train)

Run the engine to circulate the oil through the
30-128 D575A-3 SD
➀
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
4. Remove cover (1). INSTALLATION OF FINAL

5. Drain oil from gear coupling. DRIVE ASSEMBLY
Gear coupling : Approx. 1.5 • Carry out installation in the reverse order to
removal.
6. Remove mounting bolts of gear coupling (2).
★ Remove the bolts and move the gear cou-
pling towards the steering case.
Mounting bolt :
3,236 ± 196 Nm {330 ± 20 kgm}

Add gear oil through oil filler to the specified
level.
Final drive case : 160
Gear coupling : Approx. 1.5
7. Using tool E, sling final drive assembly (3).
8. Remove mounting bolts, then using forcing

screws, pull out final drive assembly from pilot
portion.
★ Use mounting bolts as the forcing screws.
9. Remove final drive assembly (3).

Final drive assembly : 6,100 kg
D575A-3 SD 30-129
➀
DISASSEMBLY OF FINAL 3. Cage

1) Remove mounting bolts, then using forcing
DRIVE ASSEMBLY screws, remove oil seal cage (6) and cage
(7).
1. Gear
1) Remove mounting bolts, then remove holder
(1).
2) Remove shim (2) and packing (3).
★ Make match marks on the taper serration
portion.
2) Remove oil seal (8) from cage.

3) Remove bearing (9) from cage.
3) Using tool F9, remove gear (4).
2. Cover
Remove cover (5).
4. No. 1 shaft
1) Using 2 eyebolts , remove No. 1 shaft
(10).
30-130 D575A-3 SD
➀
2) Using bearing puller, remove inner races (11) • Dimention of eyebolt

and (12) from shaft.
7. Holder
5. Cover 1) Remove mounting bolts, then remove holder
Remove mounting bolts, then remove cover (13). (16).
2) Remove shim (17).
6. Tube
1) Using forcing screws, disconnect tube (14).
2) Using eyebolt , remove tube (14).
3) Remove bearing (15) from tube. 8. Sprocket hub assembly
1) Using eyebolts, sling sprocket hub assembly
(18).
2) Using tool F1, remove sprocket hub assem-
bly (18) together with bearing (19).
D575A-3 SD 30-131
➀
9. Sprocket hub assembly 2) Cover assembly.

1) Set sprocket hub assembly on block (height: i) Remove mounting bolts, then remove
100mm). cover (25).
2) Remove mounting bolts, then remove cover ii) Remove floating seal (26).
(20). ★ Keep the floating seal in a safe place
3) Remove floating seal (21). and be careful not to damage it.
★ Keep the floating seal in a safe place and iii) Remove spacer (27-1).
be careful not to damage it. iv) Remove bearing (27), then remove collar
4) Remove outer race (22). (28).
10. Wear guard v) Turn over cover, remove plate (29), then
Remove mounting bolts, then lift off wear guard lift off ring gear (30).
(23). vi) Remove outer race (31).
11. Cover assembly 12. Hub, carrier assembly

1) Remove mounting bolts, then using eyebolts 1) Using eyebolts , remove hub and carrier
, remove cover assembly (24). assembly (32).
2) Remove mounting bolts, then remove cage
(33).
30-132 D575A-3 SD
➀
3) Hub and carrier assembly. viii) Pull out gear (44), bearing (45), and
i) Remove mounting bolts, then remove spacer (46).
plate (34). ix) Remove outer race (47), ring (48), and
ii) Using forcing screws , pull out inner snap ring (49) from gear (44).
race (35), then remove spacer (36).
• Disassembly of hub assembly

iii) Remove mounting bolts (37), and discon- x) Remove spacer (50).
nect plate (38) from carrier. xi) Remove bearing (51), then remove plate
★ Loosen the mounting bolts from the (38).
notched hole in the hub. xii) Remove mounting bolts, then remove
iv) Using eyebolts , remove carrier gear (52).
assembly (30) together with sun gear
(40) from hub assembly (41).
xiii) Remove mounting bolts, remove plate

• Disassembly of carrier assembly (53), then remove bearing (54) from hub
v) Pull out sun gear (40). (55).
vi) Set carrier assembly to block, and
remove plate (42).
vii) Using tool F7, remove shaft (43).
D575A-3 SD 30-133
➀
13. No. 2 shaft assembly 5) No. 2 shaft assembly.

1) Remove mounting bolts, then using forcing i) Remove mounting bolts, then remove
screws, remove cover (56). plate (60).
ii) Set gear puller to gear (61), and remove
Removal of the cover requires work
spacer (62) together with bearing (63)
under the assembly, so set 2 bolts (L
from shaft (64).
= Approx. 100 mm) in position to pre-
vent the cover from falling off.
2) Using eyebolt , remove No.2 shaft assem-
bly (57).
iii) Remove mounting bolts, then remove

plate (65).
iv) Using gear puller, remove inner race (66)
from shaft.
3) Remove cover (56), then remove shim (58). v) Remove mounting nut, then remove gear
4) Remove bearing (59) from cover. (67).
14. Bearing
Remove bearing (68) from case (69).
30-134 D575A-3 SD
➀
15. Lubrication piping ASSEMBLY OF FINAL DRIVE

1) Remove tube clamp, then remove 5 tubes
(70) and valves (71). ASSEMBLY
Coat the sliding surfaces of all parts with engine
oil before installing.
1. Lubrication piping
1) Fit O-ring, fit case (75) to final case, then
assemble filter (74).
2) Assemble spring (73), then fit O-ring and
install cover (72).
3) Fit clamp (76) and secure case.
2) Remove cover (72), then remove spring (73)

and filter (74).
3) Remove clamp (75), then remove case (76).
4) Fit O-ring and install 5 tubes (70) and valves

(71), then secure with tube clamps.
D575A-3 SD 30-135
➀
2. Bearing iii) Assemble gear (61) and spacer (62) to

Using push tool , press fit bearing (68) to case shaft, then using push tool , press fit
(69). bearing (63).
★ Assemble the gear to the shaft with
the IN stamp mark on the inside of
the chassis.
iv) Install plate (60).
Mounting bolt :
3. No. 2 shaft assembly

1) Assemble No. 2 shaft assembly as follows.
i) Set gear (67) to shaft, and tighten mount-
ing nut.
Mounting nut thread :
2) Using push tool , press fit bearing (59) to
Mounting nut :
cover.
549.2 ± 58.8 Nm {56 ± 6.0 kgm}
3) Fit O-ring to cover (56), temporarily assem-
ble shim (58), and set in position.
★ Assemble a shim thickness of 3 mm.
Carry out the final adjustment of the shim
thickness in Step 11.
ii) Using push tool , press fit inner race

(66) to shaft (64), then install plate (65).
Mounting bolt :
30-136 D575A-3 SD
➀
4) Using bolt (Length=Approx. 100mm), set • Assembly of carrier assembly

cover (56) to case. iv) Using push tool , press fit bearing (51)
5) Using eyebolts , set No. 2 shaft assembly to carrier.
(57) in position, then install cover. v) Install plate (38).
Mounting bolt :
4. Carrier, hub assembly

1) Assemble carrier and hub assembly as fol-
lows.
• Assembly of hub assembly vi) Install snap ring (49) and ring (48) to
i) Using push tool , press fit bearing (54) gear, then using push tool , press fit
to hub (55). outer race (47).
ii) Install plate (53). ★ Be careful to assemble ring (48) fac-
ing in the correct direction.
Mounting bolt :
iii) Install gear (52).
Mounting nut :
Mounting nut :
926.7 ± 103.0 Nm{94.5 ± 10.5 kgm}
D575A-3 SD 30-137
➀
vii) Assemble bearing (45) and spacer (46) ★ Install the shaft so that the bolt holes
to gear (44), and set to carrier. come to the position shown in the
★ The bearing components form a set, diagram.
so match with the marks on the outer
race to assemble.
★ When assembling the gear, set the
mounting position of ring (48) and
snap ring (49) in the direction shown
in the diagram.
★ In this case, check that the stepped
surface at the end face of gear (44) is
in the position shown in the diagram.
• Connection of carrier assembly and hub

assembly
x) Assemble spacer (50) and sun gear (40)
to hub, then using eyebolts , set car-
rier assembly (39) to hub assembly (41).
viii) Using tool F8, press fit shaft (43).

ix) Install plate (42).
Mounting bolt :
Mounting bolt :
549 ± 58.8 Nm {56 ± 6.0 kgm}
30-138 D575A-3 SD
➀
xi) Install carrier assembly (39) to hub 4) Using eyebolts , raise hub and carrier
assembly (41). assembly (32), and install to cage (33).
xii) Assemble spacer (36), then using push 5. Cover assembly

tool , press fit inner race (35). 1) Assemble cover assembly as follows.
xiii) Install plate (34). i) Using push tool , press fit outer race
(31) to cover.
Mounting bolt :
ii) Raise ring gear (30) and set in position in
cover, then install plate (29).
Mounting bolt :
2) Using push tool , press fit outer race (77)

to cage.
3) Fit O-ring and install cage (33) to case (69).
Mounting bolt :
Mounting bolt :
549.2 ± 58.8 Nm {56 ± 6.0 kgm}
D575A-3 SD 30-139
➀
2) Using eyebolts , install cover assembly 4) Fit O-ring and install cover (25).
(24) to case. ★ Install the cover so that the notched por-
tion is at the bottom.
Mating surface : Gasket sealant
 198-27-33460 
 
 (Three Bond TB1216)
★ Check that there are no dents, rust, oil,
grease, or water on the mating surface of
the case and cover, then coat the whole
circumference of the mating surface at
the case end with gasket sealant without
any break.
★ Install the cover assembly within 20 min-
utes after coating with gasket sealant.
Mounting bolt thread :
Mounting bolt : 5) Assemble collar (28), then using tool F5,
3,236 ± 196 Nm {330 ± 20 kgm} press fit bearing (27).
3) Using tool F3, install floating seal (26) to 6. Wear guard

cover (25). Raise wear guard (23), set to case, then tighten
★ Remove all oil and grease from the O- mounting bolts.
ring and O-ring contact surface, and dry
before assembling the floating seal. Mounting bolt thread :
★ After inserting the floating seal, check Thread tightener (LT-2)
that the angle is as follows. Mounting bolt :
★ Angle of floating seal : Within 1 mm 1,716 ±196 Nm {175 ± 20 kgm}
30-140 D575A-3 SD
➀
7. Sprocket hub assembly 2) Using eyebolt, set sprocket hub assembly

1) Assemble sprocket hub assembly as follows. (18) to cover.
i) Using tool F6, press fit outer race (22) to ★ Check that there is no dirt on the sliding
sprocket hub. surface of the floating seal, and coat
thinly with engine oil.
3) Assemble spacer (27-1), then using tool F5,
press fit bearing (19).
★ Rotate the sprocket drum assembly while
press fitting the bearing.
★ Push the bearing with a force of 392 kN
(40 ton).
ii) Fit O-ring and install cover (20) to

sprocket hub.
8. Holder
1) Adjusting shim thickness
i) Tighten 6 mounting bolts of holder (16)
temporarily at equal distances around
circumference.
Mounting bolt :
Approx. 49.0 Nm {5.0 kgm}
ii) Measure dimension C between end face
of cover and end face of holder, and
iii) Using tool F2, install floating seal (21). select shim thickness of C – (0.1 – 0.3).
★ Remove all oil and grease from the ★ Types of shim : 0.2 mm, 0.5 mm
O-ring and O-ring contact surface, iii) Remove holder.
and dry before assembling the float-
ing seal.
★ After inserting the floating seal, check
that the angle is as follows.
★ Angle of floating seal : Within 1 mm
D575A-3 SD 30-141
➀
2) Assemble specified shim (17), and install 10. Cover

holder (16). Fit O-ring and install cover (13).
Mounting bolt :
Mounting bolt :
549.2 ± 58.8 Nm {56 ± 6.0 kgm}
11. Adjusting clearance of No. 2 shaft bearing

1) Remove cover, then remove temporarily
assembled shim.
2) Without assembling shim, tighten cover uni-
formly with 4 bolts at a tightening torque of
9. Tube 34.3 Nm (3.5 kgm).
1) Using push tool , press fit bearing (15) to 3) Using a feeler gauge, measure clearance at
tube. mounting position of each bolt (7 points: a1
2) Fit O-ring, then using eyebolts , raise tube to a7).
(14), align position of dowel pin, and install. 4) Shim thickness. =
Mating surface of tube and hub : a1+a2+a3+a4+a5+a6+a7
+1.4 mm
Gasket sealant (LG-6) 7
★ Types of shim : 0.1 mm, 0.2 mm, 0.5 mm
5) Fit specified shim (58) and install cover (56).
Mounting bolt :
3,727 ± 245 Nm {380 ± 25 kgm}
30-142 D575A-3 SD
➀
12. No. 1 shaft ★ Press fit the bearing until dimension a is

1) Using push tools and , press fit inner 10 – 12 mm.
races (11) and (12) to shaft. ★ Be careful that dimension a is more than
12 mm, or there will be no end play in the
bearing.
2) Using 2 eyebolts , raise No. 1 shaft (10),

and assemble to case.
2) Fit O-ring and install cage (7).
13. Cage
3) Using push tool , press fit oil seal (8) to
1) Using push tool , press fit bearing (9) to
cage.
cage.
D575A-3 SD 30-143
➀
4) Install oil seal cage (6). ★ Press fit the gear with an initial force of
294KN (30 ton), then check that there is
Lip of oil seal :
a stepped difference of 3 ± 0.5 mm
Grease (G2-LI) (fill 40 – 60%)
between gear end face and shaft end
face . If it is not within the standard
value, press fit further (up to a maximum
of 392 kN (40 ton), and check that the
value is within the standard range.
14. Cover
Fit O-ring and assemble cover (5).
15.Gear
1) Using tool F9, press fit gear (4).
2) Adjusting shim thickness
Taper serration portion : Using calipers, measure dimension b
Anti-friction compound (LM-P) between gear end face and shaft end
face .
Shim thickness = b – (0.1 – 0.2)mm.
★ Types of shim : 0.1 mm, 0.2 mm, 0.5 mm
3) Fit specified shim (2) and packing (3), then

install holder (1).
30-144 D575A-3 SD
➀
DISASSEMBLY AND ASSEMBLY FINAL DRIVE, TRACK FRAME
16. Sprocket teeth REMOVAL OF TRACK FRAME

Install sprocket teeth (78).
ASSEMBLY
Seat surface of nut :
Seizure prevention agent (LM-G) 1. Remove track shoe assembly.
Mounting bolt thread : For details, see REMOVAL OF TRACK SHOE
Thread tightener (LT-2) ASSEMBLY.
Nut : 2. Using 2 jacks (490 kN (50 ton)), raise chassis

Initial torque : and set stand (Approx. 1085 mm) under
Tighten to 981 ± 98 (100 ± 10 kgm) equalizer bar and case.
2nd pass: Tighten a further 180 ± 5°
Set the stand in position securely.
3. Remove drain plug (1), and drain oil from pivot

chamber.
Pivot chamber : Approx. 18
D575A-3 SD 30-145
➀
DISASSEMBLY AND ASSEMBLY TRACK FRAME
4. Remove cover (2). 7. Sling guard (5), remove mounting bolts, then lift
off.
5. Disconnect tilt cylinder hose (3).
Guard : 100 kg
8. Remove cover (6).

★ Oil will leak from the pivot chamber, so put a
container under the pivot chamber to catch
the oil.
9. Sling front carrier roller assembly (7), remove

mounting bolts, then lift off.
Carrier roller assembly : 135 kg
6. Remove mounting bolts of seal assembly (4).

the oil.
10. Remove plate (8) and (8-1).
11. Remove caps (9) and (10).
30-146 D575A-3 SD
➀
DISASSEMBLY AND ASSEMBLY TRACK FRAME
12. Remove covers (11) and (12). INSTALLATION OF TRACK

FRAME ASSEMBLY
removal.
★ Check that the O-ring is assembled securely

to the seal ring.
Mounting bolt :
1,716 ± 196 Nm {175 ± 20 kgm}
13. Using tool T, sling track frame assembly.
★ When raising the track frame assembly, fit a
sling around the track frame assembly, and
adjust the lifting balance.
Mounting bolt :
14. Remove thrust plate (13). 926.7 ± 103.0 Nm {94.5 ± 10.5 kgm}
15. Remove plate (14) of pivot shaft.
Equalizer bar pin : Grease (G2-LI)

Mounting bolt :
926.7 ± 103.0 Nm {94.5 ± 10.5 kgm}
Mounting bolt :
1,716 ± 196 Nm {175 ± 20 kgm}
★ After inserting the track frame to the pivot

16. Move track frame assembly (15) towards outside shaft, fit plate (14) temporarily to prevent the
and remove. track frame from coming out.
★ Oil will leak from the pivot chamber, so put a ★ When installing, fit gradually and be careful
container under the pivot chamber to catch not to hit any other parts.
the oil.
Track frame assembly : 16,000 kg • Refilling with oil
Add 18 of engine oil (EO-30) to the pivot
chamber.
D575A-3 SD 30-147
➀
DISASSEMBLY AND ASSEMBLY RECOIL SPRING, TUBE
REMOVAL OF RECOIL 5. Fit wire to recoil spring and tube assembly (4),
then use a forklift truck to remove from track
SPRING, TUBE ASSEMBLY frame.
1. Remove idler assembly. Recoil spring, tube assembly : 2,600 kg

For details, see REMOVAL OF IDLER ASSEM-
BLY.
3. Sling recoil spring and tube from mounting hole

of cover (1), then remove shaft (2).
INSTALLATION OF RECOIL
SPRING, TUBE ASSEMBLY
removal.
4. Using eyebolts , remove yoke assembly (3).
Yoke, cylinder assembly : 510 kg Mounting pin :

Anti-friction compound (LC-G)
Lip of flange dust seal : Grease (G2-LI)
★ Fit wire to the tube mounting pin hole, pull

from mounting hole of cover (1), and insert
recoil spring and tube assembly (4) into the
track frame.
30-148 D575A-3 SD
➀
DISASSEMBLY OF RECOIL If the torque does not drop during Steps 1)

and 2) described above, and the torque
SPRING, TUBE ASSEMBLY when the bolts are loosened remains large,
there is probably damage to recoil spring
1. Flange assembly set bolt (18), or nut (14) at the tip of the
★ Disconnect flange assembly (2) from recoil shaft has fallen off, so there is danger that
spring case (9) as follows. the flange assembly may fly off to the front.
★ When doing this, check that there is no dam- For this reason, disassemble as follows.
age to the weld of recoil spring case (9).
1) Loosen mounting bolts (1) of flange assem-
bly gradually in turn on opposite sides.
When disconnecting the flange assembly

and recoil spring case, do not stand in front
of the flange assembly or behind the recoil
To prevent danger, never stand in front spring case until safety has been confirmed
of the flange assembly or behind the and the recoil spring assembly has been
recoil spring case. removed.
The recoil spring inside the recoil spring
case is applying a pushing force of 529
kN (54 tons) on the flange, so be careful
not to loosen the mounting bolts sud-
denly. Loosen the mounting bolts grad-
ually until clearance a between the
flange and the recoil spring case is 8 –
13 mm.
2) When the bolts are loosened, the torque will

suddenly drop. Check that the spring is not
applying any pushing force on the mounting
bolts, then remove all bolts.
★ If the torque increases (the pushing force
of the spring is applied) during the loos-
ening operation, stop the loosening oper-
ation and disassemble as follows.
D575A-3 SD 30-149
➀
i) Prepare the following parts. 3) Loosen mounting bolts (1) in turn, and
Bolt (x4): 791-730-1140 remove flange assembly (2).
Nut (x4): 01580-12419
Washer (x4): 01643-32460 (use again)
ii) Remove 4 bolts marked , then install

bolts , nuts , and washers listed
in Step i).
★ Check that dimension L is less than
420 mm.
★ Screw in bolts until they block the
bottom of the yoke thread.
iii) Remove remaining 12 bolts (those not

marked ).
iv) Hold bolts with a wrench to prevent 4) Disassemble flange assembly.

them from turning, then loosen 2 nuts i) Remove cover (3), then remove seal (4).
simultaneously on opposite sides. ii) Remove snapring (19) and bushing (5).
★ Be careful not to let the load bear on
only one bolt.
2. Bracket
★ Disconnect bracket (7) from recoil spring
v) When recoil spring is fully extended and case (9) as follows.
torque has completely dropped in loos- ★ When doing this, check that there is no dam-
ening direction of nut , remove bolt . age to the weld of recoil spring case (9).
★ When clearance b is approx. 275
mm, the spring is fully extended. 1) Loosen mounting bolts (6) of bracket gradu-
ally in turn on opposite sides.
30-150 D575A-3 SD
➀
To prevent danger, never stand in front i) Prepare the following parts.

of the bracket or behind the recoil Bolt (x4): 791-730-1140
spring case. Nut (x4): 01580-12419
The recoil spring inside the recoil spring Washer (x4): 01643-32460 (use again)
case is applying a pushing force of 529
kN (54 tons) on the flange, so be careful ii) Remove 4 bolts marked , then install
not to loosen the mounting bolts sud- bolts , nuts , and washers listed
denly. Loosen the mounting bolts grad- in Step i).
ually until clearance a between the ★ Check that dimension L is less than
flange and the recoil spring case is 8 – 420 mm.
12 mm.
★ Screw in bolts until they block the
bottom of the yoke thread.
iii) Remove remaining 10 bolts (those not

marked ).
iv) Hold bolts with a wrench to prevent

them from turning, then loosen 2 nuts
simultaneously on opposite sides.
★ Be careful not to let the load bear on
only one bolt.
2) When the bolts are loosened, the torque will

suddenly drop. Check that the spring is not
applying any pushing force on the mounting
bolts, then remove all bolts.
★ If the torque increases (the pushing force
of the spring is applied) during the loos-
ening operation, stop the loosening oper-
ation and disassemble as follows.
If the torque does not drop during Steps 1)
and 2) described above, and the torque
when the bolts are loosened remains large,
there is probably damage to recoil spring
set bolt (18), or nut (14) at the tip of the
shaft has fallen off, so there is danger that
the bracket may fly off to the front. For this
reason, disassemble as follows.
When disconnecting the bracket and recoil
spring case, do not stand in front of the
bracket assembly or behind the recoil
spring case until safety has been confirmed
and the recoil spring assembly has been
removed.
D575A-3 SD 30-151
➀
v) When recoil spring is fully extended and 2) Disassembly of recoil spring assembly (front
torque has completely dropped in loos- is given as example)
ening direction of nut , remove bolt . i) Remove holder (10).
★ When clearance b is approx. 275
mm, the spring is fully extended.
ii) Set recoil spring assembly (11) to tool I1.

The installed load of the spring is large,
3) Loosen mounting bolts (6) in turn, and
so set in position securely.
remove bracket (7).
★ Installed load of spring :
529KN (54,000 kg)/each

1) Remove recoil spring assembly (8) from tube iii) Apply hydraulic pressure slowly to com-
(9). press spring (12), remove lock (13), then
remove nut (14) from bolt (18).
iv) After removing nut (14), install guide of
tool I1, taking care not to damage thread
of bolt.
v) Release hydraulic pressure gradually to
remove tension from spring (12).
30-152 D575A-3 SD
➀
vi) Remove plate (15), pilots (16) and (17), ASSEMBLY OF RECOIL
and bolt (18) from spring (12).
vii) Remove plate (21) and bushing (20) from SPRING, TUBE ASSEMBLY
pilot (17).
1) Assembly of recoil spring assembly (front is
given as example)
i) Assemble busing (20) and plate (21) to
pilot (17).
ii) Assemble pilot (17), bolt (18), pilot (16),
and plate (15) to recoil spring (12), and
set to tool I1.
The installed load of the spring is large,
so set the tool in position securely.
iii) Apply hydraulic pressure gradually to

compress spring (12), and set so that
installed length of spring A is standard
value.
★ Installed length of spring A:
1,255 mm
D575A-3 SD 30-153
➀
iv) Fit nut (14), then install lock plate (13). vi) Install holder (10).
★ When securing the recoil spring
mounting nut, make a clearance of 8
– 9 mm between lock plate (13) and
Nut (14), then bring lock plate (13)
and bolt (18) into tight contact, and
secure in position.
Lock mounting bolt (19) :
★ Purpose of making clearance

1) If the nut is screwed in a small
amount and nut (14) protrudes
beyond bolt (18), lock plate (13)
may bend and lock bolt (19) may
fall off. 2) Raise recoil spring assembly (8) and assem-
2) If the nut is screwed in too far, the ble to tube (9).
load of the spring will always be Coat all of the recoil spring with
applied to the set bolt, and the grease (G2-LI), then assemble to
set bolt will break. the tube.
v) Release hydraulic pressure slowly to

remove spring tension completely, then
remove recoil spring assembly (11) from
tool I1.
30-154 D575A-3 SD
➀
2. Bracket iv) Install cover (3).

Set bracket (7) to tube, and tighten mounting
bolts (6).
★ Tighten the mounting bolts in turn so that the
clearance between the bracket and tube is
uniform.
Mating surface of bracket and tube :
Mounting bolt :
926.7 ± 103.0 Nm {94.5 ± 10.5 kgm}
2) Set flange assembly (2) to tube, and tighten

mounting bolts (1).
★ Tighten the mounting bolts so that the
clearance between the flange and tube is
uniform.
Mating surface of flange and tube :
Mounting bolt :
926.7 ± 103.0 Nm {94.5 ± 10.5 kgm}
3. Flange assembly
Lip of flange dust seal :
1) Assembly of flange assembly.
Grease (G2-LI)
i) Using tool I2, press fit bushing (5).
ii) Install snapring (19) on flange.
iii) Using tool I3, press fit seal (4).
D575A-3 SD 30-155
➀
DISASSEMBLY AND ASSEMBLY IDLER YOKE, CYLINDER
DISASSEMBLY OF IDLER 3. Cylinder

Set tool J2 under yoke (10), then remove cylin-
YOKE, CYLINDER ASSEMBLY der (11) with press.
1. Piston assembly
1) Remove rod (13) and piston assembly (1)
from yoke and cylinder assembly (2).
2) Disassembly of piston assembly.

i) Remove ring (3), then remove packing
(4).
ii) Remove ring (5) from piston (6).
2. Washer
1) Remove lock (7).
2) Remove mounting bolts (8), then remove
washer (9) from yoke (10).
30-156 D575A-3 SD
➀
DISASSEMBLY AND ASSEMBLY IDLER YOKE, CYLINDER
ASSEMBLY OF IDLER YOKE, 3. Piston assembly.

1) Assembly of piston assembly
CYLINDER ASSEMBLY i) Assemble ring (5) to piston (6).
1. Cylinder ii) Fit packing (4) and install ring (3).
Using tool J1, press fit cylinder (11) to yoke (10).
★ Press-fitting force : 785 kN (80 ton)
Press-fitting surface :
2) Assemble piston assembly (1) to yoke and

cylinder assembly (2).
Tip of piston: Grease (G2-LI)
★ Determine the mounting position of lubricator 3) Assemble rod (13).
(12) as shown in the diagram, then set the
cylinder to the yoke in position, and press fit.
2. Washer
1) Fit washer (9) to yoke (10) and tighten
mounting bolts (8).
2) Install lock (7).
D575A-3 SD 30-157
➀
DISASSEMBLY AND ASSEMBLY IDLER
DISASSEMBLY OF IDLER 6. Turn over idler assembly (1) and remove retainer
(6).
ASSEMBLY
1. Remove plug and drain oil.
Idler : Approx. 3.8
2. Set idler assembly (1) to block , pull out bolt

(2), then remove idler support (3).
3. Turn over idler assembly and remove idler sup-

port (5).
7. Using push tool , remove bushings (8) and (9)

from idler.
4. Using forcing screws , remove retainer (4).
8. Remove floating seals (10) and (11) from retain-

ers (4) and (6).
★ Be careful not to damage the floating seals,
and keep them in a safe place.
5. Remove shaft (7) from idler.
30-158 D575A-3 SD
➀
9. Remove floating seals (12) and (13) from idler ASSEMBLY OF IDLER ASSEM-
supports (3) and (5).
★ Be careful not to damage the floating seals, BLY
and keep them in a safe place.
1. Using tool O2, press fit bushings (8) and (9) to

idler (1).
★ Use a plastic hammer to carry out centering
before press fitting the bushing.
★ Bushing press-fitting force : 39.2 – 83.4 kN
(4 – 8.5 ton)
★ Press fit the bushing to a point where the
dimension from the end face of the idler to
the end face of the bushing is 21 ± 1 mm.
2. Using tool O1, install floating seals (10) and (11)

to retainers (4) and (6).
D575A-3 SD 30-159
➀
★ Remove all oil and grease from the O-ring Coat from the end face of the shaft to the
and O-ring contact surface, and dry before O-ring groove with anti-friction com-
assembling the floating seal. pound (LM-P).
★ After inserting the floating seal, check that
the angle is as follows.
★ Angle of floating seal : Within ±1 mm
★ Protrusion a of floating seal : 7 -11 mm
6. Fit O-ring and install retainer (4) to idler (1).
3. Fit O-ring and install retainer (6) to idler.
4. Turn over idler assembly.
7. Using tool O1, install floating seals (12) and (13)

to idler supports (3) and (5).
5. Install shaft (7) to idler.
30-160 D575A-3 SD
➀
DISASSEMBLY AND ASSEMBLY IDLER, TRACK ROLLER
★ Remove all oil and grease from the O-ring REMOVAL OF TRACK
and O-ring contact surface, and dry before
assembling the floating seal. ROLLER ASSEMBLY
the angle is as follows. 1. Remove mounting bolts (1), then remove inspec-
★ Angle of floating seal : Within 1 mm tion cover (2), loosen lubricator (3) and relieve
★ Protrusion a of floating seal : 7 – 11 mm tension of track shoe assembly.
Do not loosen lubricator (3) more than 1
turn because internal grease which is under
high pressure, may be released, causing
damage or injury.
★ If the track tension is not relieved even when

the lubricator (3) is loosened, move the
machine backward and forward.
8. Fit O-ring, install idler support (3), and secure

with bolt (2).
★ Coat the contact surface of the floating seal
thinly with oil.
★ Turn over the idler assembly, and install idler
support (5) in the same way as above.
Idler support bolt :

Anti-friction compound (LM-P) 2. Remove track roller guide (4).
Roller guide : 180 kg
9. Add gear oil through oil filler to specified level
and tighten plug. ★ If it is difficult to remove the guard bolt, use a
power wrench (x 16) to make it easier to
Idler : Approx. 3.8 (GO140B) remove.
Carefully read the precautions listed by the
Plug : 206 ± 49 Nm {21 ±5 kgm} manufacturer before using the power
wrench.
3. Remove mounting bolts of track roller assembly,

then remove cap (5).
★ If it is difficult to remove the mounting bolts,
use a power wrench. For details, see Step 2.
D575A-3 SD 30-161
➀
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
4. Operate blade to jack up front of machine, then INSTALLATION OF TRACK

use a jack to jack up rear of machine, and let
track link (6) hang down. ROLLER ASSEMBLY
After jacking up the machine, set a block • Carry out installation in the reverse order to
under the radiator guard. removal.
Always apply the safety lock to the work

equipment control levers.
★ Tighten lubricator (3), then pump in grease
through the grease fitting to adjust the track
tension.
Lubricator :
73.6 ± 14.7 Nm {7.5 ± 1.5 kgm}
Mounting bolt :
2452 ± 245 Nm {250 ± 25 kgm}
5. Insert tool U under track roller assembly, then

★ Set oil filler plug facing outside, then use tool
remove track roller assembly (7).
R and set track roller assembly (7) on top of
track link (6).
Track roller assembly :
★ Remove the block, then lower the chassis
290 kg (single flange)
slowly and set the track roller assembly to
Track roller assembly :
the mounting position.
310 kg (double flange)
★ When installing a new track roller, check that
there is a clearance between the roller and
the bogie.
★ Check that the misalignment a of the flange
outside the track rollers is within ± 1 mm.
• Adjust the tension of track shoe assembly.

For details, see Adjusting tension of track
shoe assembly.
30-162 D575A-3 SD
➀
DISASSEMBLY OF TRACK 5. Set track roller assembly facing to side, remove

mounting bolts, then remove retainers (6) and (7).
ROLLER ASSEMBLY
6. Raise shaft (8) and pull out from roller (9).
1. Remove plug and drain oil.
Track roller : Approx. 1.7
2. Raise track roller assembly (1) and set block

in position.
★ Set the track roller securely to prevent it from
falling over.
7. Remove floating seals (10) and (11), and O-rings

from collars (2) and (4).
8. Remove floating seals (12) and (13), and O-rings

from retainers (6) and (7).
9. Remove bushings (14) and (15) from retainer.
3. Push collar (2), pull out ring (3), then remove col-
lar (2).
4. Turn over track roller assembly, and remove ring

(4) and collar (5).
10. Bushing
1) Set block under roller (9).
2) Set tool P1 in position, then using press,
remove bushings (16) and (17).
D575A-3 SD 30-163
➀
ASSEMBLY OF TRACK 4. Using tool P3, assemble floating seals (13) and
(12) to retainers (7) and (6).
ROLLER ASSEMBLY
1. Set roller (9) to press, then using tool P2, press

fit bushings (17) and (16).
★ Use a plastic hammer to carry out centering
before press fitting the bushing with a press.
★ Press fit the bushing to a point where the
dimension from the end face of the roller to
the top face of the bushing is 17 – 1 mm.
★ Bushing press fitting force :
137 – 226 kN {14 – 23 ton}
★ Remove all oil and grease from the O-ring

assembling the floating seal.
★ Protrusion a of floating seal : 7 – 11 mm
2. Set shaft (8) to roller (9).
3. Press fit bushings (14) and (15) to retainers (6)

and (7), and assemble O-rings.
5. Install retainer (7) and (6) to roller (9).
6. Using tool P3, assemble floating seals (11) and

(10) to collars (2) and (5), then install O-rings.
30-164 D575A-3 SD
➀
★ Remove all oil and grease from the O-ring 8. Push collar (5), align ring groove with groove at
and O-ring contact surface, and dry before shaft end, then install ring (4), and secure collar.
★ After inserting the floating seal, check that 9. Turn over track roller, and install collar (2) and
the angle is as follows. ring (3) in same way.
★ Prorusion a of floating seal : 7 – 11 mm 10. Add gear oil through oil filler to specified level.
Track roller : Approx. 1.7 (GO140B)
Plug : 206 ± 49 Nm (21 ± 5 kgm)
7. Raise track roller assembly (1) and set on block

.
D575A-3 SD 30-165
➀
DISASSEMBLY AND ASSEMBLY BOGIE
REMOVAL OF BOGIE ASSEM- 3. Operate blade to jack up front of machine, then

use a jack to jack up rear of machine, and let
BLY track link (6) hang down.
1. Remove mounting bolts (1), then remove inspec- After jacking up the machine, set a block
tion cover (2), loosen lubricator (3), and relieve under the radiator guard.
tension of track shoe assembly.
Always apply the safety lock to the work
Do not loosen lubricator (3) more than 1 turn equipment control levers.
because internal grease which is under high
pressure, may be released, causing damage
or injury.
★ If the track tension is not relieved even when

the lubricator (3) is loosened, move the
machine backward and forward.
4. Disconnect bogie assembly from track frame,

and remove bogie assembly (7) with a crane or
forklift truck.
★ When disconnecting the bogie assembly
from the track frame, be careful not to lose
the shims, and keep them in a safe place.
2. Remove roller guide (4), then remove bogie

mounting bolts (5).
Bogie assembly : 1,200 kg
30-166 D575A-3 SD
➀
INSTALLATION OF BOGIE DISASSEMBLY OF BOGIE

ASSEMBLY ASSEMBLY
• Carry out installation in the reverse order to 1. Remove plug and drain oil.
removal.
Bogie : Approx. 1
2. Using block , Set track roller mounting side of

Mounting bolt : Thread tightener (LT-2) bogie assembly facing up, then set outer bogie
(1) and inner bogie (2) in position.
★ Use a forklift truck to set the bogie assembly in

the mounting position on the track frame, then
install with the bolts.
★ Adjusting shims
1) Tighten the mounting bolts (8) on one side of
the bogie assembly to the specified torque.
2) Measure clearance at the mating surface
of the track frame and the bogie on the oppo-
site side.
3) Assemble shims of the same thickness as
the measurement of clearance .
★ Check that the misalignment of the
flange outside the track rollers is within 3. Remove lock bolt (3), then remove flange
±1 mm. assembly (4) and washer (5).
★ Remove the flange assembly and washer on
the opposite side in the same way.
• Adjust the tension of the track shoe assembly.

For details, see ADJUSTING TENSION OF
TRACK SHOE ASSEMBLY.
D575A-3 SD 30-167
➀
★ If the flange assembly is stuck and does not 7. Remove O-ring from shaft (8), then pull out from
come out, set push-puller on the flange to bogie assembly.
remove it.
8. Disassemble cage assembly.

4. Disassemble flange assembly as follows. 1) Remove floating seal (11) from cage (9).
1) Remove floating seal (6) from flange. 2) Remove bushings (12) and (13).
2) Pull out bushing (7) from flange.
9. Remove floating seal, raise inner bogie (2), then

5. Using forcing screws, remove cage assembly disconnect from outer bogie (1).
(9).
6. Pull out washer (10).

• Remove the flange assembly and washer on
the opposite side in the same way.
30-168 D575A-3 SD
➀
10. Remove floating seal (14) from inner bogie (2), ASSEMBLY OF BOGIE
then remove bushing (15).
ASSEMBLY
1. Using tool N1, press fit bushing (15) to inner
bogie (2).
2. Assemble outer bogie (1) to inner bogie (2) tem-

porarily, then assemble tool N2.
★ When temporarily assembling the inner
bogie and outer bogie, set a block under the
bogie, and center both bogies correctly.
3. Using tool N3, assemble floating seal (14) to

inner bogie.
• Assemble the floating seal on the opposite
side in the same way.
D575A-3 SD 30-169
➀
4. Assemble washer (10) to inner bogie. 6. Using guide bolt , install cage assembly (9) to
outer bogie.
• Assemble the cage assembly on the oppo-
site side in the same way.
5. Assemble cage assembly.

1) Using push tool , press fit bushing (13) to
cage (9). 7. Assemble shaft (8) to bogie assembly.
★ Bushing press-fitting force : ★ Push shaft (8) into the bogie assembly and
0 – 79.4 kN {0 – 8.1 ton} push out tool N2.
2) Using push tool , press fit bushing (12).
★ Bushing press-fitting force :
0 – 79.4 kN {0 – 8.1 ton}
8. Assemble floating seal (11) to cage assembly.

★ Remove all oil and grease from the O-ring
3) Assemble floating seal (11) to cage (9).
30-170 D575A-3 SD
➀
9. Assemble washer (5) to cage assembly. 11. Assemble O-ring to shaft, then install flange
• Assemble the washer on the opposite side in assembly (4).
the same way. ★ When assembling the flange assembly to the
shaft, align the lock bolt hole in the flange
10. Assemble flange assembly as follows. and the notched hole in the shaft.
1) Press fit bushing (7) to flange (4). • Assemble the flange on the opposite side in
2) Assemble floating seal (6) to flange (4). the same way.
★ Remove all oil and grease from the O-
ring and O-ring contact surface, and dry Shaft (between both ends and O-ring) :
before assembling the floating seal. Anti-friction compound (LM-P)
★ After inserting the floating seal, check
that the angle is as follows.
12. Install lock bolt (3).
Lock bolt : Thread tightener (LT-2)
• Assemble the lock bolt on the opposite side

in the same way.
Bogie : Approx. 1 (GO140B)
Plug : 206 ± 49 Nm {21 ± 5 kgm}
D575A-3 SD 30-171
➀
DISASSEMBLY AND ASSEMBLY TRACK SHOE
CHECKING BEFORE REMOVAL OF TRACK SHOE

REMOVAL OF TRACK SHOE ASSEMBLY (NORMAL)
ASSEMBLY
★ If CHECKING BEFORE REMOVAL OF TRACK
In some cases, it may be extremely dangerous SHOE ASSEMBLY shows that there is no abnor-
to remove the track shoe assembly. To prevent mality, do as follows.
danger, carry out the following checks before
removing the track shoe assembly. 1. Remove blade.
For details, see REMOVAL OF BLADE ASSEM-
• Checks before starting BLY.
1) Loosen the lubricator at the adjustment cylin-
der, remove the grease, move the machine
backward and forward a short distance, and
check that the track tension is relieved. If the
track tension is not relieved and the track
shoe assembly remains tense, there may be
an abnormality inside the track frame (the
recoil spring case is broken, the recoil spring
set bolt is broken, or the nut at the end of
shaft has fallen off).
Never loosen the lubricator more than

one turn.
2. Set block at front of idler so that master link is in

position shown in diagram on right.
★ To prevent the track shoe assembly from
suddenly opening when the master link is
disconnected, connect chain blocks to the
parts on both sides of the master link.
3. Remove mounting bolt (1), then remove inspec-

tion cover (2).
2) Check that there is no interference between

the track frame and the guide shown in the
diagram. If there is any interference (when
progress of link pitch elongation is extreme),
there are cases where it is impossible to
know if there is any abnormality inside the
track frame.
30-172 D575A-3 SD
➀
4. Loosen lubricator (3), and relieve tension of track 6. Remove mounting bolts, then raise track shoe
shoe assembly. (4) and remove it.
The adjustment cylinder is under extremely Track shoe (each) : 95 kg

high internal pressure. Never loosen lubri-
cator (3) more than one turn.
If the track is not relieved by loosening the
lubricator, move the machine backwards
and forwards.
7. Separate mating face of master link slightly, then

cut middle of master bolt with a gas torch.
★ Be careful not to let the gas torch contact the
mating surface of the master link and cause
damage.
5. Using a gas torch, cut off head of master bolt.
★ When loosening the master bolt during the
operation to remove the track shoe assem-
bly, the track shoe assembly is heavy, so the
connecting parts of the master link move out
of position. If the master bolt is removed in
this condition, the threads may be damaged
or there may be seizure, so cut off the head
of the bolt.
D575A-3 SD 30-173
➀
8. Disconnect master link (5). REMOVAL OF TRACK SHOE

9. Raise tip of master link at front, and open track ASSEMBLY
shoe assembly to front. (WHEN THERE IS ABNOR-
To prevent the track shoe assembly from MALITY INSIDE TRACK
opening suddenly, use a chain block and FRAME)
remove carefully.
★ When CHECKING BEFORE REMOVAL OF
TRACK SHOE ASSEMBLY shows any abnor-
mality, do as follows.
If there is any abnormality inside the track

frame, there is danger that the track shoe
assembly may spring back when it is removed
or that the idler may spring out when the track
shoe assembly is removed. This may lead to
serious injury, so remove the track shoe
If there is any interference or abnormal catching

around the idler assembly, examine carefully
10. Raise tip of master link, move machine towards and remove the problem before starting.
rear slowly, and lay out track shoe assembly (6).
★ Track shoe length : Approx. 13.7 m 1. Remove work equipment assembly.
For details, see REMOVAL OF BLADE ASSEM-
BLY.
2. Loosen lubricator (3) of adjustment cylinder, then

move machine backwards and forwards to
release grease.
Never loosen the lubricator more than one

turn.
★ Check that all the grease has been removed.
11. Remove master bolt.

(It can be removed easily by hand or with a
wrench.)
30-174 D575A-3 SD
➀
3. Drive slowly forward to put track shoe at idler

end in contact with large block or a wall (if
another large bulldozer of the same capacity as
the machine being repaired is available, put in
contact with the blade). Stop machine when
recoil spring bends and track shoe also bends,
then apply brake. When doing this, set so that
master link is between idler and front carrier
roller. For safety reasons, fit a lever block
between carrier roller support and link.
4. Remove idler guide (2).
Always remove the idler guide without fail at

this point.
If the track shoe is opened without removing
idler guide (2), it will move to the front when
it opens, and idler guide (2) will be pushed
against the track frame. If the idler guide is
removed in this condition, the idler yoke
assembly will fly out to the front.
5. Remove shoe (4), then disconnect master link

(5).
For detail, see REMOVAL OF TRACK SHOE
ASSEMBLY.
Be extremely careful to ensure safety when

disconnecting the track shoe.
6. Move machine towards rear slowly, and lay out

track shoe assembly.
D575A-3 SD 30-175
➀
INSTALLATION OF TRACK ★ The length of the master shoe bolts is dif-

ferent, so be careful to install them in the
SHOE ASSEMBLY correct position.
Bolt : 182.5 mm
• Carry out installation in the reverse order to Bolt : 197 mm
removal.
3) Check that there is no interference at R por-
tion.
Lubricator :
73.6 ± 14.7 Nm {7.5 ± 1.5 kgm}
★ Check that there is no dirt or mud on the mat-

ing surface or thread.
Mounting bolt :
Tightening torque Retightening angle

(Nm {kgm}) (deg)
Regular
link bolt
2,060 ± 200
{210 ± 20} 120 ± 10
Master 1,961 ± 200 120 +20

link bolt {200 ± 20} 0 Adjust the tension of the track shoe assembly.
For details, see ADJUSTING TENSION OF
TRACK SHOE ASSEMBLY.
1) Check that fitting key is assembled securely
in ring groove.
2) After tightening, check that mating faces are
in tight contact.
★ Tighten the mounting bolts in the order
– .
30-176 D575A-3 SD
➀
OVERALL DISASSEMBLY OF 2. Disassembly into 1/4 parts

Because of the weight of the track assembly, if
TRACK SHOE the 1/2 assembly is too large and there are prob-
lems with disassembly and assembly work,
★ This section describes only the procedure for the divide into 1/4 assemblies.
lubricated track.
1. Shoe (master link portion)

Set the track assembly on a flat floor with the
shoe facing up, then remove the shoe bolt at the
master link, and remove the shoe.
★ Do not use an impact wrench when loosen-
ing the master link bolt.
For details of loosening master link bolt, see
REMOVAL OF TRACK SHOE ASSEMBLY
(NORMAL).
3. Shoe (regular link portion)

Raise the track assembly and set it on the floor
with the shoe facing up, then use a shoe bolt
impact wrench to remove the shoes.
★ When moving the track assembly, be careful
not to damage the master link portion.
★ If a gas cutter has to be used to remove the
shoe nut, to prevent deterioration of the seal
due to the heat, keep the temperature of the
seal portion below 80°C, and take action to
prevent welding spatter from entering the
gap between the links.
D575A-3 SD 30-177
➀
4. Draining oil 4) Turn over the link assembly so that the small
Before disassembling the link assembly, drain plug side is facing up, remove the burrs at
the oil from inside the pin and take precautions the end face of the pin with a grinder, then
so that the link press does not become dirty with use tool X to knock the small plug to the
oil. inside.
★ Before disassembling, if it is judged that it is ★ If the small plug hole is blocked with
necessary to rebuild the track as a dry type burrs, grind with a grinder until the hole
track, the following work need not be carried can be seen completely.
out.
1) Set the link assembly on a flat floor with the
large plug side facing up, then chamfer the
burrs on the end face of the pin with a
grinder.
★ If the track is disassembled with burrs
still at the end face of the pin, the pin
press-fitting hole of the link will be
scratched, and this will cause leakage
from the pin press-fitting portion after
rebuilding.
2) Using a drill (ø10 mm), make a hole in the
large plug, then remove the large plug.
★ If any dirt or deteriorated oil is stuck to
the pin hole, drill through with a longer 5) Using a drill (ø10 mm), chamfer the small
drill to remove it. When doing this, be plug hole.
careful not to damage the oil hole. 6) Blow with compressed air to remove the
metal particles when draining the oil inside
the pin or removing the burrs, then wash the
link assembly with high-pressure water or
steam.
5. Disassembly of link
1) Set the link assembly on a link press, then hit
with a hammer so that the bushing and jaw
are in tight contact.
★ If the link tread and outside diameter of
the bushing are worn, adjust the height of
the shoe or guide plate, and center the
disassembly jig with the pin and bushing
center to prevent damage to the link hole
3) After removing the large plug, use a baby when disassembling.
grinder (angle of grinder tip: 45 - 60°), and ★ If the centering is not carried out prop-
chamfer the pin hole so that the plug is not erly, the link hole may be damaged, the
damaged when the plug is knocked in. pin may break, or the bushing may crack
during disassembly.
30-178 D575A-3 SD
➀
2) Operate the left cylinder and remove the left 6. Inspection

link and pin and bushing press-fitting portion Check the following items to determine if the part
at the same time. can be reused as a lubricated track or as a
★ Check the removal force of the pin and grease-filled track. Carry out a comprehensive
bushing, and use this value as reference check to determine if the link assembly can be
to judge if it is possible to obtain the nec- rebuilt as a lubricated track or as a grease-filled
essary pin and bushing press-fitting force track.
when turning and reassembling.
★ Do not push the disassembly jig inside When making judgments about reuse of
more than is necessary as the spacer parts, see ”Guidance for Reusable Parts,
may break. Undercarriage, Lubricated Track”.
3) Return the left cylinder, then operate the right
cylinder and remove the right link and pin
and bushing press-fitting portion at the same
time.
1) Check the pins, bushings, links, and spacers

visually for damage, and carry out a color
check or use a flaw detector to check parts
that are suspected of being damaged. Any
4) Return the right cylinder, remove the left and part that is cracked must not be used again,
right links, pins, bushings, and spacers, then so scrap it.
feed the following set for one link assembly 2) Check the external appearance of the seal
into the jaw. and the end face of the bushing visually to
★ To decide if the seal can be used again, determine if they can be used again.
carry out inspection when the seal is still ★ If only the bushing is replaced with a new
installed to the link, so do not remove the part, the worn or damaged part of the seal lip
seal from the link. will contact the end face of the bushing
★ If oil is remaining, this can be used as a directly, so it may not be able to carry out its
guideline for reuse of the seal, so mark sealing function. For this reason, always
such links or seals. replace the seal together with the bushing, or
★ If the end face of the bushing and seal rebuild as a grease-filled track.
surface are damaged, it will cause oil
leakage, so be extremely careful when
handling.
D575A-3 SD 30-179
➀
3) Using calipers, measure spacer thickness a 5) Using a micrometer and cylinder gauge, mea-
and overall length b of the sliding portion of sure the outside diameter of the pin and bushing
the bushing and spacer. Check if it is possi- press-fitting portion, and the inside diameter of
ble to obtain the specified seal mounting the pin and bushing press-fitting portion of the
dimension when reassembling. link to determine if the permitted interference
★ If the amount of wear of the spacer and can be obtained. However, when rebuilding as
bushing is greater than the specified a lubricated track, check that the standard inter-
amount, the assembly precision of the ference for the pin and link can be obtained.
seal portion cannot be guaranteed, so ★ If the permitted interference can not be
replace with new parts, or rebuild as a obtained, replace with new parts or replace
grease-filled track. with an oversize part.
★ For details of the dimensions when making
judgmen t, see MA INTE NANCE STAN-
DARDS.
4) Using a micrometer, cylinder gauge, and cal-

ipers, measure the outside diameter of the
pin and the inside diameter of the bushing at
the worn portion, and judge if the parts can
be used again.
★ If the amount of wear is greater than the
specified amount, there will be play dur-
ing travel, and it will also cause oil leak-
age, so replace with new parts or rebuild
as a grease-filled track.
★ For details of the dimensions when mak-
i ng jud gment, see MA INTENA NCE
STANDARDS.
30-180 D575A-3 SD
➀
Precautions for storage OVERALL ASSEMBLY

1) To prevent rust of the counterbore portion of the
link, leave the seal installed to the link and be 1. When rebuilding as lubricated track
careful not to damage the seal lip during storage.
2) Coat the pin and bushing press-fitting portion, 1. Preparatory work
shoe mating surface, and master link mating sur- 1) Washing seal assembly
face of the link with rust prevention oil to prevent • Machines fitted with F5 type seals
rust. Remove the seal assembly from the link,
3) Coat the whole circumference of the pins, bush- then separate into the seal ring and load
ings, and spacers with rust prevention oil to pre- ring, and clean the parts.
vent rust, and be particularly careful not to ★ The seal ring and load ring deteriorate
damage the end face of the bushing during stor- easily when brought into contact with
age. cleaning agent (trichlene, etc.), so wash
the parts quickly. After cleaning, wipe the
parts with a clean cloth to remove all the
cleaning agent.
2) When reusing the pin, chamfer the corner of

the end face smooth with a grinder. Use a
grinder to remove any protruding parts stuck
to the press-fitting portion.
★ If the corner of the end face has become
sharp due to wear, there will be scuffing
at the press-fitting portion and this will
cause oil leakage.
D575A-3 SD 30-181
➀
3) Make a mark on the end face at the small iv) Knock in the bar with a hammer.
plug end to show the direction of the side ★ Dimension a to knock in from end
hole (hole in the radial direction) in the pin face of pin: 15 ± 2 mm
when assembling. ★ If there is no more place to chamfer at
★ When reusing the pin, assemble in the the pin hole because of wear, use a
same direction as when the part is new baby grinder (angle of grinder tip: 45
(side hole on the link tread side). – 60°) to carry out chamfering.
★ Coat the outside circumference of the
plug with GO140B and knock in the
smaller diameter part first.
4) If the link, pin, bushing, or spacer are dirty,

wash them. Remove any protruding parts
stuck to the link and bushing with a grinder.
★ These parts easily rust, so wash them 6) Installation of seal assembly
immediately before assembly. • Machines fitted with F3 type seal
★ Use tool Y to wash the pin hole. Clean the link counterbore, then use tool KB
★ Do not polish or carry out any other treat- to push the seal in fully to the bottom.
ment of the end face of the bushing as ★ If there is oil stuck to the link counterbore
this will cause oil leakage. and seal assembly, the seal will rotate and its
sealing performance will drop, so do not coat
with oil. In addition, be careful not to let oil
get into the counterbore portion of the seal
when pushing in.
★ If there is oil stuck to the link counterbore
and seal assembly, the seal will rotate and its
sealing performance will drop, so do not coat
with oil. In addition, be careful not to let oil
get into the counterbore portion of the seal
when pushing in.
5) Use tool Z to knock the large plug into the

pin.
i) Insert the plug into the guide hole
through the plug insertion window.
ii) Push the bar by hand and insert the plug
as far as possible.
iii) Push the plug with the bar and push the
guide itself against the pin.
30-182 D575A-3 SD
➀
7) In order to keep the protrusion of the pin and

bushing constant and the installation dimensions
of the seal within the specified value during
assembly, adjust the press-fitting jig dimensions
of the link press.
a'
★ For details of the standard dimensions, see
PRESS-FITTING JIG DIMENSION TABLE
FOR LINK PRESS.
★ To leave a small space for the pin when
assembling, ensure that the dimension
(dimension a’ is greater than dimension a at
the pin pushing portion of the left press-fitting
jig.
When assembling in order press fitting
left link, press fitting right link, provide the
extra space for the pin on the right press-fit-
ting jig.
★ If the end face of the pin (portion P) or the
side face of the link (portions Q, R) are worn,
add the amount of wear to the standard
dimension when adjusting the dimension of
the press-fitting jig so that the amount of pro-
trusion of the left and right pin and bushing
is uniform.
8) Adjust the relief pressure of the link press to

make sure that the pushing force of the press
does not exceed the specified value.
★ If the pushing force is too strong, exces-
sive force will be brought to bear on the
spacer, and it will be pushed against the
bushing. This will cause the spacer to
br ea k o r wi ll ca use ab no rma l wea r
between the spacer and bushing end face.
★ If the interference at the press-fitting por-
tion is different from when the part is
new, as when reusing a pin or bushing,
measure several of the press-fitting por-
tions, and use the table below to deter-
mine the set pushing force according to
the average interference.
★ Pushing force for pin, bushing:
2,354 kN {240ton}
Pushing force 1.8 x average press-fit-
ting force
(Adjust the relief pressure of the link
press and set the pushing force.)
D575A-3 SD 30-183
➀
2. Assembly of link 3) Using a shoe bolt hole pitch gauge, press fit
1) Use a clean brush to coat the area between until the distance between the shoe bolt
the pin and bushing with oil (GO140B), set in holes of the left and right link is the specified
position, then set in front of the jaw of the link value.
press. ★ Use compressed air to remove all metal
★ When reusing (turning) the bushing, set particles from burrs caused by press fit-
the worn surface on the outside circum- ting the bushing.
ference of the bushing facing the shoe
mounting surface of the link (facing up on 4) Turn over the master link, and check that the
the link press). left and right master links have been press
fitted in parallel.
2) Set the left and right bushing end master link

with the shoe mounting surface facing up, 5) Measure the amount of protrusion of the left
then press fit to the bushing. and right bushings with a depth gauge.
★ When doing this, use the pin end master ★ Adjust the press-fitting jig for the link
link as a support. press so that the protrusion of the left
★ Press-fitting force for bushing: and right bushings is uniform.
245 – 441 KN {25 – 45 ton}
30-184 D575A-3 SD
➀
6) Feed the master link portion, then set the pin 8) Set the right link in position and install the
and bushing in position. spacer to the pin.
★ When reusing the pin, assemble so that ★ Check that there is no dirt or dust stuck
the side hole is on the link tread side in to the seal surface and bushing end face,
the same way as when the part is new. If then use a clean cloth or brush to coat
the parts are not assembled facing the with oil (GO140B).
specified direction, the strength may ★ Wipe the spacer with a clean cloth, then
drop, so mark the direction of the side install it.
hole clearly on the end face to prevent
any mistake during assembly.
★ Align the large plugs so that they are on
the left side facing the link press when
assembling.
9) Using the right jig as the receiving end and

the left jig as the pushing end, press fit the
pin and bushing at the same time.
★ The seal may come off the link due to the
play when press fitting, so press fit
7) To prevent oil from leaking out from scuff smoothly. If the seal comes off the link,
marks on the pin press-fitting portion, coat stop the press-fitting operation and fit the
the pin press-fitting hole in the link and the seal correctly on the link, then start the
outside diameter of the pin press-fitting por- press-fitting operation again.
tion with gasket sealant (198-32-19890). ★ Press-fitting force for pin, bushing:
1,079 – 1,520 KN {110 – 155 ton}
D575A-3 SD 30-185
➀
10) Using a fine adjustment spacer, press fit so 12) Using the left jig as the receiving end and the
that the end face of the pin is in tight contact right jig as the pushing end, press fit the left
with the bottom of the receiving jig. link.
★ Adjust the depth of the hole in the receiv- ★ When press fitting, be careful that the left
ing jig so that the protrusion of the left and right seal and spacer do not come
and right pins is uniform. out of position.
★ Provide enough space on the left jig so
that the end face of the pin does not con-
tact the bottom of the jig.
★ Press-fitting force for link:
1,079 – 1,520 kN {110 – 155 ton}
11) Set the left link in position and install the

spacer to the pin.
★ Coat with oil in the same way as when
installing the right link.
13) Press fit the link, spacer, and bushing so that

they are each in tight contact.
★ It is impossible to check from outside if
they are in tight contact, so control the
hydraulic force of the link press and set
the relief pressure to a constant value.
Then apply hydraulic force and push in
until this pressure is reached.
For details of the setting for the relief
pressure, see “Preparatory work”.
★ Check that adjacent links swivel freely in
relation to each other.
30-186 D575A-3 SD
➀
14) After assembling each link, use a dial gauge 16) After assembling each link, use tool KC to
and pinch bar to measure the end play from remove the air from inside the pin, and check
the link previously assembled, to check that the sealing performance.
the link is assembled within the specified ★ Hold the space inside the pin at a vac-
value. uum of 91 – 95 kPa {680 – 710 mmHg}
★ If the end play does not come within 0 - for 5 seconds and check that there is no
0.13 mm even when applying the push- change in pressure.
ing force until the relief valve is actuated, If the pressure changes, disassemble
raise the relief pressure setting gradually and check the seal for any abnormality,
to adjust. then assemble again.
★ Adjust the relief pressure setting carefully
and be sure not to raise the pushing
force of the link press higher than neces-
sary.
17) Assemble the pin end master link as the final

link.
★ Check that the left and right master links
are press fitted in parallel.
15) Using a shoe bolt hole pitch gauge, check
that the distance between the shoe bolt
holes is within the standard value.
★ If the distance between the shoe bolt
holes is greater than the specified value,
disassemble and check for any abnor-
mality, then press fit again.
★ If the distance between the shoe bolt
holes is smaller than the specified value,
and the shoe cannot be installed, the
wear of the spacer or bushing end face is
probably greater than the repair limit, so
disassemble and replace with a new
part.
★ If the end play is too large, the sealing
performance will drop, so set the end
play to a small value.
D575A-3 SD 30-187
➀
3. Filling with oil 2) After completion of filling with oil, use tool KA
After completion of assembly of the link assem- to knock in the small plug to the specified
bly, add oil through the pin hole. position.
1) Using tool KD, remove the air inside the pin ★ Coat the outside circumference of the
from the small plug hole, set to a vacuum of small plug with GO140B.
91 – 95 kPa {680 – 710 mmHg}, then fill with ★ The depth to knock in the plug is as fol-
oil (GO140B) until the pressure is 0.2 – 0.3 lows.
MPa {2 – 3 kg/cm2}. Depth from end face: 15 ± 2 mm
★ In cold or extremely cold areas, instead 4. Washing mating faces

of GO140B, fill with Komatsu genuine oil ★ When installing the shoe, check that there is
(150-09-19270) which has excellent low- no paint, rust-preventive agent (non-liquid
temperature qualities. type), rust, or dents in the hatched area in
★ Be careful not to raise the oil pressure the diagram below. If any such abnormality is
too high as this will have an adverse found, remove it, then tighten the shoe bolts.
effect on the seal.
★ To determine the oil amount, set the 1) Regular link (both on L.H. and R.H.)
small plug end at the top (stand the link
assembly on its side), leave for 30 min-
utes, then fill with oil so that depth L of
the space at the pin hole is within the
specified value below.
Dimension L: 65 – 100 mm
30-188 D575A-3 SD
➀
2) Master link (both on L.H. and R.H.) 5. Shoe (regular link portion)
Set the link assembly on the bed, then use a
shoe bolt impact wrench and torque wrench to
install the shoe.
Shoe bolt (regular link):
Initial torque:
2,060 ± 200 Nm {210 ± 20 kgm}
Tightening angle: 120 ± 10°
3) Shoe
6. Connecting to make 1/2 assembly

Set two completely assembled portions of track
on a flat surface in a straight line with the shoes
facing up. Pull master link (1) at the pin end to
master link (2) at the bushing end, and set at the
mating surfaces. Then put shoe (3) on top,
check that shoe bolt (4) goes in easily by hand,
and connect the two parts with the master bolt.
4) Bolt and nut
Shoe bolt: Anti-friction compound
(LM-P)
Initial torque:
1,960 ± 200 Nm {200 ± 20 kgm}
Tightening angle: 120 +20°
0
D575A-3 SD 30-189
➀
★ When tightening, tighten in the order – 2. When rebuilding as grease-filled track

.
1. Preparatory work
1) Washing seal assembly
• Machines fitted with F5 type seals
Remove the seal assembly from the link,
then separate into the seal ring and load ring,
and clean the parts.
★ The seal ring and load ring deteriorate
easily when brought into contact with
cl ean i ng a ge nt , so w ash t he parts
quickly. After cleaning, wipe the parts
with a clean cloth to remove all the clean-
ing agent.
★ Do not use an impact wrench for the master

link.
2) When reusing the pin, chamfer the corner of

the end face smooth with a grinder so that
press fitting can be carried out smoothly.
30-190 D575A-3 SD
➀
3) Make a mark on the end face at the small 7) Installation of seal assembly
plug end to show the direction of the side • Machines fitted with F3 type seal
hole (hole in the radial direction) in the pin Clean the link counterbore, then use tool KB
when assembling. to push the seal in fully to the bottom.
★ When reusing the pin, assemble in the ★ If there is grease stuck to the link coun-
same direction as when the part is new terbore and seal assembly, the seal will
(side hole on the link tread side). rotate and its sealing performance will
drop, so do not coat with grease.
4) Use tools KA and Z to knock the large plug

and small plug into the pin. 8) In order to keep the protrusion of the pin and
i) Insert the plug into the guide hole bushing constant and the installation dimen-
through the plug insertion window. sions of the seal within the specified value
(Coat the plug with oil.) during assembly, adjust the press-fitting jig
ii) Push the bar by hand and insert the plug dimensions of the link press.
as far as possible. ★ For details of the standard dimensions,
iii) Push the plug with the bar and push the see PRESS-FITTING JIG DIMENSION
guide itself against the pin. TABLE FOR LINK PRESS.
iv) Knock in the bar with a hammer. ★ If the end face of the pin (portion ) or
★ Dimension a to knock in from end the side face of the link (portions ,
face of pin: ) are worn, add the amount of wear to the
Small pin: 15 ± 2 mm standard dimension when adjusting the
Large pin: 15 ± 2 mm dimension of the press-fitting jig so that
★ If the plug was not removed from the the amount of protrusion of the left and
pin during disassembly, it can be used right pin and bushing is uniform.
again as it is.
a'
5) Clean any part where outside diameter of the

pin, front face of the spacer, or end face or
inside diameter of the bushing are dirty.
6) Coat the outside diameter of the pin and the
front face of the spacer with grease.
D575A-3 SD 30-191
➀
2. Assembly of link 3) Using a shoe bolt hole pitch gauge, press fit
1) Coat the area between the pin and bushing until the distance between the shoe bolt
with lithium grease (G2-LI), set in position, holes of the left and right link is the specified
then set in front of the jaw of the link press. value.
★ When reusing (turning) the bushing, set ★ Use compressed air to remove all metal
the worn surface on the outside circum- particles from burrs caused by press fit-
ference of the bushing facing the shoe ting the bushing.
mounting surface of the link (facing up on
the link press). 4) Turn over the master link, and check that the
left and right master links have been press
fitted in parallel.
2) Set the left and right bushing end master link

with the shoe mounting surface facing up,
then press fit to the bushing. 5) Measure the amount of protrusion of the left
★ When doing this, use the pin end master link and right bushings with a depth gauge.
as a support. ★ Adjust the press-fitting jig for the link
★ Press-fitting force for bushing: press so that the protrusion of the left
245 – 441 kN {25 – 45 ton} and right bushings is uniform.
30-192 D575A-3 SD
➀
6) Feed the master link portion, then set the pin 8) Using a shoe bolt hole pitch gauge, measure
and bushing in position. the distance between the shoe bolt holes
★ When reusing the pin, assemble so that and stop press fitting when it is within the
the side hole is on the link tread side in standard value.
the same way as when the part is new. 9) Assemble the pin end master link as the final
If the parts are not assembled facing the link.
specified direction, the strength may ★ Check that the left and right master links
drop, so mark the direction of the side are press fitted in parallel.
hole clearly on the end face to prevent
any mistake during assembly.
★ If the outside diameter of the pin is worn,
assemble so that the face that is not
worn is on the pulling side. However, in
this case also assemble so that the side
hole faces the tread surface of the link.
3. Shoe (regular link portion)

Set the link assembly on the bed, then use a
shoe bolt impact wrench and torque wrench to
install the shoe.
Initial torque:
2,060 ± 200 Nm {210 ± 20 kgm}
7) Set the left and right links in position, then Tightening angle: 120 ± 10°
operate the left and right pushing jigs to
press fit the pin and bushing at the same
time.
★ The seal may come off the link due to the
play when press fitting, so press fit
smoothly. If the seal comes off the link,
stop the press-fitting operation and fit the
seal correctly on the link, then start the
press-fitting operation again.
★ Pushing force for pin, bushing:
2,354 kN {240 ton}
Pushing force 1.8 x average press-fit-
ting force
(Adjust the relief pressure of the link
press and set the pushing force.)
D575A-3 SD 30-193
➀
4. Connecting to make 1/2 assembly ★ Do not use an impact wrench for the master
Set two completely assembled portions of track link.
master link (2) at the bushing end, and set at the
mating surfaces. Then put shoe (3) on top,
check that shoe bolt (4) goes in easily by hand,
and connect the two parts with the master bolt.

(LM-P)
Shoe bolt (master link):
Initial torque:
1,960 ± 210 Nm {200 ± 20 kgm}
Tightening angle: 120 +20°
0
★ When tightening, tighten in the order –

.
30-194 D575A-3 SD
➀
PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS
Jig dimension (mm)
a 3±0.1
b 1.6
c 80.6
D575A-3 SD 30-195
➀
FIELD DISASSEMBLY OF ONE 3. Install KE-5 (plate, shaft, eyebolt, adapter) to tool
KE-4 (cylinder).
LINK Fit rope to KE-4 (eyebolt) and KE-5 (eyebolt),
then raise and set so that KE-5 (shaft) is horizon-
★ This section describes only the procedure for tal.
using the tools. For details of the procedure for 4. Insert KE-5 (shaft) into hole in KE-2 (frame)
disassembly or assembly, see OVERALL DIS- installed to track, then tighten with KE-5 (nut).
ASSEMBLY (or ASSEMBLY) OF TRACK SHOE.
1. Using two bolts (2), install tool KE-1 (adapter,

guide, bolt) to link (1).
★ It is also possible to use two track bolts for
bolt (2).
5. Set tool KE-6 (guide, screw, pusher) to KE-5

(adapter), apply hydraulic pressure, and remove
pin (3).
When the cylinder reaches the end of its stroke,
add KE-6 (pusher) and repeat the operation.
2. Install tool KE-2 (adapter) to tool KE-1 (bracket).

★ Check that the hole of tool KE-2 (adapter) is
not off center. If it is off center, tighten KE-1
(bolt) again to adjust.
Fit rope to tool KE-2 (eyebolt), raise, then
install to KE-2 (adapter).
Install KE-3 (bracket, bolt) to tool KE-1
(plate).
★ Hook KE-3 (bracket) to the rib of KE-2
(frame) to ensure that KE-2 (frame) is kept
horizontal.
30-196 D575A-3 SD
➀
6. Set tool KE-7 (294 kN {30t} puller) and spacer ➀ FIELD ASSEMBLY OF ONE
to the center of the roller tread of the link to be
disassembled, then apply hydraulic pressure to LINK
the puller, open the link 5 – 6 mm, and discon-
nect the link. 1. Assemble the link sub-assembly. Fuel injection
pump for left bank
Spacer ➀ : O.D100 mm x thickness 50 mm 1) Set tool KF-1 to the end face of the link, then
press fit bushing (1).
★ Press-fitting force for bushing:
245 – 441 KN {25 – 45 ton}
2) Set tool KF-1 to the end face of the link (pin

end), and press fit pin (2).
★ Set with the side hole in the pin facing
the link tread.
★ Press-fitting force for pin :
834 – 1,079 KN {85 – 110 ton}
2. Set link sub-assembly (3) on the link to be con-

nected.
D575A-3 SD 30-197
➀
3. Set link (4) on the opposite side, and support 6. Set link (6) at the pin end to link (5) at the bush-
with tool KF-2 (guide). ing end, connect with tool KF-6 (guide), then
remove tool KF-5 (puller).
4. Set tools KF-3 and KF-4 in the same way as for

the operation to remove the pin, then use tool 7. Set tool KF-7 at pin (7) end, then use tool KF-7
KF-3 (adapter, extension, guide, adapter, bolt) (adapter, bolt, guide) to press fit pin (7).
for press fitting the pin, and tool KF-4 (extension,
Pin press-fitting hole in link:
guide, adapter, bolt) for press fitting the bush-
Gasket sealant (198-32-19890)
ing, and press fit in turn.
★ Set with the side hole in the pin facing the
★ Press-fitting force for pin:
link tread.
834 – 1,079 KN {85 – 110 ton}
★ Press-fitting force for pin:
★ Press-fitting force for bushing:
1,667 – 2,157 KN {170 – 220 ton}
245 – 441 KN {25 – 45 ton}
5. Use tool KF-5 (294 KN {30t} puller) in the same

way as when disassembling, and push open link
(5) at the bushing end.
30-198 D575A-3 SD
➀
DISASSEMBLY OF MASTER • Master link type

1) Gas cutting, removal of master link at bush-
LINK ing end
Gas cut the portion marked WW, remove
1. Removal of track assembly , then move master links (5) and (6) up
Remove the track assembly from the track or down to remove them. Push pins (8) and
frame. (9) press fitted to regular link (7) with a press
For details, see REMOVAL OF TRACK SHOE in the direction of the arrows to remove them.
ASSEMBLY. • Special tool to use: 1. Gas cutter
2. Tool KG
2. Separation of track
Disconnect all master link portions, and divide
into four parts.
3. Removal of master link

• Master pin type
1) Gas cutting of regular link
Gas cut the portion marked WW, and remove
.
Special tool to use: Gas cutter
2) Removal of master link at pin end

Gas cut the portion marked WW, remove
, push pin (10) with a press in the direc-
tion of the arrow and remove from link (11),
then remove pin (10) and link (12) at the
same time from bushing (13).
• Special tool to use: 1. Gas cutter
2. Tool KG
2) Removal of regular link

Push pin (1) in the direction of the arrow with
a press, remove from link (2), then remove
pin (1) and link (3) at the same time from
bushing (4).
D575A-3 SD 30-199
➀
ASSEMBLY OF MASTER LINK 2) Set spacer (3) and seal assembly (4) at the
counterbore of the link at the connection.
1. Assembly of link at bushing end
1) Using a press, press fit master link (1) at the
bushing end to bushing (2).
★ When press fitting the left and right mas-
ter links, be extremely careful to keep
them parallel.
★ Be careful not to scratch or damage the
mating surface of the master link and the
end face of the bushing.
Unit: mm
Master link Regular link
L1 254 ± 0.7 222
3) Align the pin hole and bushing hole, and con-
L2 320 ± 0.7 288
nect with guide pin .
D1 39 drill hole 36 drill hole
D2 36 × 3.0 —
4) Remove tool KF-5, press fit pin (5) with tool

KG, and install master link (1) at the bushing
end.
Pin press-fitting hole in link:
2. Installation of link at bushing end Gasket sealant (198-32-19890)
1) Push open the central part of the link tread ★ Set with the side hole in the pin facing
with tool KF-5 as shown in the diagram. the link tread.
(Open approx. 10 mm at the tip of the link.)
30-200 D575A-3 SD
➀
5) Install the shoe to the link at the connection. 2) Pass pin (9) through bushing (8), set pin
master link (10) from the left and right, then
6) After knocking in large plug (6) with tool Z, fill press fit with tool KG.
with oil using tool KD, then knock in small
plug (7) with tool KA. 3) After knocking in large plug (11) with tool Z,
★ When press fitting the left and right mas- fill with oil using tool KD, then knock in small
ter links, be extremely careful to keep the plug (12) with tool KA.
left and right links parallel. (Bushing end
and pin end)
★ Be careful not to scratch or damage the
mating surface of the master link and the
end face of the bushing.
★ End play at connection (play in thrust
direction of links on both sides of pin):
0 – 0.13 mm
★ Be extremely careful not to get mud or
dust on the tap hole mating face of the
master link, bushing end face, spacer, or
seal.
4. Connecting master link portion

Set two completely assembled portions of track
master link (14) at the bushing end, and set at
the mating surfaces. Then put the shoe on top,
and check that the shoe bolt goes in easily by
hand.
(LM-P)
Shoe bolt (master link):
Initial torque:
3. Assembly of link at pin end
2,060 ± 200 Nm {210 ± 20 kgm}
1) Set spacer (3) and seal assembly (4) in the
counterbore of the master link. Tightening angle: 180 +20º
0
D575A-3 SD 30-201
➀
DISASSEMBLY AND ASSEMBLY ADJUSTING TRACK SHOE TENSION
ADJUSTING TRACK SHOE 2) Adjust tension by pumping in grease or

releasing grease from lubricator (3) as fol-
TENSION lows.
To INCREASE tension, PUMP IN grease
1. Checking track shoe tension To REDUCE tension, RELEASE grease
1) Stop machine on flat ground. ★ When releasing the grease, turn the
★ Set the gear shift lever at F and do not lubricator approx. 1 turn and release a
use the brake to stop the machine. small amount of grease each time.
2) Put a straight rod across front and rear
carrier rollers as shown in the diagram and Do not loosen lubricator (3) more than 1
check that clearance a at center between rod turn because internal grease which is
and grouser is 30 – 40 mm. under high pressure, may be released,
★ If the tension is not the standard clear- causing damage or injury.
ance, adjust as follows.
Lubricator:
73.6 ± 14.7 Nm {7.5 ± 1.5 kgm}
★ If the track tension is not relieved even

when the lubricator (3) is loosened, move
the machine backward and forward.
★ After adjusting, check that the track shoe
tension is within the standard range.
2. Adjusting track shoe tension

1) Remove bolt (1), then remove inspection
cover (2).
30-202 D575A-3 SD
➀
DISASSEMBLY AND ASSEMBLY PIVOT SHAFT
REMOVAL OF PIVOT SHAFT INSTALLATION OF PIVOT

ASSEMBLY SHAFT ASSEMBLY
1. Remove track frame assembly. • Carry out installation in the reverse order to
For details, see REMOVAL OF TRACK FRAME removal.
ASSEMBLY.
2. Remove seal assembly (1).

3. Leaving 1 mounting bolt in position, remove
Mounting bolt :
other mounting bolts (2) of shaft.
1,716 ± 196 Nm {175 ± 20 kgm}
★ After slinging the shaft assembly, removing
the remaining bolt.
4. Remove shaft assembly (3).

★ Using forcing screws, pull out the shaft from
Press-fitting surface of torsion seal :
the frame and remove.
Pivot shaft assembly : 750 kg
★ Using tool L, install so that the dimension
from the end face of the shaft at the top sur-
face of the seal is dimension L.
Dimension a : 753 ± 0.3 mm
★ When coating with gasket sealant (LG-6)

• Remove all rust, oil, grease, and water
from the mating surface.
• Coat all surfaces uniformly.
• Press fit within 20 minutes of coating with
gasket sealant.
D575A-3 SD 30-203
➀
DISASSEMBLY AND ASSEMBLY EQUALIZER BAR
REMOVAL OF EQUALIZER 5. Set stand securely under radiator guard.

★ Do not jack up the front of the machine at this
BAR ASSEMBLY point.
1. Drain oil from pivot chamber.
Pivot chamber : Approx. 18
7. Remove caps (5) and (6).
3. Remove mounting bolts of torsion seal (2) .

the oil.

★ Oil will flow out, so use a container to catch
the oil, and after disconnecting, install a blind
plug.
8. Remove equalizer bars (7) and (8).
30-204 D575A-3 SD
➀
9. Remove equalizer bar pin (9). 13. Operate chain block and crane and remove
★ Use a jack to make fine adjustments of the equalizer bar assembly (12).
height, and when the pin can move, knock
the pin out. Equalizer bar assembly : 930 kg
After removing the equalizer bar assembly,

do not lower the chassis.
10. Remove grease hose (10).
11. Operate blade to jack up front of machine, then

set stand securely under radiator guard.
★ Jack up the front of the machine to a height
where the equalizer bar can pass the main INSTALLATION OF EQUAL-
frame. IZER BAR ASSEMBLY
Always apply the safety lock to the work • Carry out installation in the reverse order to
equipment control lever. removal.
12. Remove equalizer bar shaft (11).

★ Sling the equalizer bar assembly with a
crane and chain block. Mounting bolt:
★ Remove the lock plate of the shaft, then 206 ± 49 Nm {21 ± 5 kgm}
using forcing screws at the shaft flange,
remove the shaft.

Mounting bolt :
926.3 ± 103.0 Nm {94.5 ± 10.5 kgm}
Spherical surface of pin: Grease (G2-LI)
★ After installing, pump in grease through the

grease fitting.
　Shaft : Grease (G2-LI)

Add 18 of engine oil (EO-30) to the pivot
chamber.
D575A-3 SD 30-205
➀
REPLACING EQUALIZER BAR 2. Side bushings

• Removal of side bushings
BUSHING 1) Remove dust seals (1) and ring (2).
2) Remove ring (3).
1. Centering bushing 3) Using tool K3, pull out bushing (4).
• Removal of center bushings
1) Using tool K1, remove center bushings
(1) and (2).
2) Remove dust seals (3) from center bush-
ings (1) and (2).
• Installation of side bushings

1) Using tool K5, press fit bushing (4).
★ Before press fitting, tap with plastic
hammer to center the parts.
• Installation of center bushings Spherical bushing contact

1) Using tool K2, press fit center bushings surface : Grease (G2-LI)
(1) and (2). 2) Install ring (3).
Before assembling, coat the outside sur-
face of the bushing with anti-friction com-
pound (LM-P).
Before press fitting, tap with plastic ham-
mer to center the parts.
2) Install dust seals (3) to bushings (1) and
(2).
30-206 D575A-3 SD
➀
DISASSEMBLY AND ASSEMBLY EQUALIZER BAR, SEGMENT TEETH
3) Set ring (2) and dust seals (1) in position, REMOVAL OF SEGMENT
than using tool K4, press fit ring and dust
seals. TEETH
★ Before press fitting, tap with plastic hammer
to center the ports. 1. Lift off cover (1).
★ Install sach parts so that dust seal is not
cames out from ring. 2. Rotate track to bring to easy position for remov-
ing teeth.
3. Remove nut, then lift off segment teeth (2).
Segment teeth (one) : 60 kg
INSTALLATION OF SEGMENT
TEETH
removal.
• When installing, bring drum and teeth into tight
contact.
Surface of nut seat :

Seizure prevention agent (LM-G)
Bolt thread : Thread tightener (LT-2)
Nut: Initial torque :

Tighten to 981 ± 98 Nm {100 ± 10 kgm}
2nd pass : Tighten a further 180 ± 5º
D575A-3 SD 30-207
➀
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT PUMP
REMOVAL OF WORK EQUIP- INSTALLATION OF WORK

MENT PUMP ASSEMBLY EQUIPMENT PUMP ASSEM-
BLY
1. Drain oil from hydraulic tank.
Hydraulic tank : Approx. 300 removal.

2. Remove step (1). Add oil through oil filler to the specified level.
★ Open the cover and remove the step. ★ Run the engine to circulate the oil through
3. Disconnect pump outlet hose (2).
4. Disconnect pump inlet tube (3).
5. Lift off work equipment pump assembly (4).

Work equipment pump assembly : 48 kg
30-208 D575A-3 SD
➀
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT ASSIST, CONTROL PUMP
REMOVAL OF WORK EQUIP- INSTALLATION OF WORK

MENT ASSIST, CONTROL EQUIPMENT ASSIST, CON-
PUMP ASSEMBLY TROL PUMP ASSEMBLY
1. Drain oil from hydraulic tank. • Carry out installation in the reverse order to
removal.
2. Remove step (1). Add oil through oil filler to the specified level.
★ Open the cover and remove the step. ★ Run the engine to circulate the oil through
3. Disconnect hydraulic pump outlet hose (2), and

remove block (3).
4. Disconnect power train pump outlet hose (4),

and remove block (5).
6. Disconnect pump outlet hose (7).
7. Disconnect pump inlet tube (8).
8. Lift off work equipment assist and control pump

assembly (9).
★ Be careful not to hit the pumps in the sur-
rounding area when lifting off.
Work equipment assist, control pump

assembly : 47 kg
D575A-3 SD 30-209
➀
DISASSEMBLY AND ASSEMBLY BLADE VALVE
REMOVAL OF BLADE VALVE INSTALLATION OF BLADE

ASSEMBLY (FRONT) VALVE ASSEMBLY (FRONT)
Lower the work equipment to the ground and • Carry out installation in the reverse order to
stop the engine. Operate the control levers removal.
several times to release the remaining pres-
sure in the hydraulic piping. Then loosen the • Refilling with oil
oil filler cap slowly to release the pressure Add oil to the hydraulic tank to the specified
inside the hydraulic tank. level.
1. Drain oil from hydraulic tank. the system. Then check the oil level again.
★ Bleed air from cylinder.
For details, see TESTING AND ADJUSTING.
2. Using transmission jack, remove undercover.
Undercover : 136 kg
4. Remove tube (4).
5. Disconnect PPC hoses (5).

★ Disconnect 2 hoses each at the top and bot-
tom.
6. Remove valve assembly (6).

★ Remove the floor plate, then lift off the valve
assembly.
Valve assembly : 95 kg
30-210 D575A-3 SD
➀
REMOVAL OF BLADE VALVE INSTALLATION OF BLADE

ASSEMBLY (REAR) VALVE ASSEMBLY (REAR)
Lower the work equipment to the ground and removal.
stop the engine. Operate the control levers
several times to release the remaining pres- • Refilling with oil
sure in the hydraulic piping. Then loosen the Add oil to the hydraulic tank to the specified
oil filler cap slowly to release the pressure level.
inside the hydraulic tank. ★ Run the engine to circulate the oil through
1. Drain oil from hydraulic tank. ★ Bleed air from cylinder.
2. Using transmission jack, remove undercover.

Undercover : 136 kg
4. Remove tubes (4) and (5).
5. Remove hoses (6) and (7).
6. Disconnect PPC hose (8).
7. Remove valve assembly (9).

★ Remove the floor plate, then lift off the valve
assembly.
Valve assembly : 95 kg
D575A-3 SD 30-211
➀
DISASSEMBLY OF BLADE
VALVE ASSEMBLY
1. Disassemble spool (tilt, lift).
1) Remove case (2) from body (1).
2) Remove springs (3) and (4), and retainer (5).
3) Remove spool (6) from body.
4) Remove case (7).
5) Remove springs (8) and (9) from retainer
(10).
2. Remove suction valve assemblies (11) and (12).
3. Remove suction and safety valve assembly (13).

★ The safety and suction valve cannot be
adjusted when it is installed on the machine,
so do not disassemble it.
4. Remove relief valve assembly (14).
6. Remove plate (16), then remove spring (17) and

valve (18).
7. Remove plugs (19) and (20).
8. Disassemble suction valve assembly.

1) Remove valve (22) from sleeve (21).
2) Remove seal (23) from valve.
3) Pull out spring (24).
4) Remove O-ring from sleeve.
30-212 D575A-3 SD
➀
D575A-3 SD 30-213
➀
ASSEMBLY OF BLADE VALVE

ASSEMBLY
★ Clean all parts, dry them, and check for dirt or
damage. Coat the sliding surfaces of all parts
with engine oil before installing.
1. Assemble suction valve assembly.

1) Install seal (23) to valve (22).
2) Assemble spring (24) to valve, then assem-
ble to sleeve (21).
3) Install O-ring to spool.
2. Install plugs (19) and (20).

Plug (19) :
152.0 ± 24.5 Nm {15.5 ± 2.5 kgm}
Plug (20) : 68.6 ± 9.8 Nm {7 ± 1 kgm}
3. Assemble valve (18) and spring (17), then install

plate (17).
Mounting bolt :
88.3 ± 9.8 Nm {9 ± 1 kgm}
4. Fit O-ring to flange (15), then assemble to body.
5. nstall relief valve assembly (14).
Relief valve assembly:

321.17 ± 46.58 Nm {32.75 ± 4.75 kgm}
6. Install suction and safety valve assembly (13).

Suction, safety valve assembly :
225.6 ± 9.8 Nm {23 ± 1 kgm}
7. Install suction valve assemblies (12) and (11).
Suction valve assembly :

225.6 ± 9.8 Nm {23 ± 1 kgm}
8. Assemble spool (tilt, lift).

1) Assemble spool (6) to body (1).
2) Install springs (9) and (8) to retainer (10),
assemble to case (7), then install to body.
3) Assemble springs (4) and (3) to retainer (5),
assemble to case (2), then install to body (1).
30-214 D575A-3 SD
➀
D575A-3 SD 30-215
➀
DISASSEMBLY AND ASSEMBLY MAIN RELIEF VALVE
DISASSEMBLY OF MAIN ASSEMBLY OF MAIN RELIEF

RELIEF VALVE ASSEMBLY VALVE ASSEMBLY
1. Loosen nut (1), remove adjustment screw (2), 1. Fit backup ring (15) and O-ring to sleeve (14).
then remove spacer (3), spring (4), and poppet
(5). 2. Fit poppet (12), seal (11), piston (10), and
★ Before loosening nut (1), measure the protru- springs (8) and (9) to sleeve (13), then install to
sion of screw (2) from the end face of the nut. sleeve (14).
2. Remove plug (6). 3. Assemble O-ring and seal (7) to plug (6).
3. Remove seal (7), springs (8) and (9), piston (10), 4. Assemble poppet (5), spring (4), O-ring, and
seal (11), poppet (12), and sleeve (13) from spacer (3) to plug (6).
sleeve (14).
5. Tighten adjustment screw (2) to plug (6), adjust
4. Remove O-ring and backup ring (15) from sleeve dimension of protrusion from end face of locknut
(14). (1) to same amount as before disassembly, then
secure with locknut (1).
30-216 D575A-3 SD
➀
DISASSEMBLY AND ASSEMBLY BLADE LIFT CYLINDER
REMOVAL OF BLADE LIFT 3. Disconnect 2 grease hoses (3).
CYLINDER ASSEMBLY 4. Disconnect hose (4).

★ Fit blind plugs to prevent dirt or dust from
Lower the work equipment completely and entering the piping.
stop the engine.
5. Sling lift cylinder assembly (5) and remove cap
1. Sling head end of lift cylinder assembly and (6), then lift off.
remove cap (1).
Blade lift cylinder assembly : 555 kg
Start the engine, and retract the piston rod

fully, then tie the piston rod with wire to pre- INSTALLATION OF BLADE
vent it from coming out. LIFT CYLINDER ASSEMBLY
Release the remaining pressure from the
hydraulic circuit.
removal.
ING, Releasing remaining pressure from
★ Adjust so that the play of the spherical por-
hydraulic circuit.
tion in the axial direction is within 0.5 mm
and check that it rotates smoothly.
2. Remove rod (2).
Cap mounting bolt :
1,814 ± 98 Nm {185 ± 10 kgm}
★ Install the hoses without twisting or interfer-

ence.
Yoke : Grease (G2-LI)
Mounting bolt :
1,716 ± 196 Nm {175 ± 20 kgm}
• Bleeding air
Bleed the air from the cylinder.

D575A-3 SD 30-217
➀
DISASSEMBLY AND ASSEMBLY BLADE PITCH CYLINDER
REMOVAL OF BLADE PITCH 4. Remove lock plate, then pull out pin (4) and lift
off cylinder assembly (5).
CYLINDER ASSEMBLY
Blade pitch cylinder assembly : 1,220 kg
Lower the work equipment completely and
stop the engine.
1. Lift off cover (1).
2. Sling blade pitch cylinder assembly, then remove

lock plate, and remove pin (2).
INSTALLATION OF BLADE
PITCH CYLINDER ASSEMBLY
removal.
Start the engine, and retract the piston rod
fully, then tie the piston rod with wire to pre-
vent it from coming out.
Pin : Grease (G2-LI)
Release the remaining pressure from the
hydraulic circuit. • Bleeding air
For details, see TESTING AND ADJUSTING, Bleed the air from the cylinder.
Releasing remaining pressure from hydraulic For details, see TESTING AND ADJUSTING.
circuit.
3. Disconnect 2 hoses (3). Add oil through oil filler to the specified level.
★ Fit blind plugs to prevent dirt or dust from ★ Run the engine to circulate the oil through
entering the piping. the system. Then check the oil level again.
30-218 D575A-3 SD
➀
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
DISASSEMBLY OF HYDRAU- 4. Set piston rod assembly (10) to tool R1.
LIC CYLINDER ASSEMBLY

(BLADE LIFT, BLADE PITCH
CYLINDER)
1. Cylinder tube
Remove cylinder tube.
2. Quick drop valve (blade lift cylinder)

1) Remove collar (2), valves (3) and (4), washer
(5), and spring (6) from body (1).
2) Remove block (7) from body.
5. Remove piston assembly.

(Blade lift cylinder)
1) Remove mounting bolts, then remove spacer
(11).
2) Remove piston assembly (12).
3) Remove retainer (13).
3. Piston rod assembly (blade lift, blade pitch

cylinder)
1) Set cylinder assembly (8) to tool R1.
2) Remove mounting bolts, and disconnect
head assembly (9).
3) Pull out piston rod assembly (10).
★ Set a container under the cylinder to
catch the oil.
(Blade pitch cylinder)
1) Remove mounting bolts, then remove spacer
(14).
2) Remove piston assembly (15).
D575A-3 SD 30-219
➀
6. Disassemble piston assembly. 8. Disassemble head assembly.

(Blade lift cylinder) (Blade lift, blade pitch cylinder)
1) Remove wear ring (16). 1) Remove seal (22) from head assembly.
2) Remove piston ring (17). 2) Remove snap ring (23), then remove seal
3) Remove valve seat (18) and valve (19). (24).
★ No. of valve seats: 8 3) Remove bushing (25).
★ No. of valves: 4

1) Remove wear ring (20).
2) Remove piston ring (21).
7. Remove head assembly (9).
30-220 D575A-3 SD
➀
ASSEMBLY OF HYDRAULIC 3. Assemble piston assembly.

CYLINDER ASSEMBLY 1) Using tool R2, expand piston ring (21).
(BLADE LIFT, BLADE PITCH Set the piston ring on tool R2 and turn the
CYLINDER) handle 8 – 10 times to expand the ring.
2) Set tool R3 in position, then using clamp ,
★ Coat the sliding surfaces of all parts with engine compress piston ring (21).
oil and be careful not to damage the seals and
O-rings when installing.
1. Assembly of head assembly

(Blade lift, blade pitch cylinder)
1) Install bushing (25) and seal (24), then install
snap ring (23).
2) Install seal (22).
3) Install wear ring (20).
2. Assemble head assembly (9) to rod.
D575A-3 SD 30-221
➀
(Blade lift cylinder) 4. Install piston assembly.

1) Insert valve seat (18) and valve (19) in pis- (Blade pitch cylinder)
ton. 1) Assemble piston assembly (15) to rod.
★ No. of valve seats: 8 2) Assemble spacer (14), and tighten with bolts.
★ No. of valves: 4
Clean thoroughly and remove all oil and
grease from the piston and spacer
thread, coat with hardening accelerator
(Loctite Primer T), then coat with 0.5 –
0.7 cc of adhesive (Loctite No. 262).
Mounting bolt :
274.6 ± 29.4 Nm {28 ± 3 kgm}
2) Using tool R2, expand piston ring (17).

★ Set the piston ring on tool R2 and turn
the handle 8 – 10 times to expand the
ring.
3) Set tool R3 in position, then using clamp (1),
compress piston ring (17).
4) Install wear ring (16).
(Blade lift cylinder)
1) Install retainer (13).
2) Assemble piston assembly (12) to rod.
3) Assemble spacer (11), and tighten with bolts.
★ Clean thoroughly and remove all oil and
grease from the piston and spacer
thread.
Mounting bolt :
Thread tightener (Loctite No. 262).
Mounting bolt: Hardening accelerator
(Loctite Primer T)
Mounting bolt :
227.5 ± 19.6 Nm {23.2 ± 2 kgm}
30-222 D575A-3 SD
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER, BLADE PPC VALVE
5. Piston rod assembly REMOVAL OF BLADE PPC

(blade lift, blade pitch cylinder)
1) Set cylinder assembly (8) to tool R1. VALVE ASSEMBLY
2) Assemble piston rod assembly (10) to cylin-
der (8).
Lower the work equipment to the ground and
stop the engine. Operate the control levers
several times to release the remaining pres-
sure in the hydraulic piping. Then loosen the
oil filler cap slowly to release the pressure
inside the hydraulic tank.
1. Remove side cover.
2. Remove air conditioner hose (1).
3. Disconnect 6 hoses (2).
3) Install head assembly (9) to cylinder (8).

Mounting bolt (Pitch) :
2745.9 ± 294.2 Nm {280 ± 30 kgm}
Mounting bolt (Lift) :
931.6 ± 98.1 Nm {95 ± 10 kgm}
4. Disconnect wiring harness (3).
5. Remove boot (4) from base, then loosen lock

bolt (5) and remove lever assembly (6).
6. Remove cover on the floor frame.
7. Remove bolt, then remove blade PPC valve

assembly (7) together with plate (8).
6. Quick drop valve (blade lift cylinder) ★ When removing the PPC valve assembly,
1) Fit O-ring to body (1) and install block (7). support the valve and be careful not to let it
2) Assemble spring (6), washer (5), valves (4) fall.
and (3), and collar (2) to body.
7. Fit O-ring and install cylinder tube.
D575A-3 SD 30-223
➀
DISASSEMBLY AND ASSEMBLY BLADE PPC VALVE, WORK EQUIPMENT PPC VALVE
INSTALLATION OF BLADE DISASSEMBLY OF WORK

PPC VALVE ASSEMBLY EQUIPMENT PPC VALVE
ASSEMBLY
removal. 1. Remove nut (1), then remove disc (2) and boot
(3).
• Refilling with oil (hydraulic tank) 2. Remove bolts, then remove plate (5).
Add oil through oil filler to the specified level. ★ Do not remove joint (4) unless it is to be
★ Run the engine to circulate the oil through replaced.
the system. Then check the oil level again. 3. Remove seal (6) and collar (7).
4. Pull out piston (8), then remove retainer (9),
springs (10) and (11), and shim (12).
★ Spring (10) consists of two each of two types of
springs with different installed loads, so check
the mounting position (oil pressure port) and
mark with tags to prevent mistakes when install-
ing.
5. Pull out valve (13) from body (14).
30-224 D575A-3 SD
➀
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT PPC VALVE
ASSEMBLY OF WORK EQUIP-

MENT PPC VALVE ASSEMBLY
1. Assemble valve (13) to body (14).
2. Assemble shim (12) and spring (11) to valve

(13).
★ When assembling spring (11), set the end
with the small coil diameter (inside diameter)
at shim (12) end.
3. Assemble spring (10), retainer (9), and piston

(8).
★ The number of loops in the coil for spring
(10) is different for each of the hydraulic
ports below, so be careful when installing.
Position of port Free length of spring (mm)
P1, P2 48.57
P3, P4 48.57
★ The position of each port is marked on the

bottom of the valve body.
Piston: Grease (G2-LI)
★ When assembling piston (8), coat the outside
of the piston and the inside of the hole in the
body with grease.
4. Fit O-ring to collar (7) and assemble in body (14),

then install seal (6).
5. Install plate (5).

Mounting bolt:
13.23 ± 1.47 Nm {1.35 ± 0.15 kgm}
6. Install joint (4).

Rocking portion of joint: Grease (G2-LI)
Female thread of body:
★ Coat two places on the female thread with

one drop each of Loctite as shown in the dia-
gram below.
Joint: 44.1 ± 4.9 Nm {4.5 ± 0.5 kgm}

★ Keep strictly to the tightening torque for the
joint.
7. Assemble boot (3) and disc (2), and tighten with

nut (1).
Nut: 112.7 ± 14.7 Nm {11.5 ± 1.5 kgm}
★ After assembling the disc, adjust the height
of the disc.
For details, see TESTING AND ADJUSTING,
Adjusting PPC valve.
D575A-3 SD 30-225
➀
DISASSEMBLY AND ASSEMBLY BLADE
REMOVAL OF BLADE ASSEM- 5. Remove left and right covers (4).
BLY
Lower the dozer assembly on the horizontal
ground, and set blocks securely under the left
and right straight frames.
1. Disconnect left and right potentiometer rods.

2. Remove cap (1), then remove shim (2).
★ Make marks on the cap.

★ Make marks on the hose.
★ Fit blind plugs to prevent dirt or dust from
entering the piping.
7. Remove left and right trunnion caps (6).
8. Start the engine and drive the machine slowly in
reverse to disconnect dozer assembly (7) from
trunnion (8) of the track frame.
3. Sling lift cylinder assembly (3), and start engine

and retract piston rod fully.
★ Tie the piston rod with wire to prevent it from
coming out.
4. Repeat the procedure to disconnect the cylinder
on the opposite side from the blade.
Release the remaining pressure inside the
hydraulic piping. For details, see TESTING
AND ADJUSTING, Releasing remaining pres-
sure from hydraulic circuit.
Then loosen the oil filler cap slowly to release
the pressure inside the hydraulic tank.
10. Remove bushing (10) from trunnion cap (6).
30-226 D575A-3 SD
➀
INSTALLATION OF BLADE
★ Adjust with block so that height “b” and
ASSEMBLY width “c” of the left and right straight frames
are the dimensions shown below.
• Carry out installation in the reverse order to • Trunnion height “b”: Approx. 985 mm
removal. • Frame width “c” : Approx. 4,730 mm
★ Adjust so that play “a” of the spherical portion

in the axial direction is within 0.5 mm and
check that it rotates smoothly.
★ Assemble the cylinder on the opposite side
to the blade in the same way.
Mounting bolt :
1,814 ± 98 Nm {185 ± 10 kgm}
Trunnion spherical portion : • Refilling with oil (hydraulic tank)

Grease (G2-LI) Add oil through oil filler to the specified level.
Trunnion cap mounting bolt : the system. Then check the oil level again.
2,746 ± 294 Nm {280 ± 30 kgm}
D575A-3 SD 30-227
➀
DISASSEMBLY OF BLADE 5. Set block under center brace (7), and remove
mounting bolts of cap (8) at center frame end.
ASSEMBLY ★ There are shims assembled to the cap, so
check the number and thickness of the
Set block and tool S under the blade and left shims, and keep in a safe place.
and right straight frames, and set so that the
blade is stable.
6. Raise straight frame (9), and disconnect connec-

tion with center brace.
1. Lift off covers (1) and (2).
7. Remove lock plate, then pull out pin (10), and
2. Disconnect pitch cylinder hose (3).
remove straight frame (9).
Straight frame : 3,000 kg
8. Lift off pin (10).
9. Repeat Steps 1 – 6 above to remove pitch cylin-

der assembly and straight frame on opposite
side.
3. Sling pitch cylinder assembly, remove lock plate,

pull out pins (4) and (5), then remove pitch cylin-
der assembly (6).
Pitch cylinder assembly : 1,220 kg
4. Lift off pins (4) and (5).
30-228 D575A-3 SD
➀
10. Sling center brace, remove mounting bolts, dis- ASSEMBLY OF BLADE
connect cap (11), then lift off left and right center
braces (12). ASSEMBLY
★ There are shims assembled to the cap, so
check the number and thickness of the ★ Check the number and thickness of the shims
shims, and keep in a safe place. removed during disassembly, and assemble
them in the same position as before disassem-
Center brace : 430 kg bly.
1. Raise pin (15) and set to blade.
2. Raise center link (14) and align hole position with

blade, then install pin (15), and secure with lock
plate.
Center link : 520 kg
11. Raise blade (13) and turn over.

Blade : 19,000 kg
12. Sling center link (14), remove lock plate, then

pull out pin (15), and remove.
Center link : 520 kg
13. Lift off pin (15). 3. Raise blade (13), insert tool S and block to
blade, and set securely so that blade is stable.
Blade : 19,000 kg
D575A-3 SD 30-229
➀
4. Raise center brace (12) and assemble shims, 8. Raise center brace (7) and assemble shim, then
then tighten mounting bolts of cap (11). tighten mounting bolts of cap (8).
★ Adjust so that the play of the spherical por- ★ Adjust so that the play of the spherical por-
tion in the axial direction is within 1.0 mm tion in the axial direction is within 1.0 mm
and check that it rotates smoothly. and check that it rotates smoothly.
★ Standard shim thickness: 4 mm ★ Standard shim thickness : 4 mm
★ Place a block under the center brace to set ★ Place a block under the center brace to
to the height of the straight frame. set to the height of the straight frame.
Center brace : 430 kg
9. Raise pins (4) and (5), and set to blade and

straight frame.
5. Raise pin (10) and set to blade.
10. Raise pitch cylinder assembly (6) and align hole
6. Raise straight frame (9) and align hole position
position with blade and straight frame, then
with blade, then install pin (10), and secure with
install pins (4) and (5), and secure with lock
lock plate.
plate.
Straight frame : 3,000 kg
Pitch cylinder assembly : 1,220 kg
7. Align connection portion with center brace, and
set straight frame (9) to block .
30-230 D575A-3 SD
➀
DISASSEMBLY AND ASSEMBLY BLADE, POTENTIOMETER
11. Connect pitch cylinder hose (3). REMOVAL OF POTENTIOME-

12. Install covers (2) and (1). TER ASSEMBLY
13. Repeat Steps 6 – 13 above to install straight ★ Pitch the blade fully and lower it to the ground.
frame and pitch cylinder assembly on opposite
side. 1. Disconnect rod (1).
3. Disconnect connector (3).
4. Remove potentiometer assembly (4).
14. After completion of assembly, grease parts in

diagram on right thoroughly.
Work equipment greasing points :
Grease (G2-LI)
D575A-3 SD 30-231
➀
POTENTIOMETER
DISASSEMBLY AND ASSEMBLY OPERATOR’S COMPARTMENT FRAME
INSTALLATION OF POTENTI- REMOVAL OF OPERATORíS

OMETER ASSEMBLY COMPARTMENT FRAME
ASSEMBLY
removal.
1. Remove ROPS.
For details, see REMOVAL OF ROPS.
★ For details of the procedure for adjusting, see
TESTING AND ADJUSTING.
2. Remove cab assembly.
For details, see REMOVAL OF CAB ASSEMBLY.
3. Remove floor and cover.

★ Remove the related floor and cover.
4. Disconnect wiring connector (1).
5. Disconnect car heater hose (2).
6. Disconnect air conditioner hose (3).
7. Disconnect wiring connector (4) and ground con-

nection (5).
30-232 D575A-3 SD
➀
DISASSEMBLY AND ASSEMBLY OPERATOR’S COMPARTMENT FRAME
8. Disconnect brake rod (6). 12. Disconnect wiring connector (12).
9. Disconnect steering cable (7). 13. Disconnect air conditioner hose (13).
★ Disconnect at the steering valve end.

10. Disconnect fuel control rod (8).
15. Disconnect 9 PPC hoses (15).

11. Disconnect wiring connectors (10) and (11). ★ Make match marks at the hose and the block
ends, then disconnect.
D575A-3 SD 30-233
➀
DISASSEMBLY AND ASSEMBLY OPERATORíS COMPARTMENT FRAME
16. Remove operatorís compartment frame assem- INSTALLATION OF OPERA-

bly (16).
★ Sling the operatorís compartment frame TOR’S COMPARTMENT
assembly, and remove the mounting bolts. FRAME ASSEMBLY
Operatorís compartment frame assembly:
670 kg • Carry out installation in the reverse order to
removal.
★ Bend the cotter pin securely.
30-234 D575A-3 SD
➀
DISASSEMBLY AND ASSEMBLY CAB
REMOVAL OF CAB ASSEM- 5. Remove cab assembly (7).

★ Sling the cab assembly and remove the
BLY mounting bolts.
Disconnect the cable from the negative (ñ) ter- Cab assembly : 500 kg
minal of the battery.
1. Remove panels (1), (2), and (3).
2. Remove rubber mat, then remove cover (4).
4. Disconnect car washer hose (6).
D575A-3 SD 30-235
➀
DISASSEMBLY AND ASSEMBLY CAB, ROPS
INSTALLATION OF CAB REMOVAL OF ROPS

ASSEMBLY 1. Remove cover (1).
• Carry out installation in the reverse order to ★ Sling the cover and remove the mounting
removal. bolts.
★ Install the cab assembly as follows.

1) Set so that mounting dimension a of the
adjustment joints installed to A – G in the
diagram is 10 – 12 mm.
2) Set the cab assembly on the floor frame,
tighten bolts A – N in the diagram and
screw in 3 turns to check that the bolts
can be tightened.
3) Tighten bolts H – N in the diagram.
★ When tightening the bolts, check that
adjustment joints A – G are not in con-
tact with the surface of the floor frame. 2. Disconnect wiring connector (2).
4) Screw in until adjustment joints A – G
contact the surface of the floor frame,
and tighten the mounting bolts.
★ After installing the cab, check that the instru-

ments and gauges work properly.
30-236 D575A-3 SD
➀
DISASSEMBLY AND ASSEMBLY ROPS, COUNTERWEIGHT, FRAME
3. Remove ROPS (3). REMOVAL OF COUNTER-

★ Sling the ROPS, remove mounting bolts,
screw in forcing screws , then disconnect WEIGHT, FRAME ASSEMBLY
frame and remove.
1. Remove bracket (1), and move fuel supply hose
ROPS : 1,900 kg (2) to outside.
2. Remove counterweight mounting bolts (3).
3. Sling counterweight and frame assembly (4),

remove top, bottom, left, and right pins (5), then
lift off.
Counterweight, frame assembly: 5,400 kg
INSTALLATION OF ROPS
removal.
★ Tighten the left mounting bolts uniformly.

Mounting bolt :
2,746 ± 294 Nm {280 ± 30 kgm} INSTALLATION OF
COUNTERWEIGHT, FRAME
ASSEMBLY
removal.
D575A-3 SD 30-237
➀
DISASSEMBLY AND ASSEMBLY BLADE LIFT CYLINDER SUPPORT
REMOVAL OF BLADE LIFT 4. Disconnect left and right wiring connectors (3)
and (4), and remove left and right front lamp
CYLINDER SUPPORT case assembly (5).
★ Remove the related wiring clamps.
1. Remove track shoe assembly.
For details, see REMOVAL OF TRACK SHOE 5. Disconnect left and right grease hoses (6).
ASSEMBLY.
Release the remaining pressure inside the
hydraulic piping. For details, see TESTING
AND ADJUSTING, Releasing remaining pres-
sure from hydraulic circuit.
2. Remove left and right lift cylinder hoses (1).
6. Sling lift cylinder and stay assembly (7), then

remove mounting bolts, and lift off.
Lift cylinder, stay assembly : 2,700 kg
3. Remove front lamp cover (2).
7. Remove grip (8).
8. Remove lock (9).
9. Remove holder (10).
30-238 D575A-3 SD
➀
DISASSEMBLY AND ASSEMBLY BLADE LIFT CYLINDER SUPPORT
10. Using tool M1, remove blade lift cylinder support INSTALLATION OF BLADE
(11).
LIFT CYLINDER SUPPORT
Blade cylinder support : 1,500 kg (each)
11. Repeat procedure in Steps 7 – 10 to remove removal.
blade cylinder support on opposite side.
Cylinder stay mounting bolt :

2,746 ± 294 Nm {280 ± 30 kgm}
Lock mounting bolt :

926.7 ± 103.0 Nm {94.5 ± 10.5 kgm}
Coat the center pin and rear pin holes of

the support with grease (G2-LI), then
install.
★ Check that there is no clearance on the left

and right of the center pin support. If there is
any clearance, adjust with shims.
★ Using tool M2, install the blade cylinder sup-
port to the center pin and rear pin.
D575A-3 SD 30-239
➀
90 OTHERS
POWER TRAIN HYDRAULIC CIRCUIT

DIAGRAM ......................................................... 90-3
HYDRAULIC CIRCUIT DIAGRAM FOR
WORK EQUIPMENT ........................................ 90-5
ELECTRICAL CIRCUIT DIAGRAM
Electrical circuit diagram (1/7) .......................... 90-7
Electrical circuit diagram (2/7) .......................... 90-9
Electrical circuit diagram (3/7) .........................90-11
Electrical circuit diagram (4/7) ........................ 90-13
D575A-3 SD 90-1
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
1. Oil tank
2. Strainer
3. Power train lubrication pump
(SAL(4)–250)
4. Filter
(for transmission lubrication)
5. Transmission lubrication
6. Transmission lubrication valve
Set pressure: 0.3 ± 0.05MPa{3 ± 0.5kg/cm2}
7. Power train pump
(SAL(4)–140+125)
8. Filter
(for transmission)
9. Pilot filter
10. Main rilief valve
Set pressure: 2.4 – 2.5MPa{24 – 26kg/cm2}
11. 1st ECMV valve
12. 2nd ECMV valve
13. 3rd ECMV valve
14. Forward ECMV valve
15. Reverse ECMV valve
16. 1st clutch
17. 2nd clutch
18. 3rd clutch
19. Forward clutch
20. Reverse clutch
21. Torque converter
22. Oil cooler
23. Bypass valve
24. PTO lubrication
25. Steering clutch and brake lubrication
26. Steering clutch ECMV valve (R.H.)
27. Steering brake ECMV valve (R.H.)
28. Steering brake ECMV valve (L.H.)
29. Steering clutch ECMV valve (L.H.)
30. Parking brake valve
31. Steering clutch valve (R.H.)
32. Steering brake valve (R.H.)
33. Steering brake valve (L.H.)
34. Steering clutch valve (L.H.)
35. Quick drain valve
36. Sudden stop prevention valve
Set pressure: 1.08±0.05MPa{11±0.5kg/cm2}
37. Filter (for torque converter)
38. Torque converter relief valve
Set pressure: 0.85MPa{8.7kg/cm2}
39. Torque converter case
40. Scavenging pump
D575A-3 SD 90-3
HYDRAULIC CIRCUIT DIAGRAM FOR WORK EQUIPMENT
1. Hydraulic tank
2. Strainer
3. Hydraulic pump
(SAR(4)-125+125+(1)-32)
4. Blade valve (for R.H. cylinder)
4A. Blade lift spool
4B. Blade pitch spool
4C. Main relief valve
Set pressure : 20.6Mpa {210kg/cm2}
4D. Check valve
4E. Suction valve
4F. Safety valve (with suction)
5. Left blade lift cylinder
6. Left quick drop valve
7. Right quick drop valve
8. Right blade lift cylinder
9. Left blade pitch (tilt) cylinder
10. Right blade pitch cylinder
11. Right pitch assist solenoid valve
12. Left pitch assist solenoid valve
13. Hydraulic oil cooler
14. Hydraulic pump (SAL(4)-200+200)
15. Blade valve (for L.H. cylinder)
15A. Blade lift spool
15B. Blade tilt (pitch) spool
15C. Main relief valve
15D. Check valve
15E. Suction valve
15F. Safety valve (with suction)
16. PPC relief valve assembly
16A. PPC filter
16B. PPC relief valve
16C. Oil cooler bypass valve
17. Pitchpriority solenoid
18. 1 pump cut solenoid
19. Pitch selector solenoid
20. Blade Max. raise switch
21. Blade raise switch
22. PPC valve
22A. Blade lift valve
22B. Blade tilt valve
23. Pitch back solenoid
24. Left tilt limit solenoid
25. Pitch dump solenoid
26. Right tilt limit solenoid
27. Accumulator check valve
28. Accumulator
29. PPC lock valve
30. Return filter
31. Breather
Sefety valve set pressure :
68.5±3.9Kpa {0.7±0.07kg/cm2}
Check valve set pressure :
1.9±0.2Kpa {0.02±0.002kg/cm2}
D575A-3 SD 90-5
ELECTRICAL CIRCUIT DIAGRAM (1/7)
D575A-3 SD 90-7
D575A-3 SD 90-9
D575A-3 SD 90-11
D575A-3 SD 90-13
D575A-3 SD 90-15
D575A-3 SD 90-17
D575A-3 SD 90-19

Komatsu D575-A3 Super Dozer Shop Manual Seb D 022001

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Komatsu D575-A3 Super Dozer Shop Manual Seb D 022001

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SEBM022001

MACHINE MODEL SERIAL NUMBER

D575A-3 SUPER DOZER 10101 and up

• D575A-3 Super Dozer mount the SA12V170E-2 engine.

10 STRUCTURE AND FUNCTION,

20 TESTING AND ADJUSTING ............................................................................... 20-1

30 DISASSEMBLY AND ASSEMBLY................................................................ 30-1

90 OTHERS ............................................................................................................................... 90-1

( ) Page to be deleted Discard

Pages having no marks are those previously revised

LIST OF REVISED PAGES

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL

Item number (10. Structure

Example 2 (Engine volume):

• If a part cannot be smoothly removed from

ﬂ The allowable load value is estimated to

2) Sling wire ropes from the middle portion

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

• Used to prevent rubber gaskets, rubber

• Features: Resistance to heat and chemi-

790–129–9060 Adhesive: • Used as adhesive or sealant for metal, glass

• Quick hardening type adhesive

• Quick hardening type adhesive

• Features: Resistance to heat, chemicals

• Used as adhesive or sealant for gaskets

• Used as sealant for various threads, pipe

• Features: Silicon based, quick hardening

Three bond • Used as heat-resisting sealant for repairing

• Used as lubricant for sliding portion (to pre-

SYG2-400LI • General purpose type

• Used for normal temperature, light load

Molybdenum 400 g • Used for places with heavy load

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)

Thread diameter Width

Thread diameter Width

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

Thread diameter Width across flat Tightening torque

TIGHTENING TORQUE FOR 102 ENGINE SERIIES (BOLT AND NUTS)

Thread diameter Tightening torque

TIGHTENING TORQUE FOR 102 ENGINE SERIIES (EYE JOINTS)

Thread diameter Tightening torque

TIGHTENING TORQUE FOR 102 ENGINE SERIIES (TAPERED SCREWS)

Thread diameter Tightening torque

ELECTRIC WIRE CODE

2 26 0.32 2.09 3.1 20 Lighting, signal etc.

5 65 0.32 5.23 4.6 37 Charging and signal

15 84 0.45 13.36 7.0 59 Starting (Glow plug)

40 85 0.80 42.73 11.4 135 Starting

60 127 0.80 63.84 13.6 178 Starting

100 217 0.80 109.1 17.6 230 Starting

CLASSIFICATION BY COLOR AND CODE