Shop Manual KOMATSU D475A-EO

SEN00203-00
Shop
Manual
D475A-5E0
D475ASD-5E0
BULLDOZER
SERIAL NUMBERS D475A-5E0 30001 and up
D475ASD-5E0 30001 and up
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to
make changes or improvements at any time without incurring any obligation to install such changes on products
sold previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
Copyright 2006 Komatsu

Printed in U.S.A.
Komatsu America Corp.
February 2006
SEN00205-00
BULLDOZER 1SHOP MANUAL
D475A-5E0
D475ASD-5E0
Machine model Serial number

D475A-5E0 30001 and up
00 Index and foreword 1

Index
Organization list of the shop manual.................................................................................................... 2

Table of contents .................................................................................................................................. 3
D475A, D475ASD-5E0 1
SEN00205-00 00 Index and foreword
Organization list of the shop manual 1

The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs SEN00203-00
00 Index and foreword SEN00204-00

Index SEN00205-00
Foreword and general information SEN00206-00
01 Specification SEN00207-00
Specification and technical data SEN00208-00
10 Structure, function and maintenance standard SEN00209-00

Engine and cooling system SEN00210-00
Power train, Part 1 SEN00211-00
Undercarriage and frame SEN00213-00
Hydraulic system, Part 1 SEN00214-00
Work equipment SEN00217-00
Cab and its attachments SEN00218-00
Electrical system SEN00219-00
90 Diagrams and drawings SEN00224-00

Hydraulic diagrams and drawings SEN00225-00
Electrical diagrams and drawings SEN00226-00
2 D475A, D475ASD-5E0
Table of contents 1
00 Index and foreword
Index SEN00205-00
Organization list of the shop manual ....................................................................................... 2
Table of contents ..................................................................................................................... 3
Foreword and general information SEN00206-00

Foreword and general information .............................................................................................. 2
Safety notice............................................................................................................................ 2
How to read the shop manual.................................................................................................. 6
Explanation of terms for maintenance standard ...................................................................... 8
Handling electric equipment and hydraulic component ........................................................... 10
How to read electric wire code ................................................................................................ 18
Method of disassembling and connecting push-pull type coupler ........................................... 21
Standard tightening torque table.............................................................................................. 24
Conversion table...................................................................................................................... 28
01 Specification
Specification and technical data SEN00208-00
Specification and technical data.................................................................................................. 2
Specification drawings ............................................................................................................. 2
Specifications........................................................................................................................... 3
Weight table............................................................................................................................. 12
Fuel, coolant and lubricants..................................................................................................... 16
10 Structure, function and maintenance standard

Engine and cooling system SEN00210-00
Engine and cooling system ......................................................................................................... 2
Radiator and oil cooler............................................................................................................. 2
Engine mount .......................................................................................................................... 3
Cooling fan pump .................................................................................................................... 4
Cooling fan motor .................................................................................................................... 26
Power train, Part 1 ...................................................................................................................... 2
Power train .............................................................................................................................. 2
Power train hydraulic equipment arrangement diagram.......................................................... 4
Damper and universal joint...................................................................................................... 6
Power train system .................................................................................................................. 8
General view of power train unit .............................................................................................. 8
Torque converter, PTO............................................................................................................. 10
Torque converter valve ............................................................................................................ 18
Torque converter lockup control system .................................................................................. 28
Scavenging pump.................................................................................................................... 29
Transmission control................................................................................................................ 31
Transmission ........................................................................................................................... 32
Power train, Part 2 ...................................................................................................................... 2
Transmission control valve ...................................................................................................... 2
Transmission clutch ECMV...................................................................................................... 4
Priority valve ............................................................................................................................ 8
Lubricating oil relief valve ........................................................................................................ 10
Torque converter, power train, lubricating oil pump ................................................................. 11
Steering, brake control............................................................................................................. 12
Final drive ................................................................................................................................ 14
D475A, D475ASD-5E0 3
Sprocket................................................................................................................................... 18
Steering unit............................................................................................................................. 21
Steering control valve .............................................................................................................. 32
Steering clutch ECMV, Steering brake ECMV ......................................................................... 34
Parking brake valve ................................................................................................................. 40
Sudden stop prevention valve ................................................................................................. 42
Undercarriage and frame SEN00213-00
Undercarriage and frame ............................................................................................................ 2
Track frame.............................................................................................................................. 2
Recoil spring ............................................................................................................................ 4
Idler.......................................................................................................................................... 6
Track roller ............................................................................................................................... 8
Carrier roller............................................................................................................................. 12
Track roller bogie ..................................................................................................................... 13
Track shoe ............................................................................................................................... 14
Main frame............................................................................................................................... 18
Suspension .............................................................................................................................. 20
Hydraulic system, Part 1 ............................................................................................................. 2
Work equipment hydraulic equipment arrangement diagram .................................................. 2
PPC control piping diagram ..................................................................................................... 6
Work equipment control........................................................................................................... 8
Work equipment pump............................................................................................................. 10
PPC valve ................................................................................................................................ 27
PCCS lever .............................................................................................................................. 38
Control valve............................................................................................................................ 2
CLSS ....................................................................................................................................... 17
Unload valve ............................................................................................................................ 20
Introduction of LS pressure...................................................................................................... 21
LS bypass plug ........................................................................................................................ 22
Pressure compensation valve.................................................................................................. 23
Blade lift valve.......................................................................................................................... 26
Merge-divider valve ................................................................................................................. 34
Self pressure reducing valve ................................................................................................... 36
Pilot solenoid valve .................................................................................................................. 40
Hydraulic tank, hydraulic filter .................................................................................................. 2
Accumulator............................................................................................................................. 4
Work equipment cylinder ......................................................................................................... 6
Piston valve ............................................................................................................................. 8
Quick drop valve ...................................................................................................................... 10
Blade control knob (Dual tilt specification)............................................................................... 12
Blade control knob (Superdozer specification) ........................................................................ 13
Pitch and dual solenoid valve .................................................................................................. 14
Pin puller hydraulic circuit diagram .......................................................................................... 15
Pin puller solenoid valve .......................................................................................................... 16
Work equipment SEN00217-00
Work equipment .......................................................................................................................... 2
Cylinder stay ............................................................................................................................ 2
Blade........................................................................................................................................ 4
Ripper equipment .................................................................................................................... 8
4 D475A, D475ASD-5E0
Cab and its attachments SEN00218-00

Cab and its attachments.............................................................................................................. 2
Cab mount ............................................................................................................................... 2
Cab .......................................................................................................................................... 3
Air conditioner.......................................................................................................................... 6
Electrical system SEN00219-00
Electrical system ......................................................................................................................... 2
Engine control.......................................................................................................................... 2
Engine control system ............................................................................................................. 3
Deceleration potentiometer ..................................................................................................... 4
CRI engine control system ...................................................................................................... 6
Monitor system ........................................................................................................................ 8
Monitor panel........................................................................................................................... 11
Sensors ................................................................................................................................... 15
Mode selection system ............................................................................................................ 18
Electrical equipment ................................................................................................................ 24
Steering electronic control system........................................................................................... 27
VHMS controller ...................................................................................................................... 29
Communication (ORB: ORBCOMM) controller/antenna ......................................................... 35
90 Diagrams and drawings

Hydraulic diagrams and drawings SEN00225-00
Hydraulic diagrams and drawings ............................................................................................... 3
Power train hydraulic circuit diagram....................................................................................... 3
Hydraulic circuit diagram (1/3)................................................................................................. 5
Electrical diagrams and drawings SEN00226-00
Electrical diagrams and drawings ............................................................................................... 3
Electrical circuit diagram (1/13) ............................................................................................... 3
Electrical circuit diagram (10/13) ............................................................................................. 21
Electrical circuit diagram of inside cab .................................................................................... 29
D475A, D475ASD-5E0 5
SEN00205-00
D475A, D475ASD-5E0 Bulldozer

Form No. SEN00205-00
6
SEN00206-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up
00 Index and foreword 1

Foreword and general information
Foreword and general information .................................................................................................................. 2
Safety notice ........................................................................................................................................ 2
How to read the shop manual .............................................................................................................. 6
Explanation of terms for maintenance standard................................................................................... 8
Handling electric equipment and hydraulic component...................................................................... 10
How to read electric wire code ........................................................................................................... 18
Method of disassembling and connecting push-pull type coupler...................................................... 21
Standard tightening torque table ........................................................................................................ 24
Conversion table ................................................................................................................................ 28
D475A, D475ASD-5E0 1
Foreword and general information (Rev. 2005/11)
Safety notice 1
Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1. General precautions 7) If welding repairs are needed, always

k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before w eld in g wo rk , alw ay s wear wel din g
operating the machine. gloves, apron, shielding goggles, cap and
1) Before carrying out any greasing or other clothes suited for welding work.
repairs, read all the safety plates stuck to 8) Before starting work, warm up your body
the machine. For the locations of the thoroughly to start work under good condi-
safety plates and detailed explanation of tion.
precautions, see the Operation and Main-
tenance Manual. Safety points
2) Decide a place in the repair workshop to 1 Good arrangement
keep tools and removed parts. Always
2 Correct work clothes
keep the tools and parts in their correct
places. Always keep the work area clean 3 Following work standard
and make sure that there is no dirt, water, 4 Making and checking signs
or oil on the floor. Smoke only in the areas Prohibition of operation and handling by
5
provided for smoking. Never smoke while unlicensed workers
working. 6 Safety check before starting work
3) When carrying out any operation, always Wearing protective goggles
wear safety shoes and helmet. Do not 7
(for cleaning or grinding work)
wear loose work clothes, or clothes with
Wearing shielding goggles and protectors
buttons missing. 8
(for welding work)
q Always wear safety glasses when hit-
ting parts with a hammer. 9 Good physical condition and preparation
q Always wear safety glasses when Precautions against work which you are
10
grinding parts with a grinder, etc. not used to or you are used to too much
4) When carrying out any operation with 2 or
more workers, always agree on the oper-
ating procedure before starting. Always 2. Preparations for work
inform your fellow workers before starting 1) Before adding oil or making any repairs,
any step of the operation. Before starting park the machine on hard and level
work, hang UNDER REPAIR signs in the ground, and apply the parking brake and
operator's compartment. block the wheels or tracks to prevent the
5) Only qualified workers must carry out work machine from moving.
and operation which require license or 2) Before starting work, lower the work
qualification. equipment (blade, ripper, bucket, etc.) to
6) Keep all tools in good condition, learn the the ground. If this is not possible, insert
correct way to use them, and use the the lock pin or use blocks to prevent the
proper ones of them. Before starting work, work equipment from falling. In addition,
thoroughly check the tools, machine, fork- be sure to lock all the control levers and
lift, service car, etc. hang warning signs on them.
2 D475A, D475ASD-5E0
3) When disassembling or assembling, sup- 8) When removing piping, stop the fuel or oil
port the machine with blocks, jacks, or from spilling out. If any fuel or oil drips
stands before starting work. onto the floor, wipe it up immediately. Fuel
4) Remove all mud and oil from the steps or or oil on the floor can cause you to slip
other places used to get on and off the and can even start fires.
machine. Always use the handrails, lad- 9) As a general rule, do not use gasoline to
ders or steps when getting on or off the wash parts. Do not use it to clean electri-
m a c h i n e . N e v e r j u m p o n o r o ff t h e cal parts, in particular.
machine. If it is impossible to use the 10) Be sure to assemble all parts again in their
handrails, ladders or steps, use a stand to original places. Replace any damaged
provide safe footing. parts and parts which must not be reused
with new parts. When installing hoses and
3. Precautions during work wires, be sure that they will not be dam-
1) Before disconnecting or removing compo- aged by contact with other parts when the
nents of the oil, water, or air circuits, first machine is operated.
release the pressure completely from the 11) When installing high pressure hoses,
circuit. When removing the oil filler cap, a make sure that they are not twisted. Dam-
drain plug, or an oil pressure pickup plug, aged tubes are dangerous, so be
loosen it slowly to prevent the oil from extremely careful when installing tubes for
spurting out. high pressure circuits. In addition, check
2) The coolant and oil in the circuits are hot t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
when the engine is stopped, so be careful installed.
not to get scalded. Wait for the oil and 12) When assembling or installing parts,
coolant to cool before carrying out any always tighten them to the specified
work on the oil or water circuits. torques. When installing protective parts
3) Before starting work, stop the engine. such as guards, or parts which vibrate vio-
When working on or around a rotating lently or rotate at high speed, be particu-
part, in particular, stop the engine. When l a r l y c a r e fu l t o c he c k t h a t t h ey ar e
checking the machine without stopping installed correctly.
the engine (measuring oil pressure, 13) When aligning 2 holes, never insert your
revolving speed, temperature, etc.), take fingers or hand. Be careful not to get your
extreme care not to get rolled or caught in fingers caught in a hole.
rotating parts or moving parts. 14) When measuring hydraulic pressure,
4) Before starting work, remove the leads check that the measuring tools are cor-
from the battery. Always remove the lead rectly assembled.
from the negative (–) terminal first. 15) Take care when removing or installing the
5) When raising a heavy component (heavier tracks of track-type machines. When
than 25 kg), use a hoist or crane. Before removing the track, the track separates
starting work, check that the slings (wire suddenly, so never let anyone stand at
ropes, chains, and hooks) are free from either end of the track.
damage. Always use slings which have 16) If the engine is operated for a long time in
ample capacity and install them to proper a place which is not ventilated well, you
places. Operate the hoist or crane slowly may suffer from gas poisoning. Accord-
to prevent the component from hitting any ingly, open the windows and doors to ven-
other part. Do not work with any part still tilate well.
raised by the hoist or crane.
6) When removing a cover which is under
internal pressure or under pressure from a
spring, always leave 2 bolts in diagonal
positions. Loosen those bolts gradually
and alternately to release the pressure,
and then remove the cover.
7) When removing components, be careful
not to break or damage the electrical wir-
ing. Damaged wiring may cause electrical
fires.
D475A, D475ASD-5E0 3
4. Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is seen well
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling
work.
8) When installing wire ropes to an angular
3) Keep putting on gloves during sling work.
load, apply pads to protect the wire ropes.
(Put on leather gloves, if available.)
If the load is slippery, apply proper mate-
4) Measure the weight of the load by the eye
rial to prevent the wire rope from slipping.
and check its center of gravity.
9) Use the specified eyebolts and fix wire
5) Use proper sling according to the weight
ropes, chains, etc. to them with shackles,
of the load and method of slinging. If too
etc.
thick wire ropes are used to sling a light
10) Apply wire ropes to the middle portion of
load, the load may slip and fall.
the hook.
6) Do not sling a load with 1 wire rope alone.
q Slinging near the tip of the hook may
If it is slung so, it may rotate and may slip
cause the rope to slip off the hook
out of the rope. Install 2 or more wire
during hoisting. The hook has the
ropes symmetrically.
k Slinging with one rope may cause
maximum strength at the middle por-
tion.
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60°, as a rule.
Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allow-
able load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes 11) Do not use twisted or kinked wire ropes.
sling a load vertically, up to 19.6 kN {2,000 12) When lifting up a load, observe the follow-
kg} of total weight can be suspended. ing.
This weight is reduced to 9.8 kN {1,000 q Wind in the crane slowly until wire
kg} when the 2 ropes make a hanging ropes are stretched. When settling
angle of 120°. If the 2 ropes sling a 19.6 the wire ropes with the hand, do not
kN {2,000 kg} load at a lifting angle of grasp them but press them from
150°, each of them is subjected to a force above. If you grasp them, your fingers
as large as 39.2 kN {4,000 kg}. may be caught.
q After the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.
4 D475A, D475ASD-5E0
q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over 16 22.6 2.3
wind stop device, electric shock preven-
18 28.6 2.9
tion earth leakage breaker, crane collision
20 35.3 3.6
prevention device, and power application
25 55.3 5.6
warning lamp, and check safety.
2) Observe the signs for sling work. 30 79.6 8.1
3) Operate the hoist at a safe place. 40 141.6 14.4
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
D475A, D475ASD-5E0 5
How to read the shop manual 1
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
1. Composition of shop manual

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

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

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

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

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

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

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
6 D475A, D475ASD-5E0
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revised edition mark

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

a Caution
dards are necessary when performing work.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
2 Coat Places to be coated with adhesives, etc. during assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
D475A, D475ASD-5E0 7
Explanation of terms for maintenance standard 1

The maintenance standard values necessary for judgment of products and parts are described by the follow-
ing terms.
1. Standard size and tolerance

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

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

the shaft to be fitted to that hole are indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
q Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
8 D475A, D475ASD-5E0
2. Standard clearance and standard value 5. Clearance limit

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

q The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the “repair
limit”.
q If a part is worn to the repair limit must be
replaced or repaired.
q The performance and function of a prod-
uct lowers while it is used. A value below
which the product can be used without
causing a problem is called the “allowable
value”.
q If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.
D475A, D475ASD-5E0 9
Handling electric equipment and hydraulic component 1

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

equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, con-
nectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects
of rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they
are frequently removed and installed again, so
they are likely to suffer deformation or damage.
For this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2. Main failures occurring in wiring harness

1) Defective contact of connectors (defec-
tive contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female con-
nector, or because one or both of the con-
nectors is deformed or the position is not
correctly aligned, or because there is cor-
rosion or oxidization of the contact sur-
faces.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
10 D475A, D475ASD-5E0
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof struc-
ture), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
splash water over the connector. The con-
nector 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 con-
nector, the pins will be short-circuited by
the water, so if any water gets in, immedi-
ately dry the connector or take other
appropriate action before passing electric-
ity through it.
5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
D475A, D475ASD-5E0 11
3. Removing, installing, and drying connec-

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

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

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

tors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.
12 D475A, D475ASD-5E0
2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
3) Connecting DT connectors
Since the DT 8-pin and 12-pin heavy duty
wire connectors have 2 latches respec-
tively, push them in until they click 2 times.
1. Male connector
2. Female connector
q Normal locking state (Horizontal): a,
b, d
q Incomplete locking state (Diagonal): c
D475A, D475ASD-5E0 13
4) Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do
not use high-pressure water or steam
directly on the wiring harness. If water
gets directly on the connector, do as fol-
lows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
oi l a nd wa ter fr om th e c om -
pressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
14 D475A, D475ASD-5E0
4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
5. Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.
D475A, D475ASD-5E0 15
Points to remember when handling hydraulic equipment

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

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

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

refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
16 D475A, D475ASD-5E0
5. Change hydraulic oil when the temperature

is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.
6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
D475A, D475ASD-5E0 17
How to read electric wire code 1

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

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

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

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
General wiring
wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
Insulator Soft polyvinyl chloride
automobile
Heat-resis- Conduc- Annealed copper for elec-
General wiring in extremely
tant low-volt- tor tric appliance
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
18 D475A, D475ASD-5E0
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
“f” of nominal No. denotes flexible”.
D475A, D475ASD-5E0 19
3. Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
4. Types of circuits and color codes
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
20 D475A, D475ASD-5E0
Method of disassembling and connecting push-pull type coupler 1

k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
D475A, D475ASD-5E0 21
Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
contacts contact surface (a) of the hexag-
22 D475A, D475ASD-5E0
Type 3
1. Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexag-
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
D475A, D475ASD-5E0 23
Standard tightening torque table 1

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

mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5
8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6 – 7.5
12 19 98 – 123 10 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5
18 27 320 – 400 33 – 41
20 30 455 – 565 46.5 – 58
22 32 610 – 765 62.5 – 78
24 36 785 – 980 80 – 100
27 41 1,150 – 1,440 118 – 147
30 46 1,520 – 1,910 155 – 195
33 50 1,960 – 2,450 200 – 250
36 55 2,450 – 3,040 250 – 310
39 60 2,890 – 3,630 295 – 370
a The following table corresponds to the bolts in Fig. B.

mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
a Fig. A a Fig. B
24 D475A, D475ASD-5E0
2. Table of tightening torques for split flange bolts

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

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

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

Nominal No.
mm mm Range Target
02 14 35 – 63 { 3.5 – 6.5} 44 { 4.5}
03,04 20 Varies depending 84 – 132 { 8.5 – 13.5} 103 {10.5}
05,06 24 on type of connec- 128 – 186 {13.0 – 19.0} 157 {16.0}
10,12 33 tor. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1,010 {76.0 – 103} 883 {90.0}
4. Table of tightening torques for O-ring boss plugs

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

No. mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0}
33 33 – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
D475A, D475ASD-5E0 25
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque Nm {kgm} Taper seal Face seal

Nominal Width Nominal No. -
Thread diame-
No. of across Thread size Number of
Range Target ter (mm) (Ref-
hose flats (mm) threads, type of
erence)
thread
34 – 54 { 3.5 – 5.5} – 9/16-18UN 14.3
02 19 44 { 4.5}
34 – 63 { 3.5 – 6.5} 14 – –
22 54 – 93 { 5.5 – 9.5} 74 { 7.5} – 11/16-16UN 17.5
03
24 59 – 98 { 6.0 – 10.0} 78 { 8.0} 18 – –
04 27 84 – 132 { 8.5 – 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
6. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolt BANJO bolt
mm Nm kgm Nm kgm
6 10 ± 2 1.02 ± 0.20 8± 2 0.81 ± 0.20
8 24 ± 4 2.45 ± 0.41 10 ± 2 1.02 ± 0.20
10 43 ± 6 4.38 ± 0.61 12 ± 2 1.22 ± 0.20
12 77 ± 12 7.85 ± 1.22 24 ± 4 2.45 ± 0.41
14 – – 36 ± 5 3.67 ± 0.51
7. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
Thread size Tightening torque

mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
26 D475A, D475ASD-5E0
8. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Thread size Tightening torque

inch Nm kgm
1/16 3±1 0.31 ± 0.10
1/8 8±2 0.81 ± 0.20
1/4 12 ± 2 1.22 ± 0.20
3/8 15 ± 2 1.53 ± 0.20
1/2 24 ± 4 2.45 ± 0.41
3/4 36 ± 5 3.67 ± 0.51
1 60 ± 9 6.12 ± 0.92
D475A, D475ASD-5E0 27
Conversion table 1
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
1. Convert 55 mm into inches.

1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a hori-
zontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the 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 it by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches (B)

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
28 D475A, D475ASD-5E0
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
Liters to U.S. Gallons

1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
D475A, D475ASD-5E0 29
Liters to U.K. Gallons

1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
30 D475A, D475ASD-5E0
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
D475A, D475ASD-5E0 31
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

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

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

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

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

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

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
32 D475A, D475ASD-5E0
D475A, D475ASD-5E0 33
SEN00206-00
D475A, D475ASD-5E0 BULLDOZER

34
SEN00208-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up
01 Specification 1
Specification and technical data
Specification and technical data...................................................................................................................... 2
Specification drawings.......................................................................................................................... 2
Specifications ....................................................................................................................................... 3
Weight table ....................................................................................................................................... 12
Fuel, coolant and lubricants ............................................................................................................... 16
D475A, D475ASD-5E0 1
SEN00208-00 01 Specification
Specification and technical data 1

Specification drawings 1
Dimensions
Semi-U tiltdozer Full-U tiltdozer Superdozer +

Symbol Item Unit
+ giant ripper + giant ripper counterweight
A Overall length mm 11,565 12,065 10,525
B Overall height (including ROPS) mm 4,646 4,646 4,646
C Overall width mm 5,265 6,205 6,465
2 D475A, D475ASD-5E0
Specifications 1
Semi-U tiltdozer and full-U tiltdozer specifications
Machine model D475A-5E0
Serial Number 30001 and up
Machine weight
• Tractor 83,510
Weight
• Above + Semi-U tiltdozer kg 100,010

• Above + Variable giant ripper 107,370
• Above + ROPS cab + Air conditioner 108,310
Min. turning radius m 4.6
Gradeability deg. 30
Stability (Front, Rear, Left, Right) deg. 35
1st 0 – 3.5
Forward
2nd km/h 0 – 6.3

speeds
3rd 0 – 10.9
Gear
Performance
1st 0 – 4.7
Reverse
2nd km/h 0 – 8.4

3rd 0 – 14.3
Tractor 127.5 {1.30}
Semi-U dozer 152.7 {1.56}
pressure
Ground
Semi-U dozer + Variable giant ripper kPa {kg/cm }

2
163.9 {1.67}
Above + ROPS cab + Air conditioner 165.3 {1.69}
+ Perforated side cover
Tractor 6,680
Overall
Semi-U dozer 8,705

length
mm
Semi-U dozer + Variable giant ripper 11,565
Full-U dozer + Variable giant ripper 12,065
Tractor 3,620
Overall
width
Semi-U dozer mm 5,265

Dimensions
Full-U dozer 6,205

Up to ROPS top 4,646
Overall
height
Up to exhaust pipe end mm 4,546

Up to exhaust duct top 3,861
Track gauge 2,770
Length of track on ground 4,524
mm
Track shoe width 710
Minimum ground clearance 711
D475A, D475ASD-5E0 3
Model name Komatsu SAA12V140E-3

Type 4-cycle, water-cooled, V-type, direct-injection
engine with turbocharger and aftercooler
Number of cylinder–Bore x Stroke mm 12–140 x 165
Total displacement l {cc} 30.48 {30,480}
Rated output kW/rpm {HP/rpm} 664/2,000 {890/2,000}
Performance
Max. torque Nm/rpm {kgm/rpm} 3,825/1,400 {390/1,400}

Engine
High idle rpm 2,150

Low idle rpm 600
Min. fuel consumption ratio g/kWh {g/HPh} 215 {160}
(at rated output)
Starting motor 24 V, 7.5 kW x 2
Alternator 24 V, 100 A
Battery 12V, 220 Ah x 4
Type of radiator core D-type
3-element, 1-stage, 1-phase type

Torque converter
(With lockup clutch)
Planetary gear, multiple disc clutch,
Transmission hydraulic, pump-forced lubrication,
3 forward/reverse gear speeds type
Bevel gear shaft Spiral bevel gear, splash lubrication type

Power train
Wet, multiple disc clutch, spring-actuated,

Steering clutch hydraulic (hand-operated) type
interlocked with brake
Steering brake hydraulic (foot/hand-operated) type
1-stage spur gear and 1-stage planetary
Final drive
gear, splash lubrication type
Type of suspension Hard, equalizing beam type

Undercarriage
Carrier roller 2 pieces on each side
Track roller 8 pieces on each side
Assembly type single grouser shoe,

Track shoe 41 pieces on each side,
Pitch: 317.5 mm, Width: 710 mm
Power train + Lubricating oil pump (Tandem) Gear type (BAL 160 + 160 + 112)
Scavenging pump (Tandem) Gear (BAR 63 + 320)
4 D475A, D475ASD-5E0
Max. pressure MPa {kg/cm2} 27.5 {280}

Work equipment
Type Variable swash plate type:

pump
2 pcs. (HPV 125 + 125)

Capacity l/min 542
(at engine speed of 2,000 rpm)
Variable swash plate type: 2 pcs. (LPV 90 + 30)

Cooling fan pump MPa {kg/cm } 2
Max. discharge pressure: 17.5 {178}
l/min/rpm Theoretical discharge pressure: 178/1,934
Fixed swash plate type (LMF 180)
Cooling fan motor
Work equipment hydraulic system
MPa {kg/cm } 2
Max. using pressure: 17.5 {178}
Type
Work equipment
• For blade lift

6-spool type: 1 pc.
valve
• For blade tilt

Hydraulic
• For ripper lift
• For ripper tilt
Type Double acting piston
Bore of cylinder 180

blade lift cylinder
Dimensions of
Outside diameter of piston rod 110

Stroke of piston mm 1,925
Hydraulic
Max. distance between pins 3,155

cylinders
Min. distance between pins 1,230

blade tilt cylinder
Dimensions of

Stroke of piston mm 293
D475A, D475ASD-5E0 5

(Both of right and left)
Dimensions of blade

dual tilt cylinder

Stroke of piston 293
mm

Hydraulic cylinders

ripper lift cylinder
Dimensions of

ripper tilt cylinder
Dimensions of

Hydraulic tank Box type (External control valve type)
6 D475A, D475ASD-5E0
Hydraulic semi-U tiltdozer

Type
Hydraulic full-U tiltdozer
Blade supporting method Brace type (Right tilt cylinder)
Max. lift above ground mm 1,676
Performance
Max. drop below ground mm 954

Max. tilting distance mm 770
Semi-U dozer
Changing range of blade deg. ±6

cutting edge angle
Capacity of blade m3 38.1 <SAE 27.2>
Dimensions
Width of blade mm 5,265

Height of blade mm 2,690
Angle of blade cutting edge deg. 52

Performance

Max. tilting distance mm 905
Changing range of blade deg. ±6
Full-U dozer
cutting edge angle

Dimensions

Angle of blade cutting edge deg. 52
Work equipment
Semi-U dozer
Performance
Max. tilting distance mm 1,145

+ Pitch
Max. pitch angle deg. 6

Max. pitch back angle deg. 6
Performance
Full-U dozer
Max. tilting distance mm 1,350

+ Pitch
Max. pitch angle deg. 6

Performance
Max. digging depth mm 1,124

Max. lift mm 1,196
Multi-ripper
Digging angle (Standard) deg. 45 (Adjustable steplessly to 32.5 – 54)

Dimensions
Length of beam mm 3,085
Number of shanks pcs. 3

Performance
Max. digging depth mm 1,744

Max. lift mm 1,196
Giant ripper
Digging angle (Standard) deg. 45 (Adjustable steplessly to 34 – 56)

Dimensions
Length of beam mm 1,477
Number of shanks pcs. 1
D475A, D475ASD-5E0 7
Superdozer specification
Machine model D475ASD-5E0
Machine weight
Weight
• Tractor 84,430
kg
• Superdozer + ROPS cab + Air conditioner 113,120
+ Counterweight
Min. turning radius m 4.6
Gradeability deg. 30
Stability (Front, Rear, Left, Right) deg. 35
1st 0 – 3.5
Forward
2nd km/h 0 – 6.3

Performance
Gear speeds
3rd 0 – 10.9
1st 0 – 4.7
Reverse
2nd km/h 0 – 8.4

3rd 0 – 14.3
Tractor 113.0 {1.15}
pressure
Ground
Superdozer + ROPS cab + kPa {kg/cm }

2
151.4 {1.54}
Air conditioner + Counterweight
Overall
Tractor 6,680
length
mm
Superdozer + Counterweight 10,525
Overall
Tractor 3,620
width
mm
Superdozer 6,465
Dimensions
Up to ROPS top 4,646

Overall
height
Up to exhaust pipe end mm 4,546

Up to exhaust duct top 3,861
Track gauge 2,770
Length of track on ground 4,524
mm
Track shoe width 810
Minimum ground clearance 711
8 D475A, D475ASD-5E0
Model name Komatsu SAA12V140E-3

Type 4-stroke, water-cooled, V-type, direct-injection
engine with turbocharger and aftercooler
Number of cylinder–Bore x Stroke mm 12–140 x 165
Total displacement l {cc} 30.48 {30,480}
Rated output kW/rpm {HP/rpm} 677/2,000 {908/2,000}
Max. torque Nm/rpm {kgm/rpm} 3,825/1,400 {390/1,400}
Performance
Engine
High idle rpm 2,150

Low idle rpm 600
Min. fuel consumption ratio g/kWh {g/HPh} 215 {160}
(at rated output)
Starting motor 24 V, 7.5 kW x 2
Alternator 24 V, 100 A
Battery 12 V, 220 Ah x 4
Type of radiator core D-type
3-element, 1-stage, 1-phase type
Torque converter
(With lockup clutch)
Planetary gear, multiple disc clutch,
Transmission hydraulic, pump-forced lubrication,
3 forward/reverse gear speeds type
Bevel gear shaft Spiral bevel gear, splash lubrication type
Power train

Steering clutch hydraulic (hand-operated) type
Steering brake hydraulic (foot/hand-operated) type
1-stage spur gear and 1-stage planetary gear,
Final drive
splash lubrication type
Type of suspension Hard, equalizing beam type
Carrier roller 2 pieces on each side
Undercarriage
Track roller 8 pieces on each side

Assembly type single grouser shoe,
Track shoe 41 pieces on each side,
Pitch: 317.5 mm, Width: 810 mm
Power train + Lubrication pump (Tandem) Gear type (BAL 160 + 160 + 112)
Scavenging pump (Tandem) Gear (BAR 63 + 320)
D475A, D475ASD-5E0 9
Max. pressure MPa {kg/cm2} 27.5 {280}

Work equipment
Type Variable swash plate type:

2 pcs. (HPV 125 + 125)
pump
Capacity l/min 542

(at engine speed of 2,000 rpm)
Variable swash plate type: 2 pcs. (LPV 90 + 30)

Cooling fan pump MPa {kg/cm } 2
Max. discharge pressure: 17.5 {178}
l/min/rpm Theoretical discharge pressure: 178/1,934
Fixed swash plate type (LMF 180)

Cooling fan motor
MPa {kg/cm2} Max. using pressure: 17.5 {178}
Type
Work equipment
• For blade lift

6-spool type: 1 pc.
valve
• For blade tilt

Hydraulic
• For ripper lift
• For ripper tilt
Type Double acting piston

blade lift cylinder
Dimensions of

Stroke of piston mm 1,925
Hydraulic
cylinders

blade pitch cylinder

Dimensions of

Hydraulic tank Box type (External control valve type)
10 D475A, D475ASD-5E0
Type Hydraulic superdozer (Pitchdozer)

Blade supporting method Cylinder type

Performance

Work equipment
Max. tilting distance mm 900 (at cutting edge angle of 52°)

Max. pitch dump angle deg. 15
Superdozer

Dimensions

Angle of blade cutting edge deg. 42 – 67
D475A, D475ASD-5E0 11
Weight table 1
k This weight table is a reference for handling and transportation of components.
Semi-U tiltdozer and full-U tiltdozer specifications
Unit: kg
Engine and damper assembly 4,115

• Engine assembly 3,900
• Damper assembly 215
Main radiator assembly 485
Aftercooler assembly 30
Oil cooler assembly 129
Fuel tank assembly [When full] 863 [2,335]
Power train unit (Including work equipment pump and fan pump) 5,350
• Torque converter and PTO assembly 830
• Transmission assembly 1,335
• Transmission valve assembly 40
• Steering clutch and brake assembly 2,290
• Steering valve assembly 75
• Work equipment pump 180
• Cooling fan pump 72
• Power train and lubricating oil pump 64
• Scavenging pump 25
• Power train filter assembly (3 pcs.) 100
Final drive assembly (Each side) 3,575
Main frame assembly 9,120
Track group assembly (Each side) 13,190
• Track frame 2,976
• Idler assembly (Each side) 708
• Track roller assembly (1 single flange) 248
• Track roller assembly (1 double flange) 237
• Carrier roller assembly (1 pc.) 106
Track shoe assembly (710 mm) 13,530
Pivot shaft assembly (each side) 370
Equalizer bar 733
Hydraulic tank assembly 290
Control valve 195
Blade lift cylinder assembly (Each side) 509
Blade tilt cylinder assembly 504
Tiltdozer assembly 16,500 (18,500)
• Blade 8,550 (9,760)
• Straight frame (Left) 1,770 (1,770)
• Straight frame (Right) 1,770 (1,770)
• Tilt cylinder assembly 504 (504)
Variable giant ripper assembly 7,300
• Shank assembly 1,040
• Ripper lift cylinder assembly 389
• Ripper tilt cylinder assembly 394
a Values in ( ) are for full-U blade.
12 D475A, D475ASD-5E0
Unit: kg
Radiator guard assembly 4,550

• Radiator guard 2,530
• Blade lift cylinder assembly (Each side) 509
• Cooling fan motor 65
Radiator mask (Including grille) (Each side) 100
Engine underguard (Front) 267
Engine underguard (Rear) 324
Power train underguard (Front) 340
Power train underguard (Rear) 448
Hood 197
Fender (Left) 474
Fender (Right) 570
ROPS mount assembly (Left) 527
ROPS mount assembly (Right) 520
ROPS assembly 934
Floor frame assembly 600
Cab assembly 455
Operator's seat assembly 64
D475A, D475ASD-5E0 13
Superdozer specification
Unit: kg
Engine and damper assembly 4,115

• Engine assembly 3,900
• Damper assembly 215
Main radiator assembly 485
Aftercooler assembly 30
Oil cooler assembly 129
Fuel tank assembly [When full] 863 [2,335]
Power train unit (Including work equipment pump and fan pump) 5,350
• Torque converter and PTO assembly 830
• Transmission assembly 1,335
• Transmission valve assembly 40
• Steering clutch and brake assembly 2,290
• Steering valve assembly 75
• Work equipment pump 180
• Cooling fan pump 72
• Power train and lubricating oil pump 64
• Scavenging pump 25
• Power train filter assembly (3 pcs.) 100
Final drive assembly (Each side) 3,575
Main frame assembly 9,120
Track group assembly (Each side) 13,190
• Track frame 2,976
• Idler assembly (Each side) 708
• Track roller assembly (1 single flange) 248
• Track roller assembly (1 double flange) 237
• Carrier roller assembly (1 pc.) 106
Track shoe assembly (810 mm) 14,450
Pivot shaft assembly (each side) 370
Equalizer bar 733
Hydraulic tank assembly 290
Control valve 195
Blade lift cylinder assembly (Each side) 509
Blade pitch cylinder assembly (Each side) 508
Superdozer assembly 21,200
• Blade 11,950
• Straight frame (Left) 1,770
• Straight frame (Right) 1,770
• Pitch cylinder assembly (Each side) 508
Counterweight 6,400
Radiator guard assembly 4,640
• Radiator guard 2,530
• Blade lift cylinder assembly (Each side) 509
• Cooling fan motor 65
14 D475A, D475ASD-5E0
Unit: kg
Radiator mask (Including grille) (Each side) 100

Engine underguard (Front) 267
Engine underguard (Rear) 324
Power train underguard (Front) 340
Power train underguard (Rear) 448
Hood 197
Fender (Left) 474
Fender (Right) 570
ROPS mount assembly (Left) 527
ROPS mount assembly (Right) 520
ROPS assembly 934
Floor frame assembly 600
Cab assembly 455
Operator's seat assembly 64
D475A, D475ASD-5E0 15
Fuel, coolant and lubricants 1

a For details of the notes (Note 1, Note 2 - - -) in the table, see Operation and Maintenance Manual.
16 D475A, D475ASD-5E0
Unit: l
D475A, D475ASD-5E0
Refilling points
Specified capacity Refill capacity
Engine oil pan 126 121
Damper case 2.2 2.2
Power train case 410 210
Final drive case (each) 75 75
Hydraulic system
420 170
(with blade, without ripper)
Cooling system
210 —
(including reservoir tank)
Fuel tank 1670 —
D475A, D475ASD-5E0 17
SEN00208-00

18
SEN00210-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up
10 Structure, function and

maintenance standard 1
Engine and cooling system
Engine and cooling system ............................................................................................................................. 2
Radiator and oil cooler ......................................................................................................................... 2
Engine mount ....................................................................................................................................... 3
Cooling fan pump ................................................................................................................................. 4
Cooling fan motor............................................................................................................................... 26
D475A, D475ASD-5E0 1
SEN00210-00 10 Structure, function and maintenance standard
Engine and cooling system 1

Radiator and oil cooler 1
1. Main radiator
2. Sub radiator
3. Turbocharger
4. Engine
5. Power train oil cooler
6. Water pump
2 D475A, D475ASD-5E0
Engine mount 1
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance

Clearance between bracket size Shaft Hole clearance limit
1
and cushion
–0.030 +0.006 –0.018 –
78 0.1
–0.060 –0.048 0.066
Replace
Clearance between bracket –0.043 +0.072 0.043 –
2 200 0.1
and bushing –0.083 +0.072 0.155
Standard size Repair limit
3 Free height of rubber mount
118 116
D475A, D475ASD-5E0 3
Cooling fan pump 1

Type: LPV90 + 30
DC: Discharge port

SC: Suction port
1. LPV90 Hydraulic pump

4 D475A, D475ASD-5E0
D475A, D475ASD-5E0 5
DC: Discharge port

SC: Suction port
6 D475A, D475ASD-5E0
IM: Control current input connector 1. Shaft

PA: Pump discharge port 2. Cradle
PD1: Drain port 3. Case
PD2: Drain port (Plug) 4. Rocker cam
PDA: Breather 5. Shoe
PEN: Control pressure pick-up port (Plug) 6. Piston
PEPC: EPC basic pressure input port 7. Cylinder block
PS: Pump suction port 8. Valve plate
9. Spring
10. Servo piston
D475A, D475ASD-5E0 7
Function Structure
q The rotation and torque of the engine are q Cylinder block (7) is supported on shaft (1)
transmitted to the shaft of this pump. Then, through spline (C). Shaft (1) is supported on
this pump converts the rotation and torque into the front and rear bearings.
hydraulic energy and discharges hydraulic oil q The end of piston (6) has a spherical hollow
according to the load. which is combined with shoe (5). Piston (6)
q The discharge of this pump can be changed by and shoe (5) form a spherical bearing.
changing the swash plate angle in it. q Shoe (5) is kept pressed against plane (A) of
rocker cam (4) and slid circularly. Rocker cam
(4) receives high-pressure oil and forms a
static pressure bearing and slides on cylindri-
cal surface B of cradle (2).
q Piston (6) in each cylinder of cylinder block (7)
moves relatively in the axial direction.
q Cylinder block (7) rotates relatively against
valve plate (8), sealing the hydraulic oil. The
hydraulic balance on the valve plate is main-
tained properly.
q The oil in each cylinder of cylinder block (7)
can be sucked and discharged through valve
plate (8).
8 D475A, D475ASD-5E0
Operation q If center line (X) of rocker cam (4) is equal to

the axial of cylinder block (7) (the swash plate
1) Operation of pump
angle is 0), there is not a difference between
q Cylinder block (7) rotates together with shaft
volumes (E) and (F) in cylinder block (7) and
(1). Shoe (5) slides on plane (A). At this time,
the oil is not sucked or discharged. (The
rocker cam (4) moves along cylindrical surface
(B). As a result, angle (a) between center line swash plate angle is not set to 0 actually, how-
(X) of rocker cam (4) and the axis of cylinder ever.)
block (7) changes. Angle (a) is called the
swash plate angle.
q In short, swash plate angle (a) is in proportion

to the pump discharge.
q If angle (a) is made between center line (X) of
rocker cam (4) and the axis of cylinder block
(7), plane (A) works as a cam for shoe (5).
q Accordingly, piston (6) slides inside cylinder
block (7) and a difference is made between
volumes (E) and (F) in cylinder block (7). As a
result, each piston (6) sucks and discharges oil
by (F) – (E).
q In other words, if cylinder block (7) rotates and
the volume of chamber (E) is decreased, the
oil is discharged from chamber (E). On the
other hand, the volume of chamber (F) is
increased and the oil is sucked in chamber (F).
[In the figure, chamber (F) is at the end of the
suction stroke and chamber (E) is at the end of
the discharge stroke.]
D475A, D475ASD-5E0 9
2) Control of discharge
q If swash plate angle (a) is increased, the differ-
ence between volumes (E) and (F) is
increased, or discharge (Q) is increased.
Swash plate angle (a) is changed with servo
piston (1).
q Servo piston (1) reciprocates straight accord-
ing to the signal pressure of the PC valve. This
straight motion is transmitted to rocker cam
(4). Then, rocker cam (4) supported on the
cylindrical surface of cradle (2) slides in the
rotating direction.
q The pressure receiving area of the top of servo
piston (1) is different from that of the bottom.
Main pump discharge pressure (self-pressure)
(PA) is kept led in the pressure chamber on the
small-diameter piston side (upper side).
q PC valve output pressure (PEN) is led in the
pressure chamber on the large-diameter piston
side (lower side).
q The movement of servo piston (1) is controlled
according to the difference between pressure
(PA) on the small-diameter piston side and
pressure (PEN) on the large-diameter piston
side and the ratio of the pressure receiving
area of the small-diameter piston to that of the
large-diameter piston.
10 D475A, D475ASD-5E0
3) PC valve, EPC valve, and servo piston
IM: Control current input connector

PA: Pump discharge port
PEPC: EPC basic pressure input port
Servo piston PC valve EPC valve

1. Servo piston 4. Piston 10. EPC valve
2. Lever 5. Seat
3. Spring 6. Spring
7. Spool
8. Sleeve
9. Plug
D475A, D475ASD-5E0 11
Function
q The PC valve works so the relationship
between the current input to the EPC valve
and pump swash plate angle (a) will be as
shown in the figure below.
12 D475A, D475ASD-5E0
D475A, D475ASD-5E0 13
(1) When EPC output pressure is high [When EPC current (i) is large]
14 D475A, D475ASD-5E0
Operation
q The relationship between the EPC valve input
current (i) and EPC valve output pressure (F)
is as shown in the figure below.
q If the EPC discharge pressure rises, spool (7)

is pushed to the left because of the difference
in sectional areas between parts (S1) and (S2)
of the spool (S1 > S2).
q Port (f) is connected to port (g) and pump dis-
charge pressure (PA) flows through port (g) to
port (f). Port (f) is disconnected from the drain
circuit.
q Pump discharge pressure (PA) from port (f) of
the PC valve enters chamber (X) on the large
diameter side of servo piston (1).
q Pump pressure (PA) is also constantly applied
to chamber (Y) on the small diameter side of
servo piston (1). Since a larger force is applied
to the large diameter side because of the dif-
ference in area between both ends of servo
piston (1), however, servo piston (1) moves
toward the minimum swash plate angle side
(upper side).
q If servo piston (1) moves up, piston (4) is

moved to the right through lever (2). Accord-
ingly, spring (6) is compressed and spool (7)
moves to the right.
q If spool (7) moves to the right and port (f) is
disconnected from port (g), servo piston (1)
stops moving up.
q At this time, servo piston (1) stops at a place
higher (nearer to the minimum swash plate
angle) than when the EPC discharge pressure
is low.
D475A, D475ASD-5E0 15
(2) When EPC output pressure is low [When EPC current (i) is small]
16 D475A, D475ASD-5E0
Operation
q If EPC current (i) reduces and the EPC output
pressure lowers, spool (7) is pushed to the
right by the force of spring (6).
q Accordingly, port (g) is disconnected from port
(f) and port (f) is connected to the drain circuit.
q At this time, the oil in chamber (X) on the large
diameter side of servo piston (1) flows through
port (f) of the PC valve to the drain circuit.
q As a result, servo piston (1) is moved toward
the maximum swash plate angle side (lower
side) by the pressure of chamber (Y) on the
small diameter side.
D475A, D475ASD-5E0 17
P1: Pump discharge port

PAEPC: EPC output pressure pickup port
PDA2: Breather
PEPC: EPC valve basic pressure input port
PS: Pump suction port
TO: Drain port
18 D475A, D475ASD-5E0
1. Shaft
2. Oil seal
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Spring
10. Servo piston
11. Ball
D475A, D475ASD-5E0 19
Function
q The rotation and torque of the engine are
transmitted to the shaft of this pump. Then,
this pump converts the rotation and torque into
hydraulic energy and discharges hydraulic oil
according to the load.
q The discharge of this pump can be changed by
changing the swash plate angle in it.
Structure
q Cylinder block (7) is supported on shaft (1)
through spline (B). Shaft (1) is supported on
the front and rear bearings.
q The end of piston (6) has a spherical hollow
which is combined with shoe (5). Piston (6)
and shoe (5) form a spherical bearing.
q Shoe (5) is kept pressed against plane (A) of
rocket cam (4) and slid circularly. Rocker cam
(4) slides around ball (11).
q Piston (6) in each cylinder of cylinder block (7)
moves relatively in the axial direction.
q Cylinder block (7) rotates relatively against
valve plate (8), sealing the hydraulic oil. The
hydraulic balance on the valve plate is main-
tained properly.
q The oil in each cylinder of cylinder block (7)
can be sucked and discharged through valve
plate (8).
20 D475A, D475ASD-5E0
Operation q If center line (X) of rocker cam (4) is equal to

1) Operation of pump the axial of cylinder block (7) (the swash plate
q Cylinder block (7) rotates together with shaft angle is 0), there is not a difference between
(1). Shoe (5) slides on plane (A). At this time, volumes (E) and (F) in cylinder block (7) and
rocker cam (4) tilts around ball (11). As a the oil is not sucked or discharged. (The
result, angle (a) between center line (X) of swash plate angle is not set to 0 actually, how-
rocker cam (4) and the axis of cylinder block ever.)
(7) changes. Angle (a) is called the swash q In short, swash plate angle (a) is in proportion
plate angle. to the pump discharge.
q If angle (a) is made between center line (X) of
rocker cam (4) and the axis of cylinder block
(7), plane (A) works as a cam for shoe (5).
q Accordingly, piston (6) slides inside cylinder
block (7) and a difference is made between
volumes (E) and (F) in cylinder block (7). As a
result, each piston (6) sucks and discharges oil
by (F) – (E).
q In other words, if cylinder block (7) rotates and
the volume of chamber (E) is decreased, the
oil is discharged from chamber (E). On the
other hand, the volume of chamber (F) is
increased and the oil is sucked in chamber (F).
[In the figure, chamber (F) is at the end of the
suction stroke and chamber (E) is at the end of
the discharge stroke.]
D475A, D475ASD-5E0 21
2) Control of discharge
q If swash plate angle (a) is increased, the differ-
ence between volumes (E) and (F) is
increased, or discharge (Q) is increased.
Swash plate angle (a) is changed with servo
piston (10).
q Servo piston (10) reciprocates straight accord-
ing to the signal pressure of the servo valve.
This straight motion is transmitted to rocker
cam (4). Then, rocker cam (4) supported on
ball (11) rocks around ball (11).
22 D475A, D475ASD-5E0
3) Servo valve
P: EPC valve basic pressure input port

PE: Control piston pressure output port
PH: Pump discharge pressure input port
T: Drain port
1. Plug
2. Lever
3. Retainer
4. Seat
5. Spool
6. Piston
7. Sleeve
D475A, D475ASD-5E0 23
A: Drain side D: EPC output pressure side

B: Pump discharge pressure input side P: EPC basic pressure input side
C: EPC output pressure receiving pressure
Function
q The servo valve works so the relationship
between the current input to the EPC valve
and pump swash plate angle (a) will be as
shown in the figure below.
24 D475A, D475ASD-5E0
q The relationship between the EPC valve input

current (i) and EPC valve output pressure (F)
is as shown in the figure below.
Operation
q The output oil of the EPC valve flows in the pis-
ton chamber (C) to push piston (6). Piston (6)
pushes spool (5) until it is balanced with the
spring.
q Then, land (PE) of the servo piston pressure
passage is connected to the pump discharge
passage by the cut of spool (5) and the dis-
charge pressure is led to the servo piston.
q The servo piston is raised by the rocker cam.
The position feedback is applied and the lever
moves to compress the spring.
q If spool (5) is pushed back, the pump dis-
charge circuit and the servo piston circuit are
shut off. The pressure in the servo piston
chamber lowers and the rocker cam returns
toward the maximum swash plate angle.
q These processes are repeated until the swash
plate is fixed to a position where the EPC out-
put pressure is balanced with the spring force.
q Accordingly, as the EPC output pressure is
heightened, the swash plate angle is
decreased. As the EPC output pressure is
lowered, the swash plate angle is increased.
D475A, D475ASD-5E0 25
Cooling fan motor 1

Type: LMF180
P: From fan pump

T: From cooler to tank
TC: To tank
Specifications
Type : LMF180
Capacity : 180 cc/rev
Rated speed : 982 rpm
Rated flow : 178 l/min
Check valve cracking pressure:
0.07 MPa {0.7 kg/cm2}
26 D475A, D475ASD-5E0
1. Output shaft
2. Case
3. Thrust plate
4. Shoe
5. Piston
6. Cylinder block
7. Valve plate
8. End cover
9. Center spring
10. Safety-suction valve
D475A, D475ASD-5E0 27
1. Hydraulic motor
Function
q This hydraulic motor is a swash plate type axial
piston motor, which converts the pressure of
the hydraulic oil sent from the hydraulic pump
into revolution.
Principle of operation
q The oil sent from the hydraulic pump flows
through valve plate (7) into cylinder block (5).
This oil can flow on only one side of the (Y – Y)
line connecting the top dead center and bottom
dead center of the stroke of piston (4).
q The oil sent to one side of cylinder block (5)
presses pistons (4) (4 or 5 pieces) and gener-
ates force (F1) (F1 kg = P kg/cm2 x x/4D2 cm2).
q This force is applied to thrust plate (2). Since
thrust plate (2) is fixed to the angle of (a)
degrees to the output shaft (1), the force is
divided into components (F2) and (F3).
q Radial component (F3) generates torque
against the (Y – Y) line connecting the top
dead center and bottom dead center (T = F3 x
ri).
q The resultant of this torque [T = s (F3 x ri)]
rotates cylinder block (5) through the piston.
q Since cylinder block (5) is coupled with the out-
put shaft by means of spline, the output shaft
revolves to transmit the torque.
28 D475A, D475ASD-5E0
1. Piston
2. Main valve
3. Piston spring
4. Valve seat
5. Poppet
6. Poppet spring
7. Suction valve
8. Suction valve spring
9. Adjustment screw
Function
q When the pressure in port (P) of the motor
rises at the starting time of the engine, this
valve protects the fan system circuit. (Safety
valve)
q When the fan pump stops, the hydraulic oil
does not flow into the motor. Since the motor
continues revolution because of the force of
inertia, however, the pressure on the outlet
side of the motor rises.
q When the oil stops flowing in from inlet port (P),
the safety-suction valve sucks in the oil on the
outlet side and supplies it to port (MA) where
there is not sufficient oil to prevent cavitation.
(Suction valve)
D475A, D475ASD-5E0 29
Operation q If poppet (5) opens, the pressure in port (C)

1) Operation as safety valve lowers and piston (1) moves to the right. Pis-
q Port (A) is connected to port (P) of the motor ton (1) comes in contact with the tip of poppet
and port (B) is connected through port (MB) to (5) and the hydraulic oil is drained through
port (T). throttle (b) and port (D).
q The hydraulic oil in port (A) flows through the
hole of piston (1) to port (C). Since (d2) < (d3),
main valve (2) is seated on the left side.
q The order of the diameters (areas) of the sec-
tions is (d5) > (d4) > (d1) > (d3) > (d2).
q Since the pressure in port (C) is lower than that

in port (A), main valve (2) moves to the right
and the hydraulic oil flows through port (A) to
port (B), thus generation of abnormal pressure
is prevented.
q If abnormal pressure generated in port (A) q Even if abnormal pressure is generated, suc-
reaches the set pressure of spring (6), poppet tion valve (7) having a large section diameter
(5) opens and the hydraulic oil in port (C) is does not operate since (d1) < (d4).
drained through port (D) and periphery (a) of
suction valve (7).
30 D475A, D475ASD-5E0
2) Operation as suction valve

q If negative pressure is generated in port (P) of
the motor, the pressure in ports (A) and (C)
becomes negative since those ports are con-
nected.
A right force caused by the hydraulic pressure
equivalent to the area difference between (d4)
and (d1) is applied to suction valve (7).
q If the differential pressure between ports (B)
and (A) increases above the set pressure, it
moves suction valve (7) to the right. Accord-
ingly, hydraulic oil flows from port (B) to port
(A) to prevent generation of negative pressure
in port (A).
D475A, D475ASD-5E0 31
3. Operation for forward and reverse revolution

1) Forward revolution (Counterclockwise revolution)
q If ON-OFF solenoid (1) for selector valve is de-

energized, the hydraulic oil in port (MA) is sent
to chamber (E) and spool (5) moves to the left.
q The hydraulic oil in port (MB) is returned to the
tank through passage (a) on the periphery of
spool (5).
q If ON-OFF solenoid (1) for selector valve is de-
energized, the hydraulic oil from the pump is
blocked by ON-OFF selector valve (2) and port
(C) is connected to the tank circuit.
q Accordingly, selector spool (3) is pushed by
spring (4) to the right to open motor port (MA)
and then the hydraulic oil flows in the motor to
revolve the motor forward (counterclockwise).
32 D475A, D475ASD-5E0
2) Reverse revolution (Clockwise revolution)
q If ON-OFF solenoid (1) for selector valve is

energized, the hydraulic oil in port (MB) is sent
to chamber (F) and spool (5) moves to the
right.
q The hydraulic oil in port (MA) is returned from
chamber (E) to the tank through passage (a)
on the periphery of spool (5).
q If ON-OFF solenoid (1) for selector valve is
energized, ON-OFF selector valve (2) changes
to let the hydraulic oil from the pump flow
through port (C) into spool chamber (D).
q The hydraulic oil in chamber (D) pushes selec-
tor spool (3) to the left against spring (4). As a
result, motor port (MB) opens and the hydrau-
lic oil flows in the motor to revolve the motor in
reverse (clockwise).
D475A, D475ASD-5E0 33
SEN00210-00

34
SEN00211-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up

Power train, Part 1
Power train, Part 1 .......................................................................................................................................... 2
Power train ........................................................................................................................................... 2
Power train hydraulic equipment arrangement diagram ...................................................................... 4
Damper and universal joint .................................................................................................................. 6
General view of power train unit........................................................................................................... 8
Torque converter, PTO ....................................................................................................................... 10
Torque converter valve....................................................................................................................... 18
Torque converter lockup control system............................................................................................. 28
Scavenging pump .............................................................................................................................. 29
Transmission control .......................................................................................................................... 31
Transmission ...................................................................................................................................... 32
D475A, D475ASD-5E0 1
Power train, Part 1 1

Power train 1
Outline
q The power generated by engine (1) has its tor- shaft, and it is then divided at right angles to
sional vibration dampened by damper (2), and the left and right and transmitted to the respec-
then passes through universal joint (3), and is tive steering clutches (9). The power transmit-
transmitted to torque converter (7). ted from the bevel gear shaft to the final drive
The power from the engine is transmitted is used to steer the machine by engaging or
through oil by torque converter (7) to the input disengaging steering clutch (9).
shaft (turbine shaft) of transmission (8) in The steering lever is operated to disengage
accordance with the change in the load. the steering clutch on the side to which the
There is a lockup clutch assembled to the machine is to be steered in order to change the
torque converter, and when the rotating speed direction of travel. The size of the turning
beyond the torque converter becomes higher, radius is controlled by steering brake (10)
the lockup clutch is engaged. When this hap- installed to the outside of the steering clutch.
pens, the drive case and turbine form one unit, Steering brake (10) uses the same disc system
so the power from the engine is transmitted that is used for the steering clutch.
directly to the transmission input shaft. The power output from the steering clutch
Transmission (8) uses a combination of a plan- enters final drive (11), where it is reduced, and
etary gear system and hydraulic equipment to rotates sprocket (12).
reduce the speed and shift the gears (forward: Final drive is a double reduction type consist-
3 gears, reverse: 3 gears). It connects two sets ing of a single stage spur gear and single stage
of clutches selected with the gear shift lever planetary gear system.
according to the change in the load, and trans- It rotates the sprocket to drive track shoe (13)
mits the power from the transmission to trans- and moves the machine.
fer (14) from output shaft.
The power entering transfer (14) has its speed
reduced. Its speed is further reduced by the
bevel pinion and bevel gear of the bevel gear
2 D475A, D475ASD-5E0
1. Engine (SAA12V140E-3) 6. Fan pump (LPV90+30) 13. Track shoe

2. Damper 7. Torque converter 14. Transfer
3. Universal joint 8. Transmission 15. Transfer drive gear
4. Power train, lubrication pump 9. Steering clutch 16. Bevel pinion
(BAL160+160+112) 10. Steering brake 17. Bevel gear
5. Work equipment pump 11. Final drive 18. PTO
(HPV125+125) 12. Sproket 19. Scavenging pump
D475A, D475ASD-5E0 3
Power train hydraulic equipment arrangement diagram 1
1. Torque converter oil filter A. Transmission main relief pressure pickup port (TM)
2. Transmission lubricating oil filter B. Transmission R clutch pressure pickup port (REV)
3. Transmission oil filter C. Transmission F clutch pressure pickup port (FWD)
4. Torque converter valve D. Torque converter inlet pressure pickup port (IN)
5. Transmission control valve E. Lockup clutch pressure pickup port (LU)
6. Steering control valve F. Left clutch pressure pickup port (LC)
7. Power train oil strainer G. Left brake pressure pickup port (LB)
8. Oil tank H. Right brake pressure pickup port (RB)
9. Power train, lubrication pump J. Right clutch pressure pickup port (RC)
(BAL160+160+112) K. Stator clutch pressure pickup port (SC)
10. Scavenging pump L. Torque converter outlet pressure pickup port (OUT)
11. Power train oil cooler M. Transmission 1st clutch pressure pickup port (1ST)
N. Transmission 2nd clutch pressure pickup port (2ND)
P. Transmission 3rd clutch pressure pickup port (3RD)
4 D475A, D475ASD-5E0
D475A, D475ASD-5E0 5
Damper and universal joint 1
1. Output shaft Outline

2. Flywheel q The damper damps the tensional vibration
3. Outer body caused by fluctuation of the engine torque and
4. Flange the impact torque caused by sudden accelera-
5. Oil level gauge tion and heavy digging work to protect the
6. Breather torque converter, transmission, and other
7. Cover power train components.
8. Coupling q Since this damper employs rubber coupling
9. Universal joint (10), vibrations are damped by the compres-
10. Rubber coupling sive damping effect of the rubber and less
11. Drain plug component parts are used.
Operation
q The power from the engine is transmitted
through flywheel (2) to outer body (3). The
tensional vibration of the engine is absorbed in
rubber coupling (10) and the power is transmit-
ted to output shaft (1), and then transmitted
through universal joint (9) to the torque con-
verter and transmission.
6 D475A, D475ASD-5E0
Unit: mm

Clearance between flywheel size Shaft Hole clearance limit
12
housing and cover
–0.024 +0.080 0.024 –
647.7 0.2
–0.104 +0.080 –0.184
Clearance between flywheel –0.022 +0.070 0.022 –
13 571.5 0.2 Replace
housing and damper –0.092 +0.070 0.162
Outer diameter of oil seal Standard size Repair limit

14
contact face on coupling 120 119.9
Outer diameter of bearing
15 55 54.9
contact face on output shaft
D475A, D475ASD-5E0 7
Power train system 1

General view of power train unit 1
8 D475A, D475ASD-5E0
A: Main relief pressure pickup port (TM) 1. Oil filler port

B: R clutch pressure pickup port (REV) 2. Centralized pressure pickup port
C: F clutch pressure pickup port (FWD) 3. Oil level gauge
D: Torque converter inlet pressure pickup port 4. Torque converter and PTO
(IN) 5. Torque converter valve
E: Lockup clutch pressure pickup port (LU) 6. Transmission control valve
F: Left steering clutch pressure pickup port (LC) 7. Transmission
G: Left steering brake pressure pickup port (LB) 8. Steering control valve
H: Right steering brake pressure pickup port (RB) 9. Steering unit
J: Right steering clutch pressure pickup port (RC) 10. Torque converter oil filter
K: Stator clutch pressure pickup port (SC) 11. Transmission lubricating oil filter
L: Torque converter outlet pressure pickup port 12. Power train oil filter
(OUT) 13. Torque converter, power train, and lubricating
M: 1st clutch pressure pickup port (1ST) oil pump
N: 2nd clutch pressure pickup port (2ND) 14. Power train oil strainer
P: 3rd clutch pressure pickup port (3RD) 15. Scavenging pump
R: Transmission lubricating pressure pickup port
Outline
q The power train unit broadly consists of torque
converter and PTO (4), transmission (7), and
steering unit (9). Therefore, after the power
train unit is removed, it can be divided into
torque converter and PTO (4), transmission
(7), and steering unit (9).
q Steering unit (9) consists of the transfer, bevel
gear shaft, steering clutch, and the steering
brake.
D475A, D475ASD-5E0 9
Torque converter, PTO 1

a PTO: Abbreviation for Power Take Off
10 D475A, D475ASD-5E0
D475A, D475ASD-5E0 11
A: To transmission control valve 1. Cooling fan pump mounting port

B: To transmission lubrication circuit 2. Hydraulic pump mounting port
C: To transmission oil pan 3. Power train, torque converter, and lubricating
D: From steering case oil pump mounting port
E: From power train pump 4. Scavenging pump mounting port
F: From lubricating oil pump 5. Torque converter valve
G: To transmission oil pan 6. Coupling
H: To scavenging pump 7. Retainer
J: To scavenging pump 8. Input shaft (number of teeth: 59)
K: To power train oil filter 9. Front housing
L: To transmission lubricating oil filter 10. PTO idler gear (number of teeth: 74)
M: From power train oil filter 11. PTO idler gear shaft
N: From transmission lubricating oil filter 12. Lockup clutch housing
P: Torque converter outlet oil temperature pickup 13. Drive case
port 14. Turbine
R: Torque converter outlet oil pressure pickup port 15. Rear housing
(OUT) 16. Stator
S: To power train oil cooler 17. Pump
18. Stator shaft
19. Guide
20. Retainer
21. Pump shaft
22. Transmission input shaft
23. Stator clutch hub gear
24. Stator clutch housing
25. Return spring
26. Stator clutch plate
27. Stator clutch disc
28. Stator clutch piston
29. Turbine boss
30. Lockup clutch plate
31. Lockup clutch disc
32. Lockup clutch piston
33. Scavenging pump drive gear (number of teeth:
65)
34. Sleeve
35. Bearing race
36. Power train, torque converter, lubricating oil
pump, and cooling fan pump drive gear (num-
ber of teeth: 61)
37. Drive gear boss
38. Cover
39. Cover
40. Hydraulic pump drive gear (number of teeth:
61)
41. Cover
42. Strainer
12 D475A, D475ASD-5E0
Outline Structure
q The torque converter is a 3-element, 1-stage, q Pump (17) is integral with coupling (6), input
and 1-phase type, which is integral with the shaft (8), lockup clutch housing (12), and drive
transmission. case (13), and rotated by the engine power.
q The torque converter is equipped with a wet q Turbine (14) is integral with turbine boss (29)
multiple disc clutch type torque converter and transmission input shaft (22), and rotated
lockup device and a wet double disc clutch by the oil from pump (17).
type stator clutch in order to reduce fuel con- q Stator (16) is integral with stator shaft (18) and
sumption, to increase the operability, and to stator clutch hub gear (23), and fixed to rear
reduce the horsepower consumption by the housing (15) through the stator clutch unit.
engine. q The lockup clutch unit consists of clutch plate
q For higher efficiency of continuous light dozing (30) meshed with drive case (13), clutch disc
and leveling operation, the torque converter is (31) meshed with turbine boss (29), and clutch
locked up and the engine power is transferred piston (32) which slides inside clutch housing
directly to the transmissions input shaft. (12) integral with drive case (13).
q When the torque converter is locked up (the q The stator clutch unit consists of clutch hub
pump and turbine is integrated into 1 unit), the gear (23) attached to stator shaft (18) with
oil is still supplied to the torque converter. spline, clutch disc (27) meshed with clutch hub
Accordingly, the oil flowing from the pump gear (23), clutch plate (26) supported by the
through the turbine to the stator is obstructed pins on clutch housing (24) and rear housing
by the stator blades and cannot flow in any (15), and clutch piston (28) which slides inside
direction. As a result, this oil resists the rotation rear housing (15).
of the pump and turbine (it is agitated). q The PTO unit consists of input shaft (8), PTO
q To reduce the rotating resistance of the pump idler gear (10), and pump drive gears (33), (36)
and turbine, the stator clutch is disengaged and (40).
simultaneously with lockup of the torque con-
verter so that the stator can rotate freely.
As the stator is dragged and turned by the
pump and turbine, the oil returns from the tur-
bine to the pump smoothly against less resis-
tance.
Conditions for the direct (lockup) range

Torque converter output shaft speed:
Min. 1,360 rpm
Set transmission pressure:
Min. 1.91 MPa {19.5 kg/cm2}
Both conditions must be satisfied.
Conditions for the torque converter (unlock)

range
Torque converter output shaft speed:
Max. 1,330 rpm
Set transmission pressure:
Max. 1.47 MPa {15.0 kg/cm2}
Either condition must be satisfied.
D475A, D475ASD-5E0 13
14 D475A, D475ASD-5E0
Unit: mm
Standard size Tolerance Repair limit
1 Outside diameter of oil seal contact
surface of input coupling 125 0 124.8
–0.063
Inside diameter of seal ring con- +0.035 Repair by hard
2 tact surface of sleeve 115 0 115.1 chrome plating
or replace
3 Inside diameter of seal ring contact 190 +0.046 190.5
surface of retainer 0
4 Inside diameter of seal ring contact 120 +0.035 120.5

surface of pump shaft 0
5 Backlash between input shaft and 0.198 – 0.484

PTO idler gear
Backlash between PTO idler gear
6 and power train, torque converter, 0.198 – 0.484
lubricating oil pump, and cooling
fan pump drive gear
7 Backlash between PTO idler gear 0.198 – 0.484

and hydraulic pump drive gear
8 Backlash between input shaft and 0.198 – 0.484

scavenging pump drive gear
Width 4 –0.01 3.6

9 Wear of input shaft –0.03
seal ring
Thickness 4.5 ±0.12 4.05
Thickness of lockup clutch disc 5.4 ±0.1 4.9
10 Thickness of lockup clutch plate 5.0 ±0.1 4.5

Overall thickness of lockup clutch 26.2 ±0.22 24.6
assembly
Thickness of stator clutch disc 5.4 ±0.1 4.9
11 Thickness of stator clutch plate 5.0 ±0.05 4.5

Overall thickness of stator clutch 15.8 ±0.15 14.7
assembly
Tolerance
Standard size
Shaft Hole
Fitting tolerance of
12 PTO idler gear bear- Outside 140 0 –0.008
ing diameter –0.018 –0.033 Replace
Inside 80 0 0
diameter –0.019 –0.015
Outside 0 +0.012
diameter 140 –0.018 –0.028
Fitting tolerance of (cover side)
power train, torque
13 converter, lubricat- Outside 0 +0.015
ing oil pump, and diameter 140 –0.018 –0.010
cooling fan pump (case side)
drive gear bearing
Inside 65 +0.030 0
diameter +0.011 –0.015
Outside 0 +0.012
diameter 160 –0.025 –0.028
(cover side)
Outside 0 +0.015
diameter 140 –0.018 –0.010
Fitting tolerance of (case side)
14 hydraulic pump
drive gear bearing Inside +0.030 0
diameter 75 +0.011 –0.015
(cover side)
Inside +0.030 0
diameter 65 +0.011 –0.015
(case side)
Outside 72 0 +0.009
Fitting tolerance of diameter –0.013 –0.021
15 scavenging pump
drive gear bearing Inside 35 +0.025 0
diameter +0.009 –0.010
16 Stator clutch return spring Free length Installed length Installed load Free length Installed load
125.4 N 106.9 N
54.1 37.0 50.9
{12.8 kg} {10.9 kg}
D475A, D475ASD-5E0 15
Power transmitting route
When lockup clutch is “disengaged” and stator When lockup clutch is “engaged” and stator
clutch is “engaged” clutch is “disengaged”
q If lockup clutch (3) is “disengaged”, drive case q If lockup clutch (3) is “engaged”, drive case (5)
(5) and turbine (7) are disconnected from each and turbine (7) are connected to each other.
other. If stator clutch (9) is “disengaged” at this time,
If stator clutch (9) is “engaged” at this time, rear housing (10) and stator shaft (11) are dis-
rear housing (10) and stator shaft (11) are con- connected from each other, and stator (8) is
nected to each other to fix stator (8). dragged and turned by pump (6) and turbine
Therefore, the torque converter works as an (7).
ordinary torque converter. Therefore, the torque converter works as a
q The power from the engine is transmitted to lockup torque converter.
coupling (1) through the damper and the uni- q The power from the engine is transmitted to
versal joint. coupling (1) through the damper and the uni-
q The power transmitted to coupling (1) rotates versal joint.
input shaft (2), clutch housing (4), drive case q The power transmitted to coupling (1) rotates
(5) and pump (6) integrally. input shaft (2), clutch housing (4), drive case
q The power transmitted to pump (6) rotates tur- (5) and pump (6) integrally.
bine (7) through the medium of oil and is trans- q The power transmitted to drive case (5) rotates
ferred to transmission input shaft (12) attached turbine (7) directly since lockup clutch (3) is
to turbine (7) with spline. fixed, and is transferred to transmission input
shaft (12) attached to turbine (7) with spline.
16 D475A, D475ASD-5E0
Oil flow
q The oil flows through the main relief valve and

its pressure is reduced to below the set pres-
sure by the torque converter relief valve. It then
flows in inlet port (A), goes through the oil pas-
sages of rear housing (1), pump shaft (2) and
guide (3), and flows into pump (4).
q The oil is given a centrifugal force by pump (4),
and then it enters turbine (5) to transmit its
energy to turbine (5).
q The oil from turbine (5) is sent to stator (6) and
flows in pump (4) again. A part of the oil, how-
ever, is sent through outlet port (B) to the
power train oil cooler.
D475A, D475ASD-5E0 17
Torque converter valve 1
PTF: From power train oil filter

TCF: From torque converter oil filter
TC : To torque converter
SC : To stator clutch
LC : To lockup clutch
drT: Drain (Torque converter relief)
dr: Drain
P3 : Lockup clutch oil pressure pickup port (LU)
P8 : Main relief oil pressure pickup port (TM)
PSC: Stator clutch oil pressure pickup port (SC)
PPL: Pilot oil pressure pickup port
18 D475A, D475ASD-5E0
1. Valve body 18. Plug

2. Torque converter relief valve 19. Valve body
3. Cover 20. Lockup selector valve
4. Main relief valve 21. Piston
5. Piston 22. Cover
6. Piston
7. Stator clutch modulating valve Lockup solenoid valve
8. Piston 23. Cap
9. Piston 24. Coil
10. Cover 25. Valve
11. Piston 26. Ball
12. Piston 27. Valve
13. Lockup clutch modulating valve 28. Base
14. Shaft 29. Shaft
15. Stopper 30. Case
16. Load piston 31. Plunger
17. Cover
D475A, D475ASD-5E0 19
20 D475A, D475ASD-5E0
Unit: mm

Clearance between main relief size Shaft Hole clearance limit
1
valve and valve body
–0.035 +0.016 0.035 –
40 0.081
–0.045 0 0.061
Clearance between torque con- –0.035 +0.016 0.035 –
2 40 0.081
verter relief valve and valve body –0.045 0 0.061
Clearance between stator clutch –0.035 +0.013 0.035 –
3 25 0.078
modulating valve and valve body –0.045 0 0.058
Clearance between lockup clutch –0.035 +0.013 0.035 –
4 25 0.078
modulating valve and valve body –0.045 0 0.058
Clearance between lockup selec- –0.035 +0.013 0.035 –
5 25 0.078
tor valve and valve body –0.045 0 0.058
Installed Installed Installed Replace
Free length Free length
6 Main relief valve spring length load load
1,455 N 1,383 N
120.3 101.5 116.7
{148.5 kg} {141.1 kg}
Torque converter relief valve 645.6 N 613 N
7 116.92 86.3 113.4
spring {65.83 kg} {62.5 kg}
Stator clutch modulating valve 151.9 N 144 N
8 103.5 95.2 100.4
spring {15.5 kg} {14.7 kg}
Lockup clutch modulating valve 158.6 N 151 N
9 141.4 88.7 137.2
spring (outside) {16.18 kg} {15.4 kg}
Lockup clutch modulating valve
10 80.5 80.5 — 78.1 —
spring (inside)
55.9 N 53.0 N
11 Lockup selector valve spring 66 54 64.0
{5.7 kg} {5.4 kg}
D475A, D475ASD-5E0 21
Outline
q The torque converter valve is installed at the
top of the rear housing of the toque converter,
and consists of the following 6 types of valves.
Main relief valve

q The main relief valve maintains each hydraulic
circuit of the lockup clutches and stator
clutches of the transmission, steering clutch,
steering brake and torque converter constantly
at the set pressure.
Set pressure:
2.6 – 3.0 MPa {27.0 – 30.4 kg/cm2}
Torque converter relief valve

q The torque converter relief valve maintains the
oil pressure in the torque converter inlet circuit
always below the set pressure in order to pro-
tect the torque converter from abnormally high
pressure.
Set pressure: 1.00 MPa {10.2 kg/cm2}
Lockup solenoid valve

q The lockup solenoid valve controls the lockup
selector valve by changing the pilot pressure
for it in response to electrical signals received
from the controller.
Lockup selector valve

q The lockup selector valve turns the lockup
clutch and stator clutch “engaged” and “disen-
gaged”.
Stator clutch modulating valve

q The stator clutch modulating valve maintains
the clutch pressure below the set pressure to
protect the stator clutch circuit from abnormally
high pressure, as well as raising the clutch
pressure gradually to the set pressure.
Set pressure: 2.7 MPa {27 kg/cm2}
Lockup clutch modulating valve

q The lockup clutch modulating valve maintains
the clutch pressure below the set pressure to
protect the lockup clutch circuit from abnor-
mally high pressure, as well as raising the
clutch pressure gradually to the set pressure.
22 D475A, D475ASD-5E0
Operation of main relief valve Operation of torque converter relief valve
q The oil from the hydraulic pump flows through q The oil from the main relief valve flows through
the filter, port (A) of the torque converter valve, port (C) to the torque converter, and at the
and orifice (a) of torque converter relief valve same time, also flows through orifice (b) of
(1) to chamber (B). torque converter relief valve (3) to chamber
(D).
q When the oil pressure on the torque converter
exceeds the set pressure, the oil in chamber
(D) pushes piston (4), the reaction force of
which moves torque converter relief valve (3)
to the right to open port (C) and port (E).
Then the oil in port (C) is drained from port (E)
to the oil tank.
q When the oil pressure in the circuit exceeds

the set pressure, the oil in chamber (B) pushes
piston (2), the reaction force of which moves
spool (1) to the left to open port (A) and port
(C).
Then the oil from the pump flows through port
(C) into the torque converter.
D475A, D475ASD-5E0 23
Operation of lockup solenoid valve and lockup selector valve
When traveling in torque converter range
q While the machine is in the “torque converter q The oil from the pump flows through port (D)
range”, the lockup solenoid valve is “de-ener- into port (E) and applies back pressure to sta-
gized” and therefore plunger (1) is pushed tor clutch piston (7). It turns “engaged” the sta-
back upward by the oil pressure from the tor clutch as the oil pressure in the circuit is
pump. raised.
q As the seats of valve (2) and ball (3) are At the same time, the oil which applied back
opened, the drain circuit of port (B) is opened pressure to lockup clutch piston (8) is drained
and the oil in port (A) and port (C) is drained. through port (F) into port (H) to turn the lockup
q Lockup selector valve (5) is pushed back to the clutch “disengaged”.
right by the tension of spring (6). As a result, q The oil from the pump flows into port (A) and
the passages between port (D) and port (F) port (D). The oil in port (A) is drained as the
and between port (E) and port (G) are closed, lockup solenoid valve is “de-energized”, while
while the passages between port (D) and port the oil pressure in port (D) is secured by orifice
(E) and between port (F) and port (H) are (a) and adjusted by modulating valve (9).
opened.
24 D475A, D475ASD-5E0
When traveling in direct range
q While the machine is in the “direct range”, the q The oil from the pump flows through port (D)
lockup solenoid valve is “energized” and there- into port (F) and applies back pressure to sta-
fore plunger (1) moves downward. tor clutch piston (8). It turns the lockup clutch
q As the seats of valve (2) and ball (3) are “engaged” as the oil pressure in the circuit is
closed, the drain circuit of port (B) is closed raised.
and the oil in port (A) flows to port (C) At the same time, the oil which had applied
q The oil from port (C) pushes piston (4) to move back pressure to stator clutch piston (7) is
lockup selector valve (5) to the left. As a drained through port (E) into port (G) to turn
result, the passages between port (D) and port the stator clutch “disengaged”.
(E) and between port (F) and port (H) are q The pressure of the oil which flows from the
closed, while the passages between port (D) pump into port (D) is adjusted by modulating
and port (F) and between port (E) and port (G) valve (10).
are opened.
D475A, D475ASD-5E0 25
Modulating valve
Outline
q The modulating valve is located between the
lockup selector valve and the inlet of each
clutch.
q When each clutch is turned “engaged”, it
raises the oil pressure applied to the piston
gradually to the set pressure to engage the
clutch smoothly and to reduce the shock given
to the torque converter and transmission.
a Though the following explanation on operation
takes the modulating valve for the stator clutch
as an example, the modulating valve for the
lockup clutch also operates in a similar way.
However, please note that the oil flow into the
clutches in the torque converter range and in
the direct range is opposite in direction.
Operation
When traveling in torque converter range
q While the machine is in the “torque converter
range”, lockup solenoid valve (1) is “de-ener-
gized” and the oil from the pump and the oil in
port (B) are drained.
q Lockup selector valve (2) is pushed back to the
right by the tension of spring (3). Then the pas-
sages between port (A) and port (E) and
between port (D) and port (G) are closed, while
the passage between port (A) and port (D) is
opened. As a result, the circuit is connected
through modulating valve (5) to stator clutch
(9).
q The oil from the pump flows through port (A)
into stator clutch (9), and the oil pressure in the
circuit starts rising.
q If the oil pressure in the circuit rises, the oil
flowing through orifice (a) of modulating valve
(5) pushes piston (6), the reaction force of
which moves modulating valve (5) to the left to
throttle part (C).
q Port (D) is connected to port (F) which applies
back pressure to load piston (7). Load piston
(7) is pushed to the right to retract spring (8),
the tension of which opens part (C).
q By repeating the above operation intermit-
tently, load on spring (8) increases and the oil
pressure rises gradually.
Ultimately, modulating valve (5) stops at the
position where it closed part (C). Rise in the oil
pressure is completed and stator clutch (9) is
completely turned “engaged”.
26 D475A, D475ASD-5E0
When traveling in direct range

q While the machine is in the “direct range”, the
lockup solenoid valve is “energized” to let the
oil from the pump flow into port (B).
q The oil pressure in port (B) becomes higher
than the tension of spring (3) and pushes pis-
ton (4) to move lockup selector valve (2) to the
left. As a result, the passage between port (A)
and port (D) is closed and the passage
between port (D) and port (G) is opened.
q By reducing the oil pressure in port (D), modu-
lating valve (5) is pushed back to the right by
the tension of spring (8), and fully opens part
(C).
At this time, the operating pressure of stator
clutch (9) is drained from port (D) to port (G),
and the stator clutch is turned “disengaged”.
q The oil from the pump flows through port (A) to
port (E), and lockup clutch (10) is turned
“engaged”.
D475A, D475ASD-5E0 27
Torque converter lockup control system 1

System diagram
Operation
q The torque converter lockup control system
controls the lockup operation of the torque
converter automatically with a sensor signal
and the controller in it according to the load on
the machine. When the torque converter is
locked up, the pilot lamp on the monitor panel
lights up.
q The signal of the transmission outlet speed
sensor is input to the transmission controller.
q The lockup mode is set with the mode selec-
tion panel.
q The machine controller receives the gear
speed information from the transmission con-
troller and the transmission outlet speed sen-
sor signal from the shoe slip controller and
turns ON and OFF the lockup system by con-
necting and disconnecting the lockup solenoid
and pilot lamp to and from the chassis ground.
a As for the details of the valve, refer to section
“Torque converter valve”.
28 D475A, D475ASD-5E0
Scavenging pump 1
Type: BAR(3)63+320
A: Suction port from torque converter Outline

B: Suction port from steering unit q The scavenging pump is installed to the PTO
C: Discharge port case and driven by the power from the engine.
q Front pump (1) sucks the oil collected in the
1. Front pump torque converter case through the filter and
2. Rear pump returns it to the power train oil pan.
q Rear pump (2) sucks the oil collected in the
steering case and returns it to the power train
oil pan.
Specifications
Type Tandem gear pump

Nominal delivery Front 63.3
amount
(cc/rev) Rear 319.4
Maximum discharge pressure

0.98 {10}
(MPa {kg/cm2})
Maximum speed (rpm) 1,997
D475A, D475ASD-5E0 29
30 D475A, D475ASD-5E0
Transmission control 1
a PCCS: Abbreviation for Palm Command Control System
a For steering operation concerned to operation of the Palm Command Control System lever (PCCS
lever), see “Steering and brake control”.
1. Brake pedal Lever positions

2. Lock lever A: Neutral
3. PCCS lever B: Forward
(Forward-Reverse, Gear shift) C: Reverse
4. Transmission neutral switch D: Free
5. Cable E: Lock
6. Transmission control valve
7. UP switch Outline
(Gear is shifted up each time this switch is q The transmission is controlled with PCCS lever
pressed.) (3).
8. DOWN switch The PCCS lever is used to select the travel
(Gear is shifted down each time this switch is direction and shift the gear.
pressed.) q Since the safety mechanism is employed,
transmission neutral switch (4) does not work
and the engine does not start unless lock lever
(2) is in the FREE position (D).
D475A, D475ASD-5E0 31
Transmission 1
32 D475A, D475ASD-5E0
A: To transmission lubrication circuit

B: To priority valve
C: To scavenging pump (from steering case)
D: From scavenging pump (to transmission oil pan)
E: From power train oil filter
F: To lubricating oil relief valve
G: From 1st clutch ECMV
H: From 2nd clutch ECMV
J: From F clutch ECMV
K: From 3rd clutch ECMV
L: From R clutch ECMV
M: Air vent (from steering case)
N: To steering control valve
P: From steering case (to scavenging pump)
dr: Drain
1. Transmission input shaft

2. Transmission control valve
3. Front case
4. Rear case
D475A, D475ASD-5E0 33
34 D475A, D475ASD-5E0
5. Front cover Outline

6. R sun gear (number of teeth: 32) q The transmission adopted is a “forward 3-gear
7. R ring gear (hub) (number of internal teeth: 89) speed and reverse 3-gear speed” transmission
8. Pinion shaft which consists of the planetary gear mecha-
9. R planetary pinion (number of teeth: 25) nisms and the disc clutches.
10. R ring gear (number of teeth: 82) q Out of the 5 sets of planetary gear mecha-
11. Pinion shaft nisms and disc clutches, 2 clutches are fixed
12. F ring gear (number of internal teeth: 89) hydraulically by the operation of ECMV to
13. F planetary pinion (number of teeth: 25) select 1 rotation direction and 1 speed.
14. F sun gear (number of teeth: 39) q The transmission transmits the power received
15. 3rd ring gear (number of internal teeth: 89) by the transmission input shaft to the output
16. 3rd planetary pinion (number of teeth: 25) shaft while changing the gear speed (forward
17. 3rd sun gear (number of teeth: 39) 1st-3rd or reverse 1st-3rd) by any combination
18. 2nd ring gear (number of internal teeth: 89) of the F, R clutches and 3 speed clutches.
19. 2nd planetary pinion (number of teeth: 21)
20. 2nd sun gear (number of teeth: 47)
21. Pinion shaft Number of plates and discs used
22. 1st clutch inner drum
23. Output shaft Number of
24. Collar Clutch No. Number of discs
plates
25. Drive shaft (for sensor)
R clutch 6 7
26. 1st clutch piston housing
27. 1st clutch piston F clutch 6 7
28. 2nd carrier 3rd clutch 4 5
29. 2nd clutch piston 2nd clutch 3 4
30. 2nd clutch piston housing
1st clutch 5 6
31. F and 3rd carrier
32. 3rd clutch piston
33. F and 3rd clutch piston housing
Combinations of clutches at respective gear
34. F clutch piston
35. R carrier speeds and reduction ratio
36. R clutch piston housing
37. R clutch piston Gear speed Clutch used Reduction ratio
38. Tie rod pin Forward 1st
F × 1st 3.282
39. Washer spring speed
40. Clutch spring Forward 2nd
41. Clutch plate F × 2nd 1.789
speed
42. Clutch disc
Forward 3rd
F × 3rd 1.000
speed
Neutral 1st (*) —
Reverse 1st
R × 1st 2.563
speed
Reverse 2nd
R × 2nd 1.397
speed
Reverse 3rd
R × 3rd 0.781
speed
*: Filled with oil at low pressure.
(Except for low temperature and abnormal conditions.)
D475A, D475ASD-5E0 35
36 D475A, D475ASD-5E0
Unit: mm
Installed Installed Installed
1 R clutch spring (12 pcs.) length load load
140.5 N 119.6 N
100.0 90.0 94.0
{14.3 kg} {12.2 kg}
84.3 N 70.6 N
2 F clutch spring (12 pcs.) 100.0 94.0 94.0
{8.5 kg} {7.2 kg}
150.5 N 128.5 N
3 3rd clutch spring (12 pcs.) 84.0 72.0 79.0
{15.4 kg} {13.1 kg}
119.1 N 102.0 N
4 2nd clutch spring (12 pcs.) 81.7 63.0 76.8
{12.2 kg} {10.4 kg}
238.7 N 203.0 N
5 1st clutch spring (12 pcs.) 103.5 76.0 97.3
{24.4 kg} {20.7 kg}
Total assembled thickness of Standard size Tolerance Repair limit

6
7 discs and 6 plates of R clutch 72.6 ±0.36 68.9
Total assembled thickness of
7 72.6 ±0.36 68.9
7 discs and 6 plates of F clutch
8 50.2 ±0.30 47.5
5 discs and 4 plates of 3rd clutch
9 39.0 ±0.26 36.9
4 discs and 3 plates of 2nd clutch
10 61.4 ±0.43 58.2
6 discs and 5 plates of 1st clutch
F, R,
5.4 ±0.1 4.9
11 Thickness of clutch disc 2nd, 3rd Replace
1st 5.4 ±0.15 4.9
12 Thickness of clutch plate 5.8 ±0.1 5.2
–0.01
Wear of seal ring Width 3.0 2.70
13 –0.03
(1 place)
Thickness 4.0 ±0.12 3.85
–0.01
14 –0.03
(4 places)
Thickness 5.0 ±0.15 4.85
–0.01
15 –0.03
(2 places)
Thickness 5.0 ±0.15 4.85
–0.01
16 –0.03
(2 places)
Thickness 6.8 ±0.15 6.65
–0.01
17 –0.04
(1 place)
Thickness 5.0 ±0.15 4.85
–0.01
18 –0.04
(3 places)
Thickness 4.0 ±0.15 3.85
Backlash between
19 0.16 – 0.35
sun gear and planetary pinion
Backlash between
20 0.18 – 0.38
planetary pinion and ring gear
D475A, D475ASD-5E0 37
Disc clutch
Structure Operation
When clutch is “engaged” (fixed)
q The disc clutch consists of piston (2), plates q The oil from ECMV is sent with pressure to the
(3), discs (4), pin (5), return spring (6) etc. to fix rear side of piston (2) through the oil passage
ring gear (1). of housing (7) and pushes piston (2) leftward.
q Inside teeth of disc (4) are engaged with out- q Piston (2) contacts plate (3) closely against
side teeth of ring gear (1). disc (4) to stop rotation of disc (4) by use of the
q Plate (3) is assembled to clutch housing (7) friction force generated between them.
with pin (5). q Since inside teeth of disc (4) are engaged with
outside teeth of ring gear (1), move of ring gear
(1) is stopped.
When clutch is “disengaged” (released)
q As the oil from ECMV is stopped, piston (2) is

pushed back rightward by return spring (6).
q Plate (3) and disc (4) are released from the
frictional force and ring gear (1), as the result,
is also released.
38 D475A, D475ASD-5E0
Power transmitting route

Forward 1st speed
q When the transmission is set to the forward 1st q The rotation of F and 3rd carrier (10) is trans-
s p e e d , th e F c l u t c h a n d 1 s t c l u t c h a r e mitted through 3rd planetary pinion (11) to 3rd
engaged. The power transmitted from the ring gear (12).
torque converter to input shaft (1) is then trans- q 3rd ring gear (12) and 2nd carrier (13) are
mitted to output shaft (20). meshed with each other and rotate integrally.
q The F clutch is actuated by the oil pressure Accordingly, the rotation of 3rd ring gear (12) is
applied to the F clutch piston, and fixes F ring transmitted through 2nd carrier (13) to 1st
gear (4). The 1st clutch is actuated by the oil clutch piston housing (14).
pressure applied to the 1st clutch piston, and q As 1st clutch inner drum (16) is fixed by the 1st
fixes 1st clutch inner drum (16). clutch, the power transmitted to 1st clutch pis-
q The power from the torque converter is trans- ton housing (14) is transmitted through 1st
mitted to F planetary pinion (3) through input clutch inner drum (16) to output shaft (20).
shaft (1) and F sun gear (2).
q As F ring gear (4) is fixed by the F clutch, the
power transmitted to F planetary pinion (3)
rotates F and 3rd carrier (10) located inside of
F ring gear (4).
D475A, D475ASD-5E0 39
Forward 2nd speed
q When the transmission is set to the forward q The rotation of F and 3rd carrier (10) is trans-
2nd speed, the F clutch and 2nd clutch are mitted through 3rd planetary pinion (11) to 3rd
engaged.The power transmitted from the ring gear (12).
q The F clutch is actuated by the oil pressure Accordingly, the rotation of 2nd carrier (13) is
applied to the F clutch piston, and fixes F ring transmitted to 2nd planetary pinion (15).
gear (4). The 2nd clutch is actuated by the oil q As 2nd ring gear (17) is fixed by the 2nd clutch,
pressure applied to the 2nd clutch piston, and the power transmitted to 2nd planetary pinion
fixes 2nd ring gear (17). (15) is transmitted through 2nd sun gear (18)
q The power from the torque converter is trans- to output shaft (20).
mitted to F planetary pinion (3) through input
F ring gear (4).
40 D475A, D475ASD-5E0
Forward 3rd speed
q When the transmission is set to the forward 3rd q As 3rd ring gear (12) is fixed by the 3rd clutch,
s p e ed , th e F c l u t c h an d 3 r d c l ut c h a r e the power transmitted to F and 3rd carrier (10)
engaged. The power transmitted from the is transmitted through 3rd planetary pinion (11)
torque converter to input shaft (1) is then trans- and 3rd sun gear (19) to output shaft (20).
mitted to output shaft (20).
q The F clutch is actuated by the oil pressure
applied to the F clutch piston, and fixes F ring
gear (4). The 3rd clutch is actuated by the oil
pressure applied to the 3rd clutch piston, and
fixes 3rd ring gear (12).
q The power from the torque converter is trans-
mitted to F planetary pinion (3) through input
F ring gear (4).
D475A, D475ASD-5E0 41
Reverse 1st speed
q When the transmission is set to the reverse 1st q The rotation of F and 3rd carrier (10) is trans-
s p e ed , th e R c l ut c h a nd 1 s t c l ut c h a r e mitted through 3rd planetary pinion (11) to 3rd
engaged. The power transmitted from the ring gear (12).
q The R clutch is actuated by the oil pressure Accordingly, the rotation of 3rd ring gear (12) is
applied to the R clutch piston, and fixes ring transmitted through 2nd carrier (13) to 1st
gear (7). The 1st clutch is actuated by the oil clutch piston housing (14).
pressure applied to the 1st clutch piston, and q As 1st clutch inner drum (16) is fixed by the 1st
fixes 1st clutch inner drum (16). clutch, the power transmitted to 1st clutch pis-
q The power from the torque converter is trans- ton housing (14) is transmitted through 1st
mitted to R planetary pinion (6) through input clutch inner drum (16) to output shaft (20).
shaft (1) and R sun gear (5).
q Ring gear (7) and R carrier (8) are meshed
with each other and fixed by the R clutch.
Accordingly, the rotation of R planetary pinion
(6) rotates R ring gear (9). The rotation of R
ring gear (9), the direction of which is opposite
to that of input shaft (1), rotates F and 3rd car-
rier (10).
42 D475A, D475ASD-5E0
D475A, D475ASD-5E0 43
SEN00211-00

44
SEN00212-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up

Power train, Part 2
Power train, Part 2 .......................................................................................................................................... 2
Transmission control valve................................................................................................................... 2
Transmission clutch ECMV .................................................................................................................. 4
Priority valve......................................................................................................................................... 8
Lubricating oil relief valve................................................................................................................... 10
Torque converter, power train, lubricating oil pump.............................................................................11
Steering, brake control ....................................................................................................................... 12
Final drive........................................................................................................................................... 14
Sprocket ............................................................................................................................................. 18
Steering unit ....................................................................................................................................... 21
Steering control valve......................................................................................................................... 32
Steering clutch ECMV, Steering brake ECMV .................................................................................... 34
Parking brake valve............................................................................................................................ 40
Sudden stop prevention valve............................................................................................................ 42
D475A, D475ASD-5E0 1
Power train, Part 2 1

Transmission control valve 1
2 D475A, D475ASD-5E0
PF: F clutch oil pressure pickup port (FWD) Operation table of ECMV
PR: R clutch oil pressure pickup port (REV)
P1: 1st clutch pressure pickup port (1ST) ECMV
P2: 2nd clutch pressure pickup port (2ND) F R 1st 2nd 3rd
Gear speed
P3: 3rd clutch pressure pickup port (3RD)
Forward 1st Q Q
PV: To priority valve
LV: To lubricating oil relief valve Forward 2nd Q Q
LD: Drain (from lubricating oil relief valve) Forward 3rd Q Q
CF: To F clutch Reverse 1st Q Q
CR: To R clutch
Reverse 2nd Q Q
C1: To 1st clutch
C2: To 2nd clutch Reverse 3rd Q Q
C3: To 3rd clutch * Neutral Q
dr: Drain *: Filled with oil at low pressure.
(Except for low temperature and abnormal conditions.)
1. Filter
2. Priority valve
3. Lubricating oil relief valve
4. 1st clutch ECMV
5. 2nd clutch ECMV
6. 3rd clutch ECMV
7. F clutch ECMV
8. R clutch ECMV
9. Valve seat
D475A, D475ASD-5E0 3
Transmission clutch ECMV 1

a ECMV: Abbreviation for Electronic Control Modulation Valve
a Don't try to disassemble it since adjustment for maintaining the performance will be needed.
A: To clutch
P: From pump *1:
T: Drain
Stamp of the
Dr: Drain Clutch used
nameplate
P1: Clutch oil pressure pickup port
F, R, 1st, 2nd, 3rd A*******
1. Fill switch connector
2. Proportional solenoid connector
3. Flow rate pickup valve
4. Fill switch
5. Proportional solenoid
6. Pressure control valve
7. Nameplate (*1)
4 D475A, D475ASD-5E0
Outline of ECMV ECMV and proportional solenoid

q The ECMV consists of 1 pressure control valve q For each ECMV, 1 proportional solenoid is
and 1 fill switch. installed.
q Pressure control valve The proportional solenoid generates thrust
This valve receives the current sent from the shown below according to the command cur-
transmission controller with a proportional rent from the controller.
solenoid, and then converts it into oil pressure. The thrust generated by the proportional sole-
q Fill switch noid is applied to the pressure control valve
This switch detects that the clutch is filled with spool to generate oil pressure as shown in the
oil and has the following functions. figure below. Accordingly, the thrust is changed
1. Outputs a signal (a fill signal) to the controller by controlling the command current to operate
to notify that filling is completed when the the pressure control valve to control the flow
clutch is filled with oil. and pressure of the oil.
2. Keeps outputting signals (fill signals) to the
controller to notify whether oil pressure is Current – propulsion force characteristics of
applied or not while oil pressure is applied to proportional solenoid
the clutch.
Propulsion force – Hydraulic pressure charac-

teristics of proportional solenoid
Range A: Before shifting gear (When draining)

Range B: During filling ECMV and fill switch
Range C: Pressure regulation q For each ECMV, 1 fill switch is installed.
Range D: During filling (During triggering) If the clutch is filled with oil, the fill switch is
Point E: Start of filling turned “ON” by the pressure of the clutch. The
Point F: Finish of filling oil pressure is built up according to this signal.
a The logic is so made that the controller will not

recognize completion of filling even if the fill
switch is turned “ON” during triggering (Range
D).
D475A, D475ASD-5E0 5
Operation of ECMV Before shifting gear (when draining) (Range A

q ECMV is controlled with the command current in chart)
sent from the controller to the proportional
solenoid and the fill switch output signal.
The relationship between the proportional
solenoid command current of ECMV, clutch
input pressure, and fill switch output signal is
shown below.
q Under the condition where any current is not

sent to proportional solenoid (1), pressure con-
trol valve (3) drains the oil from clutch port (A)
through drain port (T).
Also at this time, fill switch (5) is turned “OFF”
because oil pressure is not applied to pressure
Range A: Before shifting gear (When draining) detection valve (4).
Range B: During filling
Range C: Pressure regulation
Range D: During filling (During triggering)
Point E: Start of filling
Point F: Finish of filling
a The logic is so made that the controller will not

recognize completion of filling even if the fill
switch is turned “ON” during triggering (Range
D).
6 D475A, D475ASD-5E0
During filling (Range B in chart) Pressure regulation (Range C in chart)
q If current is applied to proportional solenoid (1) q If current flows in proportional solenoid (1), the
with no oil in the clutch, the oil pressure force solenoid generates thrust in proportion to the
balanced with the solenoid force is applied to current. This thrust of the solenoid is balanced
chamber (B) and pushes pressure control with the sum of the thrust generated by the oil
valve (3) to the left. This opens pump port (P) pressure in clutch port and the tension of pres-
and clutch port (A) to feed oil in the clutch. sure control valve spring (2), and then the
When the clutch is filled with oil, pressure pressure is settled.
detection valve (4) actuates to turn “ON” fill
switch (5).
D475A, D475ASD-5E0 7
Priority valve 1
Unit: mm

Clearance between spool and size Shaft Hole clearance limit
1
valve body –0.035 +0.013 0.035 –
22 0.078
–0.045 0 0.058
Standard size Repair limit Replace

2 Return spring length load load
84.7 kN 80.4 kN
38.8 28.5 37.6
{8.6 kg} {8.2 kg}
3. Valve body Outline

4. Spool q The priority valve is installed in the circuit
5. Piston between the pump and the clutch ECMV.
When shifting the gear, even if the oil pressure
in the transmission circuit decreases sharply,
the priority valve disconnects the transmission
circuit and pilot circuit and keeps the oil pres-
sure to the set pressure so that the decrease
of the brake oil pressure and stator clutch oil
pressure can be prevented during the gear
shifting operation.
8 D475A, D475ASD-5E0
Operation from start to finish of gear shifting Operation right after finishing of gear shifting
q The oil from the pump flows through port (A) q If the gear shift lever is operated, the oil pres-
and orifice (a) to chamber (C). sure in port (B) decreases sharply nearing 0
q If the oil flow from the pump increases and the MPa { 0 kg/cm2} as a result of the ECMV oper-
oil pressure rises, the oil in chamber (C) ation.
pushes piston (1). Then, the reaction force of q Then, the oil pressure in port (A) also
piston (1) compresses spring (2) and moves decreases, but valve (3) is pushed back to the
valve (3) to the left. right by the tension of spring (2).
q If valve (3) moves, port (A) and port (B) are q As a result, the oil pressure in port (A) (pilot
connected and the oil from the pump flows pressure) is kept to the set pressure.
through port (B) to the ECMV. The oil pressure
at this time is the set pressure of the priority
valve.
q Then, the oil pressure transmitted from port (B)
to the ECMV rises to the set pressure of the
clutch.
D475A, D475ASD-5E0 9
Lubricating oil relief valve 1
Unit: mm

1
valve body –0.035 +0.013 0.035 –
22 0.078
–0.045 0 0.058

2 Return spring length load load
91.9 N 87.3 N
68.5 37 66.5
{9.37 kg} {8.9 kg}
3. Lubricating oil pressure pickup port Outline

4. Spool q The lubricating oil relief valve is installed to the
5. Valve body transmission control valve. It keeps the lubri-
cating oil circuit below the set pressure.
Set pressure: 0.26 MPa {2.7 kg/cm2}
10 D475A, D475ASD-5E0
Torque converter, power train, lubricating oil pump 1

Type: BAL(4)160+(4)160+(4)112
Unit: mm
Type Standard clearance Clearance limit
1 Side clearance BAL(4)160
0.04 – 0.10 0.13
BAL(4)112
Clearance between plain bearing BAL(4)160

2 0.060 – 0.145 0.20 Replace
inner diameter and gear shaft BAL(4)112
Type Standard size Tolerance Repair limit
3 Depth to knock in pin BAL(4)160 0
14 —
BAL(4)112 –0.5
4 Rotating torque of spline shaft 5.9 Nm {0.6 kgm}

Discharge Standard
Delivery
Speed pressure delivery
Type amount limit
Delivery amount (rpm) (MPa{kg/ amount —
(ll/min)
— Oil: SAE10WCD cm2}) (ll/min)
Oil temperature: 45 – 55 °C
BAL(4)160 2,000 2.94 {30} 288 266
BAL(4)112 2,000 2.94 {30} 205 188
5. Lubricating oil pump Outline

6. Power train pump q The torque converter pump, power train pump
7. Torque converter pump and lubricating oil pump are installed to the
PTO case. They are driven by the power from
A: Suction port the engine to supply the oil pressure to the
B: Lubricating oil pump discharge port torque converter, transmission and steering
C: Power train pump discharge port unit.
D: Torque converter pump discharge port
D475A, D475ASD-5E0 11
Steering, brake control 1

a PCCS: Abbreviation for Palm Command Control System
a Regarding the transmission related description of operation of the PCCS lever, refer to “Transmission
control”.
12 D475A, D475ASD-5E0
1. Brake pedal Outline

2. Lock lever q PCCS lever (3) sends an electric signal to
3. PCCS lever (Steering) steering controller (11). After receiving it, steer-
4. Limit switch ing controller (11) sends a proportional current
5. Steering ECMV to steering ECMV (5) to operate the steering
6. Brake valve clutch and brake.
7. Parking brake lever (From lock lever) q The brake pedal (1) sends an electric signal to
8. Cable steering controller (11) through potentiometer
9. Rod (From brake pedal) (10). After receiving it, steering controller (11)
10. Potentiometer sends a proportional current to steering ECMV
11. Steering controller (5) to operate the brake. In this case, the right
12. Transmission controller and left brakes operate at the same time to
13. Engine controller activate braking. Rod (9) operates the brake
through brake valve (6) for redundant use.
Positions of lever and pedal (Only at the time of complete braking)
A: Neutral q If you slightly tilt PCCS lever (3) towards the
B: Forward straight-travel left, the left steering clutch is partially disen-
C: Reverse straight-travel gaged, causing the machine to make a slow
D: Left clutch OFF left turn.
E: Left clutch OFF q If you completely tilt PCCS lever (3) towards
Left brake ON the left, the left steering clutch is turned “disen-
F: Right clutch OFF gaged” and the left steering brake is turned
G: Right clutch OFF “engaged”, causing the machine to make a
Right brake ON sudden left turn.
H: Brake RELEASE q Lock lever (2) is connected to parking brake
J: Brake ON lever (7) and it also serves as a parking brake.
K: Free
L: Lock
D475A, D475ASD-5E0 13
Final drive 1
Outline
q The final drive is a single stage spur gear, sin-
gle stage planetary gear reduction type. The
lubrication is of splash type using the rotation
of the gears.
The final drive can be removed and installed
as a single unit.
q Floating seal (1) is installed to the rotating slid-
ing portion of the sprocket to prevent the entry
of dirt or sand and to prevent leakage of lubri-
cating oil.
14 D475A, D475ASD-5E0
1. Floating seal 11. Ring gear

2. Sun gear 12. Cover
3. Carrier 13. No. 1 gear
4. Hub 14. No. 1 gear hub
5. Cover 15. No. 1 pinion
6. Sprocket hub 16. Final drive case
7. Sprocket teeth 17. Bearing cage
8. Floating seal guard 18. Shaft
9. Cover 19. Wear guard
10. Planetary pinion
D475A, D475ASD-5E0 15
Unit: mm
Backlash between No.1 Standard clearance Clearance limit

20
pinion and No.1 gear 0.26 – 0.96 0.96
Backlash between sun gear
21 0.25 – 0.70 0.70
and planet pinion
Backlash between planetary
22 0.26 – 0.83 0.83
pinion and ring gear
Outside diameter of No.1 Standard size Repair limit
23 pinion oil seal contact sur-
face 120.0 119.9
Thickness of thrust collar of

24 24.8 24.75
inner body roller bearing Replace
Thickness of thrust coller of
25 14.0 13.95
No.1 gear boss roller bearing
26 Height of button 20 18.5

Clearance between plane- size clearance limit
Shaft Hole
27 tary pinion shaft and carrier
(small end) –0.035 –0.024 –0.024 –
110 0.030
–0.054 –0.059 0.030
Clearance between plane-
–0.035 –0.067 –0.072 –
28 tary pinion shaft and carrier 135 –0.013
–0.054 –0.107 –0.013
(large end)
Standard shim thickness for
29 2
No.1 pinion bearing cage
Dimension of end face of
30 final drive cover and end face 7.3 – 8.3 Adjust
of bearing
Clearance of floating seal
31 3.1 – 4.7
guard
Standard size Repair limit Rebuild or
32 Wear of wear guard
47.5 17 replace
16 D475A, D475ASD-5E0
Path of power transmission
q The power from the bevel gear shaft and steer- Then, the rotating force of sun gear (2) forms
ing clutch is transmitted to No. 1 pinion (15). It the rotating force of carrier (3), which supports
then passes through No. 1 gear (13), which is the planetary pinion, and is transmitted to
meshed with the No. 1 pinion, and is transmit- sprocket hub (6).
ted to sun gear (2) to rotate it. The rotation direction of carrier (3) is the same
The rotation of sun gear (2) is transmitted to as sun gear (2).
planetary pinion (10), but ring gear (11), which The rotating force transmitted to sprocket hub
is meshed with the planetary pinion, is fixed to (6) is transmitted to sprocket teeth (7).
cover (9), so the planetary pinion rotates on its
own axis and moves around the sun gear
along the ring gear.
D475A, D475ASD-5E0 17
Sprocket 1
Unit: mm

1 Wear of tooth tip Replace or
486 470 overlaying
welding
2 Thickness of tooth root 32.5 26.5
18 D475A, D475ASD-5E0
Full-scale drawing of sprocket tooth profile
D475A, D475ASD-5E0 19
20 D475A, D475ASD-5E0
Steering unit 1
A: To steering control valve 1. Transmission

B: Air vent (To transmission case) 2. Steering control valve
C: To scavenging pump 3. Steering unit
D: To pin puller solenoid valve 4. Breather
E: From pin puller solenoid valve 5. Drain plug
F: From power train oil cooler
G: Torque converter output speed sensor mount-
ing port
PLC: L.H. steering clutch oil pressure pickup port
(LC)
PLB: L.H. steering brake oil pressure pickup port
(LB)
PRC: R.H. steering clutch oil pressure pickup port
(RC)
PRB: R.H. steering brake oil pressure pickup port
(RB)
D475A, D475ASD-5E0 21
22 D475A, D475ASD-5E0
6. Output shaft 25. Brake hub

7. Sleeve 26. Brake cage
8. Pin 27. Brake piston
9. Clutch piston 28. Brake spring
10. Pin 29. Case
11. Clutch plate 30. Input shaft
12. Clutch disc 31. Drive shaft
13. Stopper 32. Drive gear (number of teeth: 27)
14. Clutch hub 33. Transmission output speed sensor
15. Clutch cage 34. Case
16. Flange 35. Cage
17. Bevel gear (number of teeth: 37) 36. Torque converter output speed sensor
18. Cage 37. Cage
19. Steering shaft 38. Drum
20. Clutch spring 39. Cover
21. Housing 40. Cage
22. Stopper 41. Driven gear (number of teeth: 30)
23. Brake plate 42. Bevel pinion (number of teeth: 22)
24. Brake disc
D475A, D475ASD-5E0 23
Outline
Transfer Steering brake

q The transfer transmits the output power from q The steering brakes are connected to the L.H.
the transmission to the bevel pinion with and R.H. steering clutch respectively. They
reduced speed. control the power transmitted from the steering
q The transfer consists of input shaft (30) clutches to the final drive to change the turning
meshed with the transmission output shaft, direction of the machine and to brake the
drive gear (32), driven gear (41) and bevel pin- machine.
ion (42). q The steering brakes have wet-type multiple-
disc hydraulic clutches and are driven hydrauli-
Bevel gear shaft cally together with the clutches by the brake
q The bevel gear shaft changes the direction of pedal and steering control valve operated with
the power transmitted to the bevel pinion by a the PCCS lever.
right angle to the left-and-right direction by q As for the lubrication, the steering brakes
using a bevel pinion and a bevel gear, and also adopt the forced lubrication system where the
decelerates the output speed. oil from the power train lubricating pump is
q The bevel gear shaft has spiral gears for a sent through the hydraulic circuit in the steer-
bevel pinion and a bevel gear, and adopts the ing case to the cage, and eventually to the
forced lubrication by the pressurized oil for the discs and plates.
lubrication. q While the engine is stopped, even if the brake
q The bevel gear shaft consists of bevel gear pedal is not depressed, the back pressure of
(17) meshed with the bevel pinion, steering the brake piston decreases and the steering
shaft (19) and the bearing to support the steer- brakes become “applied”.
ing shaft. When restarting the engine, if the parking
brake lever is not in “locked” position, the
Steering clutch engine does not start.
q The steering brakes consist of hub (25) con-
q The steering clutch is connected to the bevel
nected to housing (21), discs (24) engaged
gear shaft through the spline. It transmits and
with the hub, plates (23) fixed to piston (27) by
cuts out the power from the bevel gear shaft to
pin (8), piston (27) to press the discs and
the final drive to change the turning direction of
plates against each other, cage (26) to support
the machine.
these parts, case (29), the bearing and output
q The steering clutch has a wet-type multiple-
shaft (6) connected to the hub by the spline.
disc hydraulic clutch and is driven hydrauli-
And piston (27) and case (29) are fixed to the
cally, together with the brake by the steering
steering case.
control valve operated with the PCCS lever.
q As for the lubrication, the steering clutch
adopts the forced lubrication system where the
oil from the power train lubricating pump is
sent through the hydraulic circuit in the steer-
ing case to the cage and hub, and eventually
to the discs and plates.
q The steering clutch consists of hub (14) con-
nected to the bevel gear shaft by the spline,
discs (12) engaged with the hub, plates (11)
whose periphery is fixed to housing (21) by pin
(10), housing (21), piston (9) to press the discs
and the plates against each other and cage
(15), and the bearing to support these parts.
And as housing (21) is connected to hub (25),
the power from the bevel gear shaft is transmit-
ted to output shaft (6) through hub (25).
24 D475A, D475ASD-5E0
D475A, D475ASD-5E0 25
26 D475A, D475ASD-5E0
Unit: mm
Standard size Tolerance Repair limit
Replace
1 Brake plate Thickness 4.2 ±0.1 3.8
Strain — Max. 0.3 0.4 Repair or replace
Thickness 5.4 ±0.1 4.3 Replace
2 Brake disc
3 82.2 ±0.41 72.6
8 brake plates and 9 discs Replace
Thickness 4.2 ±0.1 3.8
4 Clutch plate
Thickness 5.4 ±0.1 4.5 Replace
5 Clutch disc
6 76.8 ±0.40 69.3
8 clutch plates and 8 discs
Inside diameter of seal ring +0.046
7 190 190.5
contact surface of sleeve 0
Large
+0.089
diameter 350 350.1
Inside diameter 0
parts
8 of seal ring contact
surface of brake piston Small
+0.052
diameter 300 300.1
0
parts
Large
+0.089
diameter 350 350.1
Inside diameter 0
parts
9 of seal ring contact
face of clutch piston Small
+0.052
diameter 300 300.1
0
parts

10 Brake spring length load load
46.97 kN 44.62 kN
19.7 12.9 19.1
{4,790 kg} {4,550 kg}
55.7 kN 52.96 kN
11 Clutch spring 20.4 12.9 20.0
{5,680 kg} {5,400 kg}

Clearance between bevel gear size Shaft Hole clearance limit
12
and reamer bolt
+0.023 +0.033 –0.023 –
20 Max. 0.031
+0.002 0 0.031
Backlash between brake hub and Standard clearance Clearance limit

13
disc 0.4 – 0.7 1.0
Backlash between clutch hub and
14 0.4 – 0.7 1.0
disc
Backlash between bevel pinion and
15 0.30 – 0.40 0.75 Adjust or replace
bevel gear
Standard rotating torque: 9.8 – 11.8 Nm {1.0 – 1.2 kgm}
Preload of bevel gear shaft taper
16 (When bevel pinion and gear are not meshed: Adjust
roller bearing
51 – 61.8 Nm {5.2 – 6.3 kgm} at bevel gear end )
Standard shim thickness of bearing
17 2.0 Adjust shim
cage
D475A, D475ASD-5E0 27
Unit: mm
Standard clearance Clearance limit
18 Backlash between transfer gears Adjust or replace
0.26 – 0.67 0.75
Thickness of collar between Standard size Tolerance Repair limit

19 Replace
transfer gear and bearing 19.3 ±0.1 18.9
Standard shim thickness of
20 2.0 Adjust shim
bearing cage
28 D475A, D475ASD-5E0
Operation of steering clutch
When steering clutch is turned “engaged” When steering clutch is turned “disengaged”
q When the PCCS lever is in the “neutral” posi- q If the PCCS lever is operated to the left or
tion, the oil in the back side of clutch piston (1) right, the oil pressure is applied to the back of
is drained by the steering control valve. clutch piston (1) by the steering control valve.
q At this time, clutch piston (1) is pushed back to q As the oil pressure rises, clutch piston (1) com-
the right by the tension of clutch spring (2) to press clutch spring (2) and moves to the left to
press discs (3) and plates (4) against stopper eliminate the pressing force between discs (3)
(5). and plates (4).
q The power from steering shaft (6) is transmit- q The power from steering shaft (6) is not trans-
ted through clutch hub (7), pressed discs (3) mitted after housing (8) and accordingly is not
and plates (4) to housing (8). transmitted to the final drive.
q Since housing (8) is connected to brake hub q If the PCCS lever is released, the oil in the
(9) and output shaft (10), the power is transmit- back side of clutch piston (1) is drained by the
ted through output shaft (10 ) to the final drive. steering control valve, thus the steering clutch
is turned “engaged”.
q If the L.H. steering clutch is turned “disen-
gaged”, the power is transmitted only to the
R.H. steering clutch, and consequently the
machine turns to the left.
D475A, D475ASD-5E0 29
Operation of steering brake
When steering brake is “released” When steering brake is “applied”

(When PCCS lever is “operated”)
q When the PCCS lever is in the “neutral” posi- q If the PCCS lever is operated to the left or
tion and the brake pedal is released, the steer- right, the steering control valve turns the steer-
ing control valve only sets the brake pressure ing clutch “disengaged” and the oil in the back
to the maximum. Accordingly, the steering side of piston (1) starts to be drained.
clutch is turned “engaged” and the oil pressure q At this time, brake piston (1) is pushed back to
is applied to the back of brake piston (1). the right by the tension of brake spring (2) to
q As the oil pressure rises, brake piston (1) compress discs (3) and plates (4) against stopper
presses brake spring (2) and moves to the left (5).
to eliminate the pressing force between discs q Brake piston (1) and stopper (5) are fixed to
(3) and plates (4). the steering case by the pin.
q The power transmitted from the steering shaft q Brake hub (7) and output shaft (8), which tend
(6) through the steering clutch to brake hub (7) to rotate by the inertia force even after the
is further transmitted through output shaft (8) steering clutch is turned “disengaged”, can be
to the final drive. stopped by pressing discs (3) and plates (4) to
each other.
q The turning radius and speed can be adjusted
by the brake force controlled by the oil pres-
sure in the back side of piston (1) according to
the stroke of the PCCS lever to the left and
right.
30 D475A, D475ASD-5E0
When steering brake is “applied”

(When PCCS lever is in “neutral” and brake pedal
is “depressed”)
q If the brake pedal is depressed while the

PCCS lever is in the “neutral” position, the
steering control valve starts to drain the oil in
the back of brake piston (1). Then the steering
brake operates with the steering clutch turned
“engaged” and stops the rotation of output
shaft (8).
q The brake force can be adjusted by controlling
the oil pressure applied to the back side of
brake piston (1) according to the stroke of the
brake pedal.
D475A, D475ASD-5E0 31
Steering control valve 1
32 D475A, D475ASD-5E0
P: From power train pump Outline

L: From power train oil cooler q The steering control valve consists of 4
PS: To pin puller solenoid valve ECMV's installed on the valve seat, to control
LC: To L.H. steering clutch the steering clutch and steering brake.
LL: To L.H. steering lubrication circuit q The steering control valve is located in the cir-
LB: To L.H. steering brake cuit between the power train pump and pistons
LBL: To L.H. bevel gear shaft bearing lubrication of the steering clutch and steering brake. It
circuit consists of 2 sets of the steering clutch ECMV
RC: To R.H. steering clutch (L.H. and R.H.) and 2 sets of the steering
RL: To R.H. steering lubrication circuit brake ECMV (L.H. and R.H.).
RB: To R.H. steering brake q The steering control valve sends the oil from
RBL: To R.H. bevel gear shaft bearing lubrication the power train pump to the steering clutch and
circuit steering brake to control each disc clutch.
BPL: To bevel pinion bearing lubrication circuit q If the PCCS lever is leaned to the right or left,
DPS: From pin puller solenoid valve the steering clutch is disengaged. The steering
DLC: Drain (L.H. steering clutch) brake will operate by further leaning the PCCS
DLC: Drain (L.H. steering clutch pilot) lever.
DLB: Drain (L.H. steering brake) q The controller sends commands to each
DRC:Drain (R.H. steering clutch) ECMV according to the right or left stroke of
DRP: Drain (R.H. steering clutch pilot) the PCCS lever and adjusts the gradual or
DRB: Drain (R.H. steering brake) sharp turns.
DB: Drain (Sudden stop prevention valve) q If the brake pedal is depressed, the controller
DBP: Drain (Sudden stop prevention valve pilot) sends commands to the steering brake ECMV
DPB: Drain (Parking brake) according to the pedal stroke to apply the L.H.
and R.H. brake, thus stopping the machine.
q The controller, connected electrically to the
1. Filter PCCS lever and brake pedal operates the
2. R.H. steering clutch ECMV steering clutch and steering brake by control-
3. L.H. steering clutch ECMV ling each ECMV.
4. Sudden stop prevention valve q The sudden stop prevention valve is installed
5. R.H. steering brake ECMV to prevent the machine from stopping sud-
6. L.H. steering brake ECMV denly, when an abnormality takes place in the
7. Parking brake valve electrical system.
8. Valve seat q When the parking brake lever is set in the
“lock” position, the parking brake valve port is
changed to drain the oil between the L.H. and
R.H. steering brake ECMV and the brake pis-
ton to operate the brake. Also the parking
brake valve is connected to the brake pedal by
the linkage.
D475A, D475ASD-5E0 33
Steering clutch ECMV, Steering brake ECMV 1

a ECMV: Abbreviation for Electronic Control Modulation Valve
a Don’t try to disassemble it since adjustment for maintaining the performance will be needed.
A: To clutch or brake
P: From pump *1:
T: Drain
Clutch used Stamp of the nameplate
Dr: Drain
P1: To clutch or brake pressure pickup port Steering clutch,
R*******
Steering brake
1. Fill switch connector
2. Proportional solenoid connector Outline
3. Pressure detection valve q Each ECMV keeps the steering clutch oil pres-
4. Fill switch sure and steering brake oil pressure to the set
5. Proportional solenoid pressure and furthermore changes the circuit
6. Pressure control valve to the piston chamber of the steering clutch
7. Nameplate (*1) and steering brake.
34 D475A, D475ASD-5E0
Outline of ECMV
q The ECMV consists of 1 pressure control valve
and 1 fill switch.
q Pressure control valve
A proportional solenoid in this valve receives a
current sent from the steering controller and
this valve converts it to an oil pressure.
q Fill switch
This is a switch to detect that a clutch or brake
is filled with oil and has the following functions.
1. At the moment when the clutch or brake is
filled with oil, the fill switch outputs the sig-
nal (fill signal) to the controller to notify the
finishing of filling.
2. While the oil pressure is applied to the
clutch or brake, the fill switch outputs the
signal (fill signal) to the controller to notify
the presence of the oil pressure.
ECMV and proportional solenoid

q One proportional solenoid is mounted for
each ECMV.
The propulsion force is generated accord-
ing to the command current from the con-
troller.
The propulsion force generated by the
proportional solenoid is actuated on the
spool of the pressure control valve and
generates the oil pressure. Accordingly, by
controlling the amount of the command
current, the propulsion force changes and
the pressure control valve is actuated,
then the oil flow and oil pressure is con-
trolled.
ECMV and fill switch

q For each ECMV, 1 fill switch is installed.
If the clutch is filled with oil, the fill switch
is turned “engaged” by the pressure of the
clutch. The oil pressure is built up accord-
ing to this signal.
Operation of ECMV
q The ECMV is controlled by the command
current from the controller to the propor-
tional solenoid and the fill switch output
signal.
D475A, D475ASD-5E0 35
When PCCS lever is in “neutral” position, brake pedal is “released”, and parking brake lever is in
“free” position: Straight travel
(L.H. and R.H. clutches are turned “engaged”, L.H. and R.H. brakes are “released”, and parking brake is
“released”.)
q When the PCCS lever is in “neutral” position q Proportional solenoid (5) of the brake ECMV is
and the brake pedal is “released”, proportional energized and pushes ball (6) to the left and
solenoid (1) of the clutch ECMV is de-ener- closes the sealing part.
gized and the sealing part of ball (2) is opened. q The oil in port (Pb) of the brake ECMV flows in
q The oil from the power train pump flows port (E) and pushes valve (7) to the left to con-
through port (Pc) of the clutch ECMV to orifice nect port (Pb) with port (B) and disconnect port
(a), then it is drained through the sealing part (B) from port (Dr). At this time, the oil flows in
of ball (2). the back pressure port of the brake piston. As
q Valve (3) is moved to the right by the tension of the oil pressure rises, the brake piston is
spring (4) to disconnect port (Pc) from port (C), pushed to the left to compress the brake
and connect port (C) with port (Dr). At this spring, then the brake is “released”.
time, the oil from the back pressure port of the q When the parking brake lever is in “free” posi-
clutch piston is drained through port (C) and tion, as the parking brake valve is closed, the
the clutch is turned “engaged” by the tension of oil in the brake circuit is not drained.
the clutch spring.
q The oil pressure in the brake circuit, etc. is
secured by orifice (a).
36 D475A, D475ASD-5E0
When PCCS lever is “operated to the left halfway”, brake pedal is “released”, and parking brake lever
is in “free” position: Gradual left turn
(L.H. clutch is turned “disengaged”, L.H. brake is “semi-released”, R.H. clutch is turned “engaged”, R.H.
brake is “released”, and parking brake is “released”.)
q When the PCCS lever is “operated to left half- q Proportional solenoid (5) generates the propul-
way” and the brake pedal is “released”, propor- sion force in proportion to the command cur-
tional solenoid (1) of the L.H. clutch ECMV is rent. This propulsion force is balanced with the
energized and the sealing part of ball (2) is sum of the propulsion force generated by the
closed. oil pressure in the back pressure port of the
q The oil from the power train pump flows brake piston and the tension of spring (8), then
through port (Pc) of the clutch EMCV and ori- the brake pressure is set up to adjust the brake
fice (a) to port (F) and pushes valve (3) to the force.
left to connect port (Pc) with port (C) and dis- q Accordingly, if the stroke of the PCCS lever is
connect port (C) from port (Dr). At this time, the short, the oil pressure after port (B) is set high
oil flows in the back pressure port of the clutch and the brake is turned from “released” to
piston. As the oil pressure rises, the clutch pis- “semi-released”. If the stroke of the PCCS
ton is pushed to the left to compress the clutch lever is long, the oil pressure after port (B) is
spring, then the clutch is turned “disengaged”. set low and the brake is turned from “semi-
q Proportional solenoid (5) of the brake ECMV is released” to “applied”.
energized and pushes ball (6) to the left and q When the parking brake lever is in “free” posi-
closes the sealing part. tion, as the parking brake valve is closed, the
q The oil in port (Pb) of the brake ECMV flows in oil in the brake circuit is not drained.
port (E) and pushes valve (7) to the left. As for
the oil pressure after port (B), the controller
outputs the command current to proportional
solenoid (5) according to the stroke of the
PCCS lever.
D475A, D475ASD-5E0 37
When PCCS lever is “operated fully to the left”, brake pedal is “released”, and parking brake lever is
in “free” position: Sharp left turn
(L.H. clutch is turned “disengaged”, L.H. brake is “applied”, R.H. clutch is turned “engaged”, R.H. brake is
“released”, and parking brake is “released”.)
q When the PCCS lever is shifted from “operated q When the parking brake lever is in “free” posi-
to left halfway” to “operated to left fully”, pro- tion, as the parking brake valve is closed, the
portional solenoid (5) of the L.H. brake ECMV oil in the brake circuit is not drained.
is de-energized and the sealing part of ball (6)
is fully opened.
q Since the oil in port (E) is drained through the
sealing part, valve (7) is moved to the right by
the tension of spring (8) to disconnect port (Pb)
from (B) and connect port (B) with port (Dr). At
this time, the oil from the back pressure port of
the brake piston is drained through port (B)
and the brake is turned “applied” by the tension
of the brake spring.
q The oil from the power train pump flows
through port (Pb) of the brake ECMV and ori-
fice (b), then it is drained through sealing part
of ball (6).
q The oil pressure in the clutch circuit, etc. is
secured by orifice (b).
38 D475A, D475ASD-5E0
When PCCS lever is in “neutral”, brake pedal is “depressed”, and parking brake lever is in “free”
position: Stop
(L.H. and R.H. clutches are turned “engaged”, L.H. and R.H. brakes are “applied”, and parking brake is
“released”.)
q When the brake pedal is depressed fully, pro- q If the brake pedal is depressed, the parking
portional solenoids (5) of L.H. and R.H. brake brake valve connected by the linkage operates
ECMV are de-energized to open the sealing to open the brake circuit and drain the oil.
part of ball (6).
q The controller outputs the command current to
proportional solenoid (5) according to the
brake pedal stroke.
q Proportional solenoid (5) generates the propul-
sion force in proportion to the command cur-
rent. This propulsion force is balanced with the
sum of the propulsion force generated by the
oil pressure in the back pressure port of the
brake piston and the tension of spring (8), then
the brake pressure is set up to adjust the brake
force.
q Since the PCCS lever is in “neutral” position,
proportional solenoids (1) of L.H. and R.H.
clutch ECMV are de-energized and L.H. and
R.H. clutch are turned “engaged”.
D475A, D475ASD-5E0 39
Parking brake valve 1
Unit: mm

1 Replace
valve body –0.020 +0.011 0.020 –
14 0.05
–0.030 0 0.041
Standard size Tolerance Repair limit Repair by hard
Outside diameter of dust seal
2 –0.020 chrome plating
contact surface of spool 14 13.9
–0.030 or replace

3 Return spring length load load Replace
38.2 N 36.3 N
65 47.7 63
{3.9 kg} {3.7 kg}
4. Spool Outline
5. Valve body q The parking brake valve is installed to the
steering control valve, and spool (4) operates
with the parking brake lever.
q When the parking brake lever is in “lock” posi-
tion, the brake operates by draining the operat-
ing pressure of the L.H. and R.H. steering
brake.
40 D475A, D475ASD-5E0
When PCCS lever is in “neutral” position, brake pedal is “released”, and parking brake lever is in
“lock” position : Parking
(L.H. and R.H. clutches are turned “engaged”, L.H. and R.H. brakes are “applied”, and parking brake is
“applied”.)
q If the parking brake lever is turned to the “lock”

position, spool (1) is moved to the left to open
ports (A), (B) and (C).
q The oil which had flown into the brake piston
back pressure port is drained through ports
(A), (B) and (C).
q The oil pressure in the back pressure port of
the brake piston continues to decrease, then
the brake is fully “applied” and that situation is
kept.
q When the engine is started again, as ports (A),
(B) and (C) are still opened, the brake is con-
tinuously “applied”.
q If the parking brake lever is shifted to “free”
position, spool (1) moves to the right to discon-
nect ports (A), (B) and (C). Then the oil pres-
sure from the brake ECMV is applied to the
back pressure port of the brake piston and the
brake becomes “released”.
D475A, D475ASD-5E0 41
Sudden stop prevention valve 1
Outline
q The sudden stop prevention valve is installed
to prevent the machine from stopping suddenly
when an abnormality takes place in the electri-
cal system.
q Sudden stop prevention valve (1) is installed in
the drain circuit of the brake ECMV so that the
sudden oil pressure drop of port (DR) when
brake ECMV coil (2) is de-energized, and con-
sequently the sudden brake can be avoided.
q If an abnormality takes place in the electrical
system, also solenoid (3) of sudden stop pre-
vention valve (1) is de-energized. Then, the oil
of port (DR) is drained through orifice (a) so
that the brake is applied gradually.
42 D475A, D475ASD-5E0
D475A, D475ASD-5E0 43
SEN00212-00

44
SEN00213-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up

Undercarriage and frame
Undercarriage and frame ................................................................................................................................ 2
Track frame .......................................................................................................................................... 2
Recoil spring ........................................................................................................................................ 4
Idler ...................................................................................................................................................... 6
Track roller ........................................................................................................................................... 8
Carrier roller ....................................................................................................................................... 12
Track roller bogie................................................................................................................................ 13
Track shoe.......................................................................................................................................... 14
Main frame ......................................................................................................................................... 18
Suspension ........................................................................................................................................ 20
D475A, D475ASD-5E0 1
Undercarriage and frame 1

Track frame 1
1. Idler Track roller, bogie

2. Recoil spring assembly (Semi U, full U, superdozer specification)
3. Carrier roller
4. Track frame Track roller flange type arrangement
5. Sprocket 1st 2nd 3rd 4th 5th 6th 7th 8th
6. Sprocket guard
S D D D D D D S
7. Track roller bogie
8. Track roller
9. Cap S: Single
10. Idler yoke D: Double
11. Cylinder
12. Guide
2 D475A, D475ASD-5E0
Outline
q The track roller uses K-shape bogie mount to
increase the ground contact area between the
track shoe and ground surface on rough sur-
faces, thereby increasing the drawbar pull.
q The K-shape bogie is fitted with rubber pads to
absorb the shock from the ground surface.
Unit: mm
Item Repair limit
Deformation of track frame Curvature 7 (for length of 3,000) Repair or

4
outer cylinder Twisting 3 (for level length of 3,000) Replace
Dents (cylinder portion) 12

Clearance between inner size Shaft Hole clearance limit
13 Replace
cylinder and guide
–0.15 +0.3
70 0.15 – 0.65 2.0
–0.35 +0.3
Clearance between idler Standard clearance Clearance limit

14 Adjust
bogie and guide 0 – 0.5 3.0
Press-fitting force for car-
15 294.20 – 490.33 kN {30 – 50 ton} —
tridge
D475A, D475ASD-5E0 3
Recoil spring 1
1. Yoke Outline
2. Nut q Recoil spring (10) damps sudden shocks
3. Retainer applied to the idler.
4. Rod q The recoil spring is also used to adjust the
5. Spring cylinder track shoe tension by supplying or discharging
6. Retainer grease through lubricator (8) and moving rod
7. Piston (4) forward or in reverse.
8. Lubricator
(for supplying and discharging grease)
9. Grease chamber cylinder
4 D475A, D475ASD-5E0
Unit: mm

Installation Installation Installation
10 Recoil spring length load load
725.7 kN 683.1 kN
1,713 1,425 1,696
{74,000 kg} {69,700 kg} Replace

Clearance between inner size clearance limit
Shaft Hole
11 cylinder and outer cylinder of
outer cylinder bushing –0.068 +0.323 0.128 –
445 0.8
–0.165 +0.600 0.488
Press-fitting force for outer
12 cylinder bushing 129.4 – 389.1 kN {13.2 – 39.7 ton}
(inner cylinder side)
Adjust
Clearance between recoil
13 spring mount nut and lock 0 – 1.0
plate
D475A, D475ASD-5E0 5
Idler 1
Unit: mm
6 D475A, D475ASD-5E0
Outside diameter of Standard size Repair limit

1
protruding part 1,043 —
Outside diameter of tread
2 990 959 Rebuild or
surface
replace
3 Depth of tread 26.5 42
4 Thickness of tread 36 20.5
5 Overall width 347 —
6 Width of tread 96 105

Replace
Clearance between shaft size Shaft Hole clearance limit
7 bushing
and bushing
–0.350 +0.168 0.353 –
180 —
–0.413 +0.003 0.581
Standard size Repair limit Rebuild or
8 Width of shaft flange
335.0 — replace
Standard Tolerance Standard Interference

Interference between ring size Shaft Hole interference limit
9
and shaft
+0.046 –0.15
115 0.15 – 0.246 — Replace ring
+0.046 –0.20
10 End play
0.52 – 0.98 —
D475A, D475ASD-5E0 7
Track roller 1
8 D475A, D475ASD-5E0
2nd – 7th track rollers (double flanged roller)

Unit: mm
Outside diameter of flange Standard size Repair limit

1
(outside) 344 —
Outside diameter of flange
2 332 —
(inside)
3 Outside diameter of tread — 246
4 Thickness of tread 71.5 44.5
Rebuild or
5 Overall width 423 — replace
6 Width of tread 99.5 —
Width of flange
7 34.5 19.5
(Outside of flange)
Width of flange
8 27.5 12.5
(Inside of flange)
9 Width of shaft flange 379 —

Clearance between shaft size Shaft Hole clearance limit Replace
10
and bushing bushing
–0.350 +0.170 0.350 –
147 —
–0.413 +0.170 0.583

Interference between shaft size Shaft Hole interference limit
11 Replace
and seal ring
+0.046 –0.15 0.150 –
84 —
+0.046 –0.20 0.246
Standard size Clearance limit Adjust or
12 End play
0.44 – 0.91 — replace
D475A, D475ASD-5E0 9
1st and 8th track rollers (single flanged roller)

Unit: mm

1 Outside diameter of flange
349 —
3 Outside diameter of tread 315 240
4 Thickness of tread 74 36.5 Rebuild or
5 Overall width — — replace
6 Width of tread — —
7 Width of flange 34.5 19.5
9 Width of shaft flange 377 —

Clearance between shaft and size Shaft Hole clearance limit Replace
10
bushing bushing
–0.350 +0.171 0.350 – 0.343 –
157
–0.413 +0.007 0.583 0.584
Tolerance Standard Interfer-
Standard
interference
Interference between shaft size Shaft Hole
11 ence limit Replace
and seal guide
0 +0.054
93.5 0 – 0.174 —
–0.12 0
Adjust or
12 End play 0.44 – 0.91 —
replace
10 D475A, D475ASD-5E0
D475A, D475ASD-5E0 11
Carrier roller 1
Unit: mm

1 Outside diameter of flange
275 —
Outside diameter of carrier
2 240 215 Rebuild or
roller tread
replace
3 Width of carrier roller tread 96 —
4 Thickness of tread 49.5 37
5 Width of flange 25 14
Standard Tolerance Standard Standard

Interference between shaft size Shaft Hole interference clearance
6
and ring
+0.046 –0.15 0.150 –
95 —
+0.046 –0.20 0.246
Replace
Clearance between shaft –0.2 +0.35
7 90 — 0 – 0.55
and support –0.2 +0.35
Play in axial direction of Standard size Clearance limit

8
roller 0 – 0.22 0.3
12 D475A, D475ASD-5E0
Track roller bogie 1
Outline 1. Guide
q The track rollers are installed to small bogie 2. Cap
(6). The track rollers and track shoes are 3. Track roller assembly (double)
always in contact. 4. Large bogie
q The vibration of the machine from the ground 5. Rubber mount
surface is absorbed by rubber mount (5). 6. Small bogie
7. Track roller assembly (single)
8. Cover
9. Cartridge pin
D475A, D475ASD-5E0 13
Track shoe 1
a Portion P shows the link on the side where the bushing is pressed fitted.
14 D475A, D475ASD-5E0
Unit: mm
Standard size Repair limit Turn or

1 Link pitch
317.8 320.8 replace
2 Height of grouser 105 35 Weld lug,

rebuild, or
3 Overall height of shoe 133 63 replace
Turning
Standard size
4 Outside diameter of bushing Load Heavy load Turn or
116 107.5 110 replace
5 Thickness of bushing 22.5 14 16.5

6 Height of link
109 181 (*1) Rebuild or
replace
Thickness of link
7 53.5 35.5 (*2)
(bushing press-fitting portion)
Clearance One side 1.6 —

8
between links Both sides 3.2 —
Tolerance Standard
Standard size
Interference between bushing Shaft Hole interference Adjust or
9 replace
and link
+0.652 +0.087
113 0.465 – 0.652
+0.552 +0.087
Interference between regular +0.496 +0.124
10 70 0.312 – 0.446
pin and link +0.436 +0.050
a. Regular Tightening torque (Nm {kgm}) Tightening angle (deg)

link 785 ± 78 {80 ± 8} 180 ± 10
11 Shoe bolt Retighten
b. Master
980 ± 98 {100 ± 10} 180 ± 10
link
*1: If wear has reduced the outside diameter of the double flange track roller to less than 250 mm, the limit
is 183 mm.
*2: If wear has reduced the outside diameter of the double flange track roller to less than 250 mm, the limit
is 37.5 mm.
D475A, D475ASD-5E0 15
Triple grouser shoe
Unit: mm

1 Height
37 25
2 Thickness 18
3 33 Repair by
Length of base build-up
4 27 welding or
replace
5 25.5
6 Length of tip 17.5
7 23.5
16 D475A, D475ASD-5E0
D475A, D475ASD-5E0 17
Main frame 1
18 D475A, D475ASD-5E0
Unit: mm

size Shaft Hole clearance limit
Interference between steer-
1
ing case and bushing (Std.inter-
–0.108 +0.052 ference)
315 Min. 0
+0.056 +0.052 0.004 –
0.108
Clearance between steering –0.018 +0.057 0.018 –
2 390 0.2
frame and final drive cage –0.075 +0.057 0.132
Clearance between bracket –0.030 +0.006 –0.018 –
3 78 0.1
and cushion –0.060 –0.048 0.066
Clearance between ripper
–0.043 +0.210 0.093 –
4 arm mounting pin and 140 1.5
–0.106 +0.050 0.316
bushing
Clearance between ripper
–0.036 +0.301 0.154 –
5 cylinder mounting pin and 110 1.5 Replace
–0.090 +0.118 0.371
bushing
Clearance between radiator
Hole 100.2 –0.036 +0.164 0.298 –
6 guard mounting pin and 1.5
Shaft 100 –0.090 +0.062 0.454
bushing
Clearance between radiator
Hole 115.2 –0.043 +0.140 0.274 –
7 guard mounting pin and 1.5
Shaft 115 –0.106 +0.031 0.446
bushing
Clearance between equalizer –0.043 +0.208 0.174 –
8 140 1.5
bar shaft and bushing –0.083 +0.131 0.291
Protrusion of rubber at end Standard size Repair limit

9
face of seal 1 0.5
Free height of front mount
10 118 116
rubber
Free height of rear mount
11 58 56
rubber
Press-fitting force for ripper
12 126.5 – 253 kN {12.9 – 25.8 ton}
arm mounting bushing
Press-fitting force for ripper
13 111.8 – 267.7 kN {11.4 – 27.3 ton}
cylinder mounting bushing
Press-fitting force for radiator
14 62.8 – 142.2 kN {6.4 – 14.5 ton}
guard mounting bushing Adjust
Press-fitting force for radiator
15 53.9 – 106.9 kN {5.5 – 10.9 ton}
guard mounting bushing
Press-fitting force for
16 equalizer bar shaft mounting 65.7 – 153 kN {6.7 – 15.6 ton}
bushing
D475A, D475ASD-5E0 19
Suspension 1
20 D475A, D475ASD-5E0
1. Equalizer bar Outline

2. Pivot shaft assembly q The front part of the track frame moves up and
3. Cover down around pivot shaft (6) at its rear end.
4. Thrust plate Equalizer bar (1) rocks around center pin (11)
5. Thrust plate and is connected to the right and left track
6. Pivot shaft frames by side pins (10).
7. Seal cage
8. Cover
9. Seal cage
10. Side pin
11. Center pin
D475A, D475ASD-5E0 21
Unit: mm
Press-fitting force for side

12 47.0 – 96.0 kN {4.8 – 9.8 ton}
pin bushing
Press-fitting force for side
13 121.5– 294 kN {12.4 – 30 ton} —
pin bushing
Press-fitting force for cen-
14 68.6 – 232.2 kN {7 – 23.8 ton}
ter pin bushing

Clearance between cen- size Shaft Hole clearance limit
15
ter pin and bushing
–0.043 +0.225 0.186 –
140 1.0
–0.083 +0.143 0.308
Clearance between side –0.048 +0.015 0.033 – Replace
16 115 1.0 bushing
pin and bushing –0.078 –0.015 0.093
Clearance between pivot –0.190 +0.138 0.216 –
17 260 1.0
shaft and bushing –0.271 +0.026 0.409
Clearance between pivot –0.145 +0.114 0.204 –
18 220 1.0
shaft and bushing –0.208 +0.038 0.340

Interference between side size Shaft Hole interference limit
19
pin boss and bushing
+0.051 –0.033 0.064 –
200 —
+0.031 –0.079 0.130
Interference between +0.216 –0.234 0.320 – Replace
20 270 —
thrust washer and seal +0.086 –0.286 0.502
Interference between +0.096 –0.075 0.125 –
21 194 —
thrust washer and seal +0.050 –0.147 0.243
Interference between pivot +0.108 –0.122 0.178 –
22 263 —
shaft and seal +0.056 –0.203 0.311
22 D475A, D475ASD-5E0
D475A, D475ASD-5E0 23
SEN00213-00

24
SEN00214-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up

Hydraulic system, Part 1
Hydraulic system, Part 1 ................................................................................................................................. 2
Work equipment hydraulic equipment arrangement diagram............................................................... 2
PPC control piping diagram ................................................................................................................. 6
Work equipment control ....................................................................................................................... 8
Work equipment pump ....................................................................................................................... 10
PPC valve .......................................................................................................................................... 27
PCCS lever ........................................................................................................................................ 38
D475A, D475ASD-5E0 1
Hydraulic system, Part 1 1

Work equipment hydraulic equipment arrangement diagram 1
Semi U-dozer (single tilt)
1. Blade tilt cylinder 7. Fan pump

2. R.H. blade lift cylinder 8. Work equipment pump
3. Main control valve 9. L.H. blade lift cylinder
4. Accumulator 10. Fan motor
5. Dual tilt solenoid valve 11. Oil cooler
6. Hydraulic tank
2 D475A, D475ASD-5E0
Superdozer (full U-dozer + dual tilt)
1. Blade tilt cylinder 7. Fan pump

2. R.H. blade lift cylinder 8. Work equipment pump
3. Main control valve 9. L.H. blade lift cylinder
4. Accumulator 10. Blade pitch cylinder
5. Dual tilt solenoid valve 11. Fan motor
6. Hydraulic tank 12. Oil cooler
D475A, D475ASD-5E0 3
Multi-shank ripper
1. Main control valve

2. Divider block
3. Ripper tilt cylinder (right)
4. Ripper lift cylinder (right)
5. Ripper lift cylinder (left)
6. Ripper tift cylinder (left)
4 D475A, D475ASD-5E0
Giant ripper
q The diagram shows a machine equipped with a pin puller cylinder
1. Main control valve 6. Ripper lift cylinder (left)

2. Divider block 7. Ripper tilt cylinder (left)
3. Ripper tilt cylinder (right) 8. Pin puller solenoid valve
4. Ripper lift cylinder (right) 9. Brake valve
5. Pin puller cylinder
D475A, D475ASD-5E0 5
PPC control piping diagram 1

Blade and ripper control
1. Blade control PPC valve

2. Main control valve
3. Accumulator
4. Ripper control PPC valve
5. PPC lock valve
6. Work equipment lock lever
7. Work equipment pump
6 D475A, D475ASD-5E0
D475A, D475ASD-5E0 7
Work equipment control 1

q The diagram shows a machine equipped with pitch dozer and pin puller cylinder.
1. Work equipment lock lever 5. Ripper control lever

2. Blade control lever 6. Pin puller switch
3. Pitch button 7. PPC lock valve
4. Tilt switch
8 D475A, D475ASD-5E0
Lever and switch positions

A : Blade HOLD
B : Blade LOWER
C : Blade FLOAT
D : Blade RAISE
E : Blade LEFT TILT/PITCH
F : Blade RIGHT TILT/PITCH
G : Ripper HOLD
H : Ripper RAISE
J : Ripper LOWER
K : Ripper TILT IN
L : Ripper TILT BACK
M : FREE
N : LOCK
P : Single tilt
Q : Dual tilt
R : Pitch OFF
S : Pitch ON
T : Pin puller switch PUSH IN
U : Pin puller switch PUSH OUT
Outline
q The work equipment control employs a PPC
method which uses a PPC valve to move each
control valve spool.
q Work equipment lock lever (1) is intercon-
nected with PPC lock valve (7), and at the
LOCK position (N), the oil in the PPC circuit is
stopped.
D475A, D475ASD-5E0 9
Work equipment pump 1

3
Type: HPV125 + 125 (140 cm /rev specification)
DC: Discharge Outline

SC: Suction q This pump consists of two variable-capacity
swash plate-type piston pumps, CO valve, LS
valve, and EPC valve.
10 D475A, D475ASD-5E0
A PBF : Front pump pressure input port L PLSR : Load pressure input port
B PAF : Front pump discharge port M PLSRC: Load pressure pickup port
C PLSC : LS set selector pressure pickup port N PLSFC : Load pressure pickup port
D PBR : Rear pump pressure input port P PLSF : Load pressure input port
E PENR : Control pressure pickup port Q PEPC : EPC basic pressure port
F PAR : Rear pump discharge port R PFC : Front pump discharge pressure pickup
G PENF : Control pressure pickup port port
H PD1F : Case drain port S PD2F : Drain plug
J PEPB : EPC basic pressure pickup port T ISIG : LS set selector current
K PRC : Rear pump discharge pressure pickup U PS : Pump suction port
port V PD2R : Air breather mounting port
1. Front main pump 10. Shoe

2. Rear main pump 11. Piston
3. LS valve 12. Cylinder block
4. CO valve 13. Valve plate
5. LS-EPC valve 14. End cap
6. Front shaft 15. Rear shaft
7. Cradle 16. Rear case
8. Front case 17. Servo piston
9. Rocker cam
D475A, D475ASD-5E0 11
Function Structure
q The rotation and torque transmitted to the q Cylinder block (7) is supported to shaft (1) by a
pump shaft are converted into hydraulic pres- spline, and shaft (1) is supported by the front
sure, and pressurized oil is discharged accord- and rear bearings.
ing to the load. q The tip of piston (6) is a concave ball, and shoe
q It is possible to change the discharge amount (5) is caulked to it to form one unit. Piston (6)
by changing the swash plate angle. and shoe (5) form a spherical bearing.
q Shoe (5) is always pressed against flat surface
(A) of rocker cam (4) while sliding in a circular
movement.
q Rocker cam (4) brings high pressure oil at cyl-
inder surface (B) with cradle (2), which is
secured to the case, and forms a static pres-
sure bearing when it slides.
q Piston (6) carries out relative movement in the
axial direction inside each cylinder chamber of
cylinder block (7).
q The cylinder block (7) seals the pressure oil to
valve plate (8) and carries out relative rotation.
This surface is designed so that the oil pres-
sure balance is maintained at a suitable level.
The oil inside each cylinder chamber of cylin-
der block (7) is sucked in and discharged
through valve plate (8).
12 D475A, D475ASD-5E0
Operation q If center line (X) of rocker cam (4) is in line

with the axial direction of cylinder block (7)
1. Operation of pump
(swash plate angle = 0), the difference
q Cylinder block (7) rotates together with between volumes (E) and (F) inside cylin-
shaft (1), and shoe (5) slides on flat sur- der block (7) becomes 0, so the pump
face (A). does not carry out any suction or dis-
When this happens, rocker cam (4) moves charge of oil.
along cylindrical surface (B), so angle (a) (In actual fact, the swash plate angle
between center line (X) of rocker cam (4) never becomes 0.)
and the axial direction of cylinder block (7)
changes. (Angle (a) is called the swash
plate angle.)
q Center line (X) of rocker cam (4) maintains

swash plate angle (a) in relation to the
axial direction of cylinder block (7), and
flat surface (A) moves as a cam in relation
to shoe (5).
q In this way, piston (6) slides on the inside
of cylinder block (7), so a difference
between volumes (E) and (F) is created
inside cylinder block (7). The suction and
discharge is carried out by this amount (F)
– (E) per each piston.
q In other words, when cylinder block (7)
rotates and the volume of chamber (E)
becomes smaller, the oil is discharged
during that stroke. On the other hand, the
volume of chamber (F) becomes larger,
and as the volume becomes bigger, the oil
is sucked in.
D475A, D475ASD-5E0 13
2. Control of delivery amount

q If the swash plate angle (a) becomes
larger, the difference between volumes (E)
and (F) becomes larger and delivery
amount (Q) increases.
q Swash plate angle (a) is changed by servo
piston (12).
q Servo piston (12) moves in a reciprocal
movement according to the signal pres-
sure from the CO valve and LS valve. This
straight line movement is transmitted
through rod (13) to rocker cam (4), and
rocker cam (4), which is supported by the
cylindrical surface to cradle (2), slides in a
rotating movement.
q With servo piston (12), the area receiving
the pressure is different on the left and the
right, so main pump discharge pressure
(self pressure) (PP) is always brought to
the chamber receiving the pressure at the
small diameter piston end.
q Output pressure (PEN) of the LS valve is
brought to the chamber receiving the pres-
sure at the large diameter end. The rela-
tionship in the size of pressure (PP) at the
small diameter piston end and pressure
(PEN) at the large diameter end, and the
ratio between the area receiving the pres-
sure of the small diameter piston and the
large diameter piston controls the move-
ment of servo piston (12).
14 D475A, D475ASD-5E0
3. LS valve
A. PLS : LS pressure input port 1. Sleeve

B. PP : Pump port 2. Piston
C. PLP : LS control pressure output port 3. Spool
D. PPL : CO control pressure input port 4. Spring
E. PDP : Drain port 5. Seat
F. PSIG : LS mode selection pilot port 6. Sleeve
G. PA : Pump port 7. Plug
8. Locknut
4. CO valve
A. PPL : CO control pressure output port 3. Ball

B. PA : Pump port 4. Spool
A. PDP : Drain port 5. Spring
6. Retainer
1. Plug 7. Cover
2. Servo piston assembly 8. Spring
D475A, D475ASD-5E0 15
Function 2) CO valve
1) LS valve q When the pump pressure in the hydraulic cir-
q The LS (Load Sensing) valve detects the load cuit becomes maximum, the CO (Cut-OFF)
and controls the discharge amount. valve minimizes the pump swash plate angle
q This valve controls main pump delivery amount to limit the pressure and protect the circuit.
(Q) according to differential pressure (dPLS) q Since the pump swash plate angle is mini-
between main pump pressure (PP) and con- mized, the pump absorption torque is reduced
trol valve outlet port pressure (PLS) (= PP – and the fuel consumption is reduced.
PLS) [called the LS differential pressure].
q Main pump pressure (PP), pressure (PLS)
[called the LS pressure] from the control valve
output, and pressure (PSIG) from the propor-
tional solenoid valve [called the LS selector
pressure] enter this valve.
q The relationship between differential pressure
(dPLS) between main pump pressure (PP) and
LS pressure (PLS) (= PP – PLS) and delivery
amount (Q) changes according to LS selector
current (ISIG) of the LS-EPC valve as shown in
the figure below.
q As (ISIG) changes from 0 to 0.9 A, the set
force of the spring changes. As a result, the
median of the standard changing point of the
pump delivery amount changes from 2.5 to
0.98 MPa {from 25 to 10 kg/cm2}.
16 D475A, D475ASD-5E0
Operation
1) LS valve
(1) When control valve is at neutral position
q The LS valve is a three-way selector valve, q At this point, spool (6) is pushed to the right,
with pressure (PLS) (LS pressure) from the and port (C) and port (D) are connected. Pump
inlet port of the control valve brought to spring pressure (PP) enters the large diameter end of
chamber (B), and main pump discharge pres- the piston from port (K) and the same pump
sure (PP) brought to port (H) of sleeve (8). The pressure (PP) also enters port (J) at the small
size of this LS pressure (PLS) + force of spring diameter end of the piston, so the swash plate
(4) and the main pump pressure (self pres- is moved to the minimum angle by the differ-
sure) (PP) determines the position of spool (6). ence in the area of piston (12).
q However, the size of the output pressure
(PSIG) (the LS selection pressure) of the EPC
valve for the LS valve entering port (G) also
changes the position of spool (6). (The set
pressure of the spring changes).
q Before the engine is started, servo piston (12)
is pushed to the right. (See the diagram on the
right)
q When the engine is started and the control
lever is at the neutral position, LS pressure
(PLS) is 0 MPa {0 kg/cm2}. (It is interconnected
with the drain circuit through the control valve
spool.)
D475A, D475ASD-5E0 17
(2) Operation in direction of maximum pump delivery amount
q When the difference between main pump pres- q If the output pressure of the EPC valve for the
sure (PP) and LS pressure (PLS), or LS differ- LS valve is applied to port (G) at this time, it
ential pressure (dPLS), becomes smaller (for pushes piston (7) to the left.
example, when the area of opening of the con- q If piston (7) is pushed to the left, the set force
trol valve becomes larger and LS pressure of spring (4) is reduced and LS differential
(PLS) increases), the combined force of LS pressure (dPLS) [the difference between oil
pressure (PLS) and force of spring (4) pushes pressures (PLS) and (PP)] changes when
spool (6) to the right. ports (D) and (E) of spool (6) are connected.
q As spool (6) moves, ports (D) and (E) are con-
nected to each other and to the CO valve.
q At this time, the CO valve is connected to the
drain port and the pressure in circuit (D) – (K)
becomes drain pressure (PT). (Operation of
the CO valve will be explained later.)
q Accordingly, the pressure on the large diame-
ter end of servo piston (12) becomes drain
pressure (PT). Since pump pressure (PP) is
constantly applied to port (J) on the small
diameter end, servo piston (12) is pushed to
the left and the swash plate is moved in the
direction for increasing the delivery amount.
18 D475A, D475ASD-5E0
(3) Operation in direction of minimum pump delivery amount
q The following explains the case where servo

piston (12) moves to the right (where the deliv-
ery amount becomes smaller). When LS dif-
ferential pressure (dPLS) increases [for
example, when the area of opening of the con-
trol valve becomes smaller and LS pressure
(PLS) lowers], pump pressure (PP) pushes
spool (6) to the left.
q As spool (6) moves, main pump pressure (PP)
flows from port (C) to port (D), and then it
enters the large diameter end of the piston
through port (K).
q Main pump pressure (PP) also enters port (J)
on the small diameter end of servo piston (12),
but servo piston (12) is pushed to the right
because of the difference in area between its
large diameter end and small diameter end.
As a result, the swash plate angle is reduced.
D475A, D475ASD-5E0 19
(4) When servo piston is balanced
q Let us take the area receiving the pressure at q At this time, the relationship between the areas
the large diameter end of the piston as (A1), receiving the pressure at both ends of servo
the area receiving the pressure at the small piston (12) is (A0) : (A1) = 1 : 2. Accordingly,
diameter end as (A0), and the pressure flowing the relationship between the pressures applied
into the large diameter end of the piston as to both ends of the piston when the piston is
(PEN). balanced becomes (PP) : (PEN) C 2 : 1.
q When main pump pressure (PP) of the LS q The position where spool (6) is balanced and
valve is balanced with the combined force of stopped is the standard center. The force of
LS pressure (PLS) and the force of spring (4) spring (4) is so adjusted that the standard cen-
and their relationship is (A0) × (PP) = (A1) × ter will be decided when (PP) – (PLS) = 2.5
(PEN), servo piston (12) stops in the current MPa {25 kg/cm2}.
position. q When the input current to the LS-EPC valve
q Then, swash plate is kept at an intermediate changes from 0 to 0.9A and (PSIG) (the output
position. [It stops at a position where the pressure of the LS-EPC valve varying from 0 to
opening between ports (D) and (E) of spool (6) 2.9 MPa {0 to 30 kg/cm2}) is applied to port (G),
and that between ports (C) and (D) are approx- however, the balancing and stopping position
imately the same.] changes in proportion to the (PSIG) pressure
in the range from (PP) – (PLS) = 2.5 to 0.98
MPa {25 to 10 kg/cm2}.
20 D475A, D475ASD-5E0
q The operation of the LS valve is shown in the following table.
Solenoid drive table

Superdozer
Single specification Dual specification
specification
Raise
Lift
Lower
Left tilt q q q
Left tilt limit q
Single tilt
Right tilt q q q
Right tilt limit q
Blade
Left tilt q
Left tilt limit q
Dual tilt
Right tilt q
Right tilt limit q
Rear pitch q
Pitch
Forward pitch q
Raise
Lift
Lower
Ripper
Raise
Tilt
Lower
D475A, D475ASD-5E0 21
2) CO valve
(1) When actuator load is small and pump pressure (PP) is low
q Spool (3) is a little to the left position. At this

time, port (C) is connected to port (D) through
the internal passage of spool (3).
q Port (C) of the CO valve is connected to port
(E) of the LS valve.
q Pump pressure (PP) is applied to port (B) and
small diameter side of servo piston (9). The
pressure in port (E) of the LS valve is drain
pressure (PT).
q If ports (E) and (G) of the LS valve are con-
nected at this time, the pressure on the large
diameter side of the piston becomes drain
pressure (PT) and servo piston (9) moves to
the left.
q As a result, the pump swash plate angle is
increased to increase the pump delivery
amount.
22 D475A, D475ASD-5E0
(2) When actuator load is large and pump discharge pressure reaches maximum
q When the load is large and pump discharge

pressure (PP) is high, the force to push spool
(3) to the right is increased and spool (3) is set
in the position shown in the above figure.
q Port (C) of the CO valve is connected to port
(E) of the LS valve.
q Pump pressure (PP) is applied to port (B) and
small diameter side of servo piston (9).
q Then, the pressure applied through port (C) to
the LS valve is main pump pressure (PP) from
port (B).
q If ports (E) and (G) of the LS valve are con-
nected at this time, main pump pressure (PP)
is applied to the large diameter side of servo
piston (9).
q Main pump pressure (PP) is applied to the
small diameter side of the piston, too. Servo
piston (9) is pushed to the right, however,
because of the difference in area between the
large diameter side and small diameter side of
the piston.
q As a result, the pump swash plate angle is
decreased to decrease the pump delivery
amount.
D475A, D475ASD-5E0 23
5. LS-EPC valve
A. PSIG : To LS valve 1. Coil

B. PT : To tank 2. Body
C. PEPC: From self pressure reducing valve 3. Spring
4. Spool
5. Rod
6. Plunger
7. Connector
24 D475A, D475ASD-5E0
Function Operation
q The EPC valve consists of the solenoid portion 1) When signal current is 0
and the hydraulic valve portion. (coil de-energized)
q When it receives signal current (i) from the q When there is no signal current flowing from
pump controller, it generates the EPC output the controller to coil (1), coil (1) is de-energized.
pressure in proportion to the size of the signal, q For this reason, spool (4) is pushed to the right
and outputs it to the LS valve. in the direction of the arrow by spring (3).
q As a result, port (C) (PEPC) closes and the
pressurized oil from the main pump does not
flow to the LS valve.
q At the same time, the pressurized oil from the
LS valve passes from port (A) (PSIG) through
port (B) (PT) and is drained to the tank.
D475A, D475ASD-5E0 25
2) When signal current is small (Coil is ener- 3) When signal current is maximum (Coil is
gized) energized)
q If a small signal current flows in coil (1), coil (1) q If the signal current flows in coil (1), coil (1) is
is “energized” and a thrust to the right is gener- “energized”.
ated in plunger (6). q Since the signal current is at the maximum, the
q Rod (5) pushes spool (2) to the right and the oil thrust in plunger (6) becomes maximum.
from port (C) (PEPC) flows in port (A) (PSIG). q Accordingly, rod (5) presses spool (2) to the
q The pressure in port (A) (PSIG) rises. If the right.
total of the force applied to spool (2) and the q As a result, the maximum oil flows from port
load of spring (3) exceeds the thrust of plunger (C) (PEPC) to port (A) (PSIG) and the pressure
(6), spool (2) is pushed to the left. Then, port in the circuit between the EPC valve and LS
(C) (PEPC) and port (A) (PSIG) are discon- valve becomes highest.
nected and port (A) (PSIG) and port (B) (PT) q At this time, port (C) (PT) is closed and the oil
are connected simultaneously. does not flow in the tank.
q As a result, spool (2) moves up and down until
the thrust of plunger (6) is balanced with the
total of the pressure in port (A) (PSIG) and the
load of spring (3).
q Accordingly, the pressure in the circuit
between the EPC valve and LS valve is con-
trolled in proportion to the signal current.
26 D475A, D475ASD-5E0
PPC valve 1
1. Blade PPC valve
P : From self pressure reducing valve P3 : To blade tilt valve (LEFT TILT) PPC port
P1 : To blade lift valve (LOWER) PPC port P4 : To blade tilt valve (RIGHT TILT) PPC port
P2 : To blade lift valve (RAISE) PPC port T : To hydraulic tank
D475A, D475ASD-5E0 27
1. Spool 7. Joint
2. Metering spring 8. Plate
3. Centering spring 9. Retainer
4. Piston 10. Body
5. Disc 11. Filter
6. Nut (For connecting lever)
28 D475A, D475ASD-5E0
Unit: mm

Free length
Centering spring x Outside Free length
12 length load load
(For port P1) diameter
94 N 75.2 N
34.0 x 15.5 31.9 —
{9.6 kg} {7.68 kg}
Centering spring 78.5 N 62.8 N If spring is
13 43.2 x 15.5 34.0 —
(For port P2) {8 kg} {6.4 kg} damaged or
Centering spring 107.9 N 86.3 N deformed,
14 48.57 x 15.5 32.5 — replace it
(For ports P3 and P4) {11 kg} {8.8 kg}
Metering spring 16.7 N 13.3 N
15 29.27 x 8.15 25.4 —
(For port P1) {1.70 kg} {1.36 kg}
16 26.3 x 8.15 24.1 —
(For port P2) {1.70 kg} {1.36 kg}
17 26.53 x 8.15 24.9 —
(For ports P3 and P4) {1.70 kg} {1.36 kg}
D475A, D475ASD-5E0 29
Operation
1) When in neutral
(1) For lifting blade (2) For tilting blade
q Ports (A) and (B) of the blade lift valve of the q Ports (C) and (D) of the blade tilt valve of the
control valve and ports (P1) and (P2) of the control valve and ports (P3) and (P4) of the
PPC valve are connected through fine control PPC valve are connected through fine control
hole (f) of spool (1) to drain chamber (D). hole (f) of spool (1) to drain chamber (D).
30 D475A, D475ASD-5E0
2) When in fine control

(Neutral o Fine control)
q If piston (4) is pushed by disc (5), retainer (9) is
pushed and spool (1) is also pushed down
through metering spring (2).
q Accordingly, fine control hole (f) is discon-
nected from drain chamber (D) and connected
to pump pressure chamber (PP) almost simul-
taneously, and then the pilot oil flows from port
(P1) through fine control hole (f) to port (B).
q If the pressure in port (P1) rises, spool (1) is
pushed back and fine control hole (f) is discon-
nected from pump pressure chamber (PP) and
connected to drain chamber (D) almost simul-
taneously to release the pressure in port (P1).
q As a result, spool (1) moves up and down to
balance the force of metering spring (2) with
the pressure in port (P1).
q The positional relationship between spool (1)
and body (10) [where fine control hole (f) is
between drain chamber (D) and pump pres-
sure chamber (PP)] does not change until
retainer (9) comes in contact with spool (1).
q Since metering spring (2) is compressed in
proportion to the stroke of the control lever, the
pressure in port (P1) rises in proportion to the
stroke of the control lever.
q Accordingly, the control valve spool moves to a
position at which the pressure in port (B) [equal
to the pressure in port (P1)] is balanced with
the force of the control valve spool return
spring.
D475A, D475ASD-5E0 31
3) When in fine control 4) When lever is operated to stroke end

(When control lever is returned) q If disc (5) pushes down piston (4) and retainer
q If lever (5) begins to return, the force of center- (9) pushes down spool (1), fine control hole (f)
ing spring (3) and the pressure in port (P1) is disconnected from drain chamber (D) and
push up spool (1). connected to pump pressure chamber (PP).
q As a result, fine control hole (f) is connected to q Accordingly, the pilot oil flows through fine con-
drain chamber (D) and the oil in port (P1) is trol hole (f) and port (P1) into port (B) and
released. pushes the control valve spool.
q If the pressure in port (P1) lowers too much, q The oil returning from port (A) flows through
spool (1) is pushed down by metering spring port (P2) and fine control (f’) into drain cham-
(2) and fine control hole (f) is disconnected ber (D).
from drain chamber (D) and connected to
pump pressure chamber (PP) almost simulta-
neously. Then, the pump pressure is applied
until the pressure in port (P1) is restored to the
level corresponding to the position of the lever.
q When the control valve spool returns, the oil in
drain chamber (D) flows in through fine control
hole (f’) of the valve which is not in operation
and then flows through port (P2) into port (A).
32 D475A, D475ASD-5E0
5) When blade is “floated” 6) When “FLOAT” state of blade is reset

q If piston (4) on the “LOWER” side of port (P1) q Disc (5) is pushed down with a force larger
is pushed down by disc (5), ball (11) touches than the oil pressure in chamber (E) to return
projection (a) of the piston in the middle of the from the “FLOAT” position.
stroke (The detent starts to operate). q As a result, chamber (E) is disconnected from
q If piston (4) is pushed in further, ball (11) passage (d) and connected to the drain cham-
pushes up collar (12) supported on detent ber. Accordingly, the oil pressure in chamber
spring (13) and escapes out to go over projec- (E) is lost and the “FLOAT” state is reset.
tion (a) of the piston.
q At this time, piston (4') on the opposite side is
pushed up by spring (14).
q As a result, the oil in chamber (F) flows
through (b) and (c) to chamber (E) and piston
(4') follows disc (5). Since passage (d) is con-
nected to port (P1), almost the same pressure
is applied to passage (d) and port (P1).
q Chamber (E) is normally connected to drain
chamber (D). If ball (11) goes over projection
(a) of the piston, passage (d) and chamber (E)
are connected and the oil starts flowing.
q At this time, the control valve moves to the
“FLOAT” position and the blade is floated.
q Since piston (4') is pushed up by the pressure
in chamber (E), the “FLOAT” state is kept even
if the lever is released.
D475A, D475ASD-5E0 33
2. Ripper PPC valve
P : From self pressure reducing valve 1. Spool

P1 : To ripper tilt valve PPC port 2. Metering spring
P2 : To ripper tilt valve PPC port 3. Centering spring
P3 : To ripper lift valve PPC port 4. Piston
P4 : To ripper lift valve PPC port 5. Disc
T : To tank 6. Nut (For connecting lever)
7. Joint
8. Plate
9. Retainer
10. Body
11. Filter
34 D475A, D475ASD-5E0
Unit: mm

Free length
Centering spring x Outside Free length
12 length load load
(For ports P3 and P4) diameter
If spring is
55.9 N 44.7 N damaged or
50.4 x 15.5 34.0 —
{5.7 kg} {4.56 kg} deformed,
replace it
Centering spring 71.4 N 56.9 N
13 50.1 x 15.5 34.0 —
(For ports P1 and P2) {7.28 kg} {5.8 kg}
16.7 N 13.3 N
14 Metering spring 26.5 x 8.20 24.9 —
{1.70 kg} {1.36 kg}
D475A, D475ASD-5E0 35
Operation q Since metering spring (2) is compressed in

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

(Neutral o Fine control)
q If piston (4) is pushed by disc (5), retainer (9) is
pushed and spool (1) is also pushed down
through metering spring (2).
q Accordingly, fine control hole (f) is discon-
nected from drain chamber (D) and connected
to pump pressure chamber (PP) almost simul-
taneously, and then the pilot oil flows from port
(P1) through fine control hole (f) to port (A).
q If the pressure in port (P1) rises, spool (1) is
pushed back and fine control hole (f) is discon-
nected from pump pressure chamber (PP) and
connected to drain chamber (D) almost simul-
taneously to release the pressure in port (P1).
q As a result, spool (1) moves up and down to
balance the force of metering spring (2) with
the pressure in port (P1). The positional rela-
tionship between spool (1) and body (10)
[where fine control hole (f) is between drain
chamber (D) and pump pressure chamber
(PP)] does not change until retainer (9) comes
in contact with spool (1).
36 D475A, D475ASD-5E0
3) When in fine control 4) When lever is operated to stroke end

(When control lever is returned) q If disc (5) pushes down piston (4) and retainer
q If disc (5) begins to return, the force of center- (9) pushes down spool (1), fine control hole (f)
ing spring (3) and the pressure in port (P1) is disconnected from drain chamber (D) and
push up spool (1). connected to pump pressure chamber (PP).
q As a result, fine control hole (f) is connected to q Accordingly, the pilot oil flows through fine con-
drain chamber (D) and the oil in port (P1) is trol hole (f) and port (P1) into chamber (A) and
released. pushes the control valve spool.
q If the pressure in port (P1) lowers too much, q The oil returning from chamber (B) flows
spool (1) is pushed down by metering spring through port (P2) and fine control (f’) into drain
(2) and fine control hole (f) is disconnected chamber (D).
from drain chamber (D) and connected to
pump pressure chamber (PP) almost simulta-
neously. Then, the pump pressure is applied
until the pressure in port (P1) is restored to the
level corresponding to the position of the lever.
q When the control valve spool returns, the oil in
drain chamber (D) flows in through fine control
hole (f’) of the valve which is not in operation
and then flows through port (P2) into chamber
(B).
D475A, D475ASD-5E0 37
PCCS lever 1
Travel and steering PCCS lever
a Do not disassemble the PCCS lever. If it is disassembled, the output voltage characteristics and operat-
ing effort characteristics will need to be adjusted.
1. Bellows 5. Screw
2. Bracket 6. Lever
3. Plate 7. Connector
4. Bolt
38 D475A, D475ASD-5E0
Function
1. Operating effort characteristics
1) Operation for forward and reverse travel 2) Operation for steering
q The control lever is held at 3 positions of For- q Free return.
ward, Neutral, and Reverse.
D475A, D475ASD-5E0 39
2. Output voltage characteristics

q The control unit is installed to the left control
stand and the control lever is installed directly
onto it.
q The operating angle (stroke) of the control
lever is sensed with potentiometers and signal
voltages are output to the transmission and
steering controller.
q A potentiometer is installed in each of longitu-
dinal direction and lateral direction. Each
potentiometer outputs 2 signal voltages which
are opposite to each other as shown in the fig-
ure at right.
40 D475A, D475ASD-5E0
D475A, D475ASD-5E0 41
SEN00214-00

42
SEN00215-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up

Control valve ........................................................................................................................................ 2
CLSS.................................................................................................................................................. 17
Unload valve ...................................................................................................................................... 20
Introduction of LS pressure ................................................................................................................ 21
LS bypass plug................................................................................................................................... 22
Pressure compensation valve ............................................................................................................ 23
Blade lift valve .................................................................................................................................... 26
Merge-divider valve............................................................................................................................ 34
Self pressure reducing valve.............................................................................................................. 36
Pilot solenoid valve ............................................................................................................................ 40
D475A, D475ASD-5E0 1

Control valve 1
Outline
q This control valve consists of a 6-spool valve
and a merge-divider valve.
q Since the 6-spool valve and the merge-divider
valve are assembled into 1 unit by connecting
bolts and each passage is connected inside,
the whole unit is compact and easy to main-
tain.
A1 : To ripper lift cylinder head P10 : From blade tilt PPC valve
A2 : To blade tilt right cylinder head P11 : From ripper tilt PPC valve
A3 : To blade lift cylinder head P12 : From ripper tilt PPC valve
A4 : To blade lift cylinder head PLS1 : To rear pump control
A5 : To blade tilt left cylinder head PLS2 : To front pump control
A6 : To ripper tilt cylinder head PP1 : From rear main pump
B1 : To ripper lift cylinder bottom PP2 : From front main pump
B2 : To blade tilt right cylinder bottom PPS1: To rear pump control
B3 : To blade lift cylinder bottom PPS2: To front pump control
B4 : To blade lift cylinder bottom PR : To solenoid valve, PPC valve, and EPC valve
B5 : To blade tilt left cylinder bottom PS : From merge-divider solenoid valve
B6 : To ripper tilt cylinder bottom PST : From port PR
P1 : From ripper lift PPC valve SA : Pressure sensor mounting port
P2 : From ripper lift PPC valve SB : Pressure sensor mounting port
P3 : From blade tilt PPC valve T : To tank
P4 : From blade tilt PPC valve TS : To tank
P7 : From blade lift PPC valve
P8 : From blade lift PPC valve
P9 : From blade tilt PPC valve
1. 6-spool valve
2. Cover 1
3. Cover 2
4. Merge-divider valve
2 D475A, D475ASD-5E0
6-spool valve
(1/8)
D475A, D475ASD-5E0 3
(2/8)
4 D475A, D475ASD-5E0
(3/8)
1. Unload valve 8. Pressure compensation valve

2. Pressure compensation valve (on ripper lift bottom side)
(on ripper tilt head side) 9. Pressure compensation valve
3. Pressure compensation valve (on blade right tilt bottom side)
(on blade left tilt head side) 10. Pressure compensation valve
4. Pressure compensation valve (on blade lift bottom side)
(on blade lift head side) 11. Pressure compensation valve
5. Pressure compensation valve (on blade lift bottom side)
(on blade lift head side) 12. Pressure compensation valve
6. Pressure compensation valve (on blade left tilt bottom side)
(on blade right tilt head side) 13. Pressure compensation valve
7. Pressure compensation valve (on ripper tilt bottom side)
(on ripper lift head side) 14. Main relief valve
D475A, D475ASD-5E0 5
(4/8)
6 D475A, D475ASD-5E0
1. Spool (Ripper tilt)

2. Spool (Blade left tilt)
3. Spool (Blade lift)
4. Spool (Blade lift)
5. Spool (Blade right tilt)
6. Spool (Ripper lift)
7. Unload valve
8. Main relief valve
Unit: mm

Free length
x Outside Free length
9 Spool return spring length load load
diameter
393 N 315 N
54.5 x 34.8 51.2 —
{40.1 kg} {32.1 kg}
If spring is
377 N 301 N damaged or
10 Spool return spring 54 x 34.8 50.5 —
{38.4 kg} {30.7 kg} deformed,
replace it.
390 N 312 N
11 Spool return spring 69.9 x 34.8 65 —
{39.8 kg} {31.8 kg}
354 N 283 N
12 Spool return spring 72.3 x 37.0 65.5 —
{36.1 kg} {28.9 kg}
274 N 219 N
{27.9 kg} {22.3 kg}
D475A, D475ASD-5E0 7
(5/8)
8 D475A, D475ASD-5E0
1. Safety-suction valve (Blade left tilt head)

2. Safety-suction valve (Blade lift head)
Plug (Superdozer Spec.)
3. Safety-suction valve (Blade lift head)
4. Safety-suction valve (Blade right tilt head)
5. Suction valve (Ripper lift head)
6. Safety-suction valve (Ripper lift bottom)
7. Safety-suction valve (Blade right tilt bottom)
8. Safety valve (Blade lift bottom)
9. Safety valve (Blade lift bottom)
10. Safety-suction valve (Blade left tilt bottom)
11. LS shuttle valve (Arm and right travel)
12. LS shuttle valve (Boom, left travel, and bucket)
13. LS check valve
14. Pressure release plug
Unit: mm

Free length If spring is
x Outside Free length damaged or
15 Check valve spring length load load
diameter deformed,
replace it.
1.5 N 1.2 N
11.5 x 4.6 8.5 —
{0.15 kg} {0.12 kg}
D475A, D475ASD-5E0 9
(6/8)
10 D475A, D475ASD-5E0
1. Unload valve
Ripper tilt valve

3. Spool
4. Pressure compensation valve (Head)
5. LS shuttle valve
6. Pressure compensation valve (Bottom)
Blade left tilt valve

8. Spool
9. Pressure compensation valve (Head)
10. LS shuttle valve
11. Pressure compensation valve (Bottom)
Unit: mm

Free length If spring is
x Outside Free length damaged or
13 Piston return spring length load load
diameter deformed,
replace it.
29.4 N 23.5 N
36.9 x 11.1 28 —
{3 kg} {2.4 kg}
D475A, D475ASD-5E0 11
(7/8)
12 D475A, D475ASD-5E0
Blade lift valve

2. Spool
3. Pressure compensation valve (Right)
4. Pressure compensation valve (Left)
5. Suction valve
Blade lift valve

7. Spool
8. Pressure compensation valve (Raise)
9. LS shuttle valve
10. Pressure compensation valve (Lower)
11. Suction valve
12. Check valve for regeneration circuit
Blade right tilt valve

13. Suction valve
14. Spool
15. Pressure compensation valve (Reverse)
17. Pressure compensation valve (Forward)
18. Suction valve
Ripper lift valve

19. Suction valve
20. Spool
21. Pressure compensation valve (Curl)
23. Pressure compensation valve (Dump)
Unit: mm

Free length
x Outside Free length If spring is
25 Regeneration valve spring length load load
diameter damaged or
6.2 N 4.9 N deformed,
31.5 x 10.3 19.5 — replace it.
{0.6 kg} {0.5 kg}
29.4 N 23.5 N
26 Piston return spring 36.9 x 11.1 28 —
{3 kg} {2.4 kg}
D475A, D475ASD-5E0 13
(8/8)
14 D475A, D475ASD-5E0
1. Unload valve
3. Merge-divider valve (For main)
4. Spool return spring
5. Merge-divider valve (For LS)
6. Spool return spring
7. Valve (Sequence valve)
8. Spring (Sequence valve)
9. LS bypass plug
10. Spring (Safety valve)
11. Ball
12. Valve (Pressure reducing valve)
13. Spring (Main pressure reducing valve)
14. Spring (Pilot pressure reducing valve)
15. Poppet
16. Screw
17. Spring (Safety valve)
18. Ball
Unit: mm

Free length
x Outside Free length
19 Check valve spring length load load
diameter
1.5 N 1.2 N If spring is
11.5 x 4.6 8.5 —
{0.15 kg} {0.12 kg} damaged or
156.8 N 125.5 N deformed,
20 Spool return spring 46.6 x 21.8 33 — replace it.
{16.0 kg} {12.8 kg}
177.5 N 142.0 N
{18.1 kg} {14.5 kg}
199.8 N 160.0 N
22 Sequence valve spring 70.9 x 18 59 —
{20.4 kg} {16.3 kg}
D475A, D475ASD-5E0 15
Main relief valve
1. Spring
2. Poppet
Function
q The main relief valve sets the maximum pump
pressure of the main valve.
Operation
q The set pressure of the relief valve depends on
the installed load of spring (1).
16 D475A, D475ASD-5E0
CLSS 1
1. Outline of CLSS
Features Structure
CLSS stands for Closed center Load Sensing Sys- q The CLSS consists of a main pump (2 pumps),
tem, and has the following features. control valve, and actuators for the work equip-
q Fine control not influenced by load ment.
q Control enabling digging even with fine control q The work equipment pump body consists of
q Ease of compound operation ensured by flow the pump itself, CO valve and LS valve.
divider function using area of opening of spool
during compound operations
q Energy saving using variable pump control
D475A, D475ASD-5E0 17
2. Basic principle
1) Control of pump swash plate
q The pump swash plate angle (pump delivery q If LS differential pressure (dPLS) becomes
amount) is controlled so that LS differential lower than the set pressure of the LS valve
pressure (dPLS) [the difference between pump (when the actuator load pressure is high), the
pressure (PP) and control valve outlet port LS pump swash plate moves towards the maxi-
pressure (PLS)] (load pressure of actuator) is mum position; if it becomes higher than the set
constant. pressure of the LS valve (when the actuator
[LS pressure (dPLS) = Pump discharge pres- load pressure is low), the pump swash plate
sure (PP) – LS pressure (PLS)] moves towards the minimum position.
18 D475A, D475ASD-5E0
2) Pressure compensation
q A pressure compensation valve is installed to
the outlet port side of the control valve to bal-
ance the load.
q When two actuators are operated together, this
valve acts to make pressure difference (dP)
between the upstream (inlet port) and down-
stream (outlet port) of the spool of each valve
the same regardless of the size of the load
(pressure).
q In this way, the flow of oil from the pump is
divided (compensated) in proportion to the
area of openings (S1) and (S2) of each valve.
D475A, D475ASD-5E0 19
Unload valve 1
Function
q When the pump flow is merged and the control
valve group on one side is actuated (with the
remaining control valve group at neutral), the
sub-unload valve drains the pump flow to the
group that is at neutral.
Operation
q The pressure in pump passages (A) is
received at the end portion of valve (1). The
control valve is at neutral, so the pressure in
LS circuit (B) is 0 MPa {0 kg/cm2}.
q The pressurized oil in pump passage (A) is
stopped by valve (1) and cannot escape, so
the pr essur e r ises . When this pr essur e
becomes larger than the force of spring (2),
valve (1) moves to the left, ports (C) and (D)
are interconnected, and the pump pressure
flows to tank passsage (E). In addition, the
pressurized oil in LS circuit (B) passes from
orifice (f) through port (D) and is drained to
tank passage (E). Therefore, in this operation,
LS pressure C tank pressure.
q In this unload operation, pump discharge pres-
sure – LS circuit pressure is greater than the
pump LS control pressure, so a signal is sent
to set the pump swash plate to the minimum
angle.
20 D475A, D475ASD-5E0
Introduction of LS pressure 1
(LS shuttle valve)
1. Main pump 4. Check valve

2. Main spool 5. LS shuttle valve
3. Pressure compensation valve
Function Operation
q LS pressure (PLS) is the actuator load pres- q When main spool (2) is operated, pump dis-
sure at the output side of the control valve. charge pressure (PP) starts to flow to actuator
q The upstream pressure (= spool meter-in circuit (A).
downstream pressure) of pressure compensa- q First, this pump discharge pressure (PP)
tion valve (3) is taken inside main spool (2) and passes through introduction hole (a) of main
goes to LS shuttle valve (5). spool (2), and is taken to LS circuit (PLS).
q When this happens, it connects actuator circuit q When actuator circuit pressure (A) rises to the
(A) and LS circcuit (PLS) through check valve necessary pressure, pump pressure (PP) rises
(4), and sets so that LS pressure (PLS) C actu- and check valve (4) inside main spool (2)
ator load pressure. opens. The high pressure of LS circuit (PLS)
q Introduction hole (a) inside main spool (2) has then flows to actuator circuit (A).
a small diameter, so it also acts as a throttle. q In this way, LS pressure (PLS) becomes
almost the same as actuator circuit pressure
(A).
D475A, D475ASD-5E0 21
LS bypass plug 1
1. Main pump Function

2. Main spool q The residual pressure in LS circuit (PLS) is
3. Pressure compensation valve released from orifices (b) and (c).
4. LS shuttle valve q This reduces the speed of the rise in the LS
5. LS bypass plug pressure, and prevents any sudden change in
the oil pressure. Furthermore, a pressure loss
is generated by the circuit resistance between
LS shuttle valve (4) and throttle (a) of main
spool (2) according to the bypass flow from LS
bypass plug (5). As a result, the effective LS
differential pressure drops, and the dynamic
stability of the actuator is increased.
22 D475A, D475ASD-5E0
Pressure compensation valve 1

1. When the load pressure is higher than other actuators
1. Main pump Function

2. Valve q When the maximum load pressure is gener-
3. Shuttle valve ated during compound operations and during
4. Piston independent operations, and the load pressure
5. Spring is higher than other actuators, the pressure
6. LS shuttle valve compensation valve acts as a load check valve
to prevent reverse flow in the circuit.
Operation
q If pump pressure (PP) and LS pressure (PLS)
are lower than actuator circuit (B), shuttle valve
(3) inside the pressure compensation valve
moves to the left in the direction of the arrow to
interconnect spring chamber (C).
q When this happens, piston (4) is pushed to the
right by spring (5), so pump outlet circuit (A)
closes. This prevents the oil from flowing back
from actuator circuit (B) to pump outlet circuit
(A).
D475A, D475ASD-5E0 23
2. When the load pressure is lower than other actuators
Function Operation
q During compound operations, if the load pres- q During compound operations, if the load pres-
sure is lower than the other actuators and the sure for the other actuators rises, the oil flow in
flow of oil starts to increase, the pressure com- actuator circuit (B) tries to increase.
pensation valve carries out compensation. In q When this happens, LS pressure (PLS) for the
this case, it tries to make the load pressure for other actuator also increases, so this LS pres-
the other actuators greater and reduce the flow sure (PLS) pushes shuttle valve (3) of the
of oil. pressure compensation valve to the right in the
direction of the arrow, passes through the pas-
sage inside piston (4), and flows to spring
chamber (C).
q As a results, piston (4) is pushed to the right in
the direction of the arrow, and the outlet side of
pump circuit (PP) is closed, so outlet port pres-
sure (A) (spool meter-in downstream pressure)
becomes the same as the outlet port pressure
of the other actuators.
q Pump pressure (PP) (spool meter-in upstream
pressure) is the same between all actuators,
so pump pressure (PP) and outlet port pres-
sure (A) become the same between all spools
that are being operated. Therefore, the pump
flow is divided in proportion to the area of the
opening of each valve.
24 D475A, D475ASD-5E0
D475A, D475ASD-5E0 25
Blade lift valve 1

Function
q The blade lift valve supplies hydraulic oil to the
blade lift cylinder according to the 4 operations
of NEUTRAL, RAISE, LOWER, and FLOAT of
the blade lift PPC valve lever.
1. When blade lift lever is in NEUTRAL
26 D475A, D475ASD-5E0
Operation
q When the blade lift lever is in NEUTRAL, spool
(3) is held in the neutral position by springs (1)
and (6) through retainers (2) and (4).
q At this time, the oil does not flow in either of the
head and bottom of the blade lift cylinder.
D475A, D475ASD-5E0 27
2. When blade lift lever is set in RAISE position
28 D475A, D475ASD-5E0
Operation
q If the blade lift lever is set in the RAISE posi-
tion, the pilot pressure is applied through the
blade PPC valve to chamber (E) and spool (3)
moves to the left.
q The oil from the main pump flows through
notch (11) of spool (3) and cylinder port (A) to
the cylinder head.
q The oil returning from the cylinder bottom flows
through cylinder port (B) and notch (9) of spool
(3) to drain port (D).
D475A, D475ASD-5E0 29
3. When blade lift lever is set in LOWER position
30 D475A, D475ASD-5E0
Operation
q If the blade lift lever is set in the LOWER posi-
tion, the pilot pressure is applied through the
blade PPC valve to chamber (F) and spool (3)
moves to the right.
q If the blade lift lever is set to the LOWER
stroke end, retainer (4) moves to retainer (5)
and the load of spring (7) is added to the load
of spring (6) and spool (3) stops moving.
q At this time, the oil from the main pump flows
through notch (10) of spool (3) and cylinder
port (B) to the cylinder bottom.
q The oil returning from the cylinder head flows
through cylinder port (A) and notch (12) of
spool (3) to drain port (C).
D475A, D475ASD-5E0 31
4. When blade lift lever is set in FLOAT position
32 D475A, D475ASD-5E0
Operation
q If the blade lift lever is moved from the LOWER
position to the FLOAT position, the pilot pres-
sure is applied through the blade PPC valve to
chamber (F) and spool (3) moves further to the
right.
q At this time, retainer (5) moves against the
total load of springs (6) and (7) until its right
end touches plug (8).
q Since cylinder ports (A) and (B) are connected
to drain ports (C) and (D) respectively, both
head and bottom of the blade lift cylinder are
connected to the drain port and the blade is
“FLOATED”.
D475A, D475ASD-5E0 33
Merge-divider valve 1
1. Main spool Operation

2. Spring 1. When oils from pumps are merged
3. LS spool (When pilot pressure (PS) is turned OFF)
4. Spring q Since pilot pressure (PS) is turned OFF, main
spool (1) is pressed to the left by spring (2) and
Function ports (E) and (F) are connected.
q The merge-divider valve merges or divides oils q Accordingly, oils (PP1) and (PP2) discharged
(PP1) and (PP2) discharged from 2 pumps (It from the 2 pumps are merged in ports (E) and
distributes those oils to each control valve (F) and sent to the control valves which need
group). them.
q This valve also merges and divides the LS cir- q Similarly, LS spool (3) is pressed to the left by
cuit pressures. spring (4) and the connection of the LS circuit
changes as follows.
Connection of circuit:
(A) is connected to (D).
(B) is connected to (C).
q As a result, the LS pressure transmitted from
each control valve spool to LS circuit ports (A),
(D), (B), and (C) is transmitted to all the pres-
sure compensation valves and other hydraulic
equipment.
34 D475A, D475ASD-5E0
2. When oils from pumps are divided

(When pilot pressure (PS) is turned ON)
q When pilot pressure (PS) is turned ON, main
spool (1) is pressed to the right by the (PS)
pressure and ports (E) and (F) are discon-
nected.
q Accordingly, oils discharged from the 2 pumps
are sent to the set control valves respectively.
Pressure (PP1): Blade right tilt valve
Pressure (PP2): Blade left tilt valve
q Similarly, LS spool (3) is pressed to the right by
the (PS) pressure and the connection of the LS
circuit changes as follows.
Connection of circuit:
(B) is connected to (D).
The other ports are disconnected.
q As a result, the pressures in LS circuit ports
(A), (B), (C), and (D) are transmitted to the set
control valves respectively.
D475A, D475ASD-5E0 35
Self pressure reducing valve 1
Function q Poppet (11) is pressed by spring (12) against

q The self pressure reducing valve lowers the the seat and the passage between port (PR)
discharge pressure of the main pump and sup- and (TS) is closed.
plies it as the control pressure for the solenoid q Valve (14) is pressed to the left by spring (13)
valves, PPC valves, etc. and the passage between ports (P2) and (PR)
is open.
Operation q Valve (7) is pressed to the left by spring (8) and
1. When engine is stopped the passage between ports (P2) and (A2) is
closed.
36 D475A, D475ASD-5E0
2. When in neutral and when load pressure (P2) is low

[When load pressure (A2) is lower than self pressure reducing valve output pressure (PR)]
Operation
q Valve (7) is pressed by spring (8) and (PR) q Accordingly, differential pressure is generated
pressure (which is 0 MPa {0 kg/cm2} while the over orifice (a) in spool (14), and spool (14)
engine is stopped) to close the passage moves in the direction to close the passage
between ports (P2) and (A2). If hydraulic oil between ports (P2) and (PR). The P2 pressure
flows in through port (P2), however, (ød area x is lowered and controlled to a constant pres-
pressure P2) = force of spring (8) + (ød area x sure (set pressure) by the opening ratio of the
PR pressure), and they are balanced. Then, passage at this time and supplied as the PR
the passage between ports (P2) and (A2) is so pressure.
adjusted that the P2 pressure will be kept at a
certain value higher than the PR pressure.
q If the PR pressure rises higher than the set
level, poppet (11) opens and the hydraulic oil
flows from port (PR) through orifice (a) in spool
(14) and opening of poppet (11) into seal drain
port (TS).
D475A, D475ASD-5E0 37
3. When load pressure (P2) is high
Operation
q If load pressure (A2) is heightened and the q Accordingly, differential pressure is generated
pump delivery amount is increased because of over orifice (a) in spool (14) and spool (14)
digging operation, etc., the P2 pressure rises moves in the direction to close the passage
{(ød area × P2 pressure) > force of spring (8) + between ports (P2) and (PR). The P2 pressure
(ød area × PR pressure)}, then valve (7) is lowered and controlled to a constant pres-
moves to the right stroke end. sure (set pressure) by the opening ratio of the
q As a result, the opening ratio of the passage passage at this time and supplied as the PR
between ports (P2) and (A2) is increased and pressure.
the passage resistance is reduced. Conse-
quently, the loss of the engine horsepower is
reduced.
q If the PR pressure rises higher than the set
level, poppet (11) opens and the hydraulic oil
flows from port (PR) through orifice (a) in spool
(14) and opening of poppet (11) into seal drain
port (TS).
38 D475A, D475ASD-5E0
4. When abnormally high pressure is generated
Operation
q If the PR pressure of the self pressure reduc-
ing valve is raised abnormally, ball (16) sepa-
rates from the seat against the force of spring
(15). As a result, the hydraulic oil flows from
output port (PR) to (TS) and the PR pressure
lowers. Accordingly, the devices receiving the
oil pressure (PPC valves, solenoid valves, etc.)
are protected from abnormally high pressure.
D475A, D475ASD-5E0 39
Pilot solenoid valve 1
PPB : Rear pitch solenoid

PPD : Forward pitch solenoid
TLL : Left tilt limit solenoid
TLR : Right tilt limit solenoid
PTH : Pitch changeover solenoid
DUL : Dual changeover solenoid
PPV : Pitch priority solenoid
MFD: Merge-divider solenoid
40 D475A, D475ASD-5E0
q The operation of the pilot solenoid valve is shown in the following table.
Solenoid drive table (Dual tilt specification)

PPB PPD TLL TLR PTH DUL PPV MFD
Raise
Lift
Lower
Left tilt
Single tilt
Right tilt
Left tilt q q
Blade
Left tilt limit q q q
Dual tilt
Right tilt q q
Right tilt limit q q q
Rear pitch q q
Pitch
Forward pitch q q
Raise
Lift
Lower
Ripper
Raise
Tilt
Lower
Solenoid drive table (Superdozer specification)

PPB PPD TLL TLR PTH DUL PPV MFD
Raise
Lift
Lower
Left tilt
Left tilt limit q
Blade Single tilt
Right tilt
Right tilt limit q
Rear pitch q q q q
Pitch
Forward pitch q q q q
Raise
Lift
Lower
Ripper
Raise
Tilt
Lower
D475A, D475ASD-5E0 41
SEN00215-00

42
SEN00216-00

2SHOP
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up

Hydraulic tank, hydraulic filter .............................................................................................................. 2
Accumulator ......................................................................................................................................... 4
Work equipment cylinder...................................................................................................................... 6
Piston valve.......................................................................................................................................... 8
Quick drop valve ................................................................................................................................ 10
Blade control knob (Dual tilt specification) ......................................................................................... 12
Blade control knob (Superdozer specification)................................................................................... 13
Pitch and dual solenoid valve............................................................................................................. 14
Pin puller hydraulic circuit diagram .................................................................................................... 15
Pin puller solenoid valve .................................................................................................................... 16
D475A, D475ASD-5E0 1

Hydraulic tank, hydraulic filter 1
1. Pressure valve 6. Oil filler cap

2. Cover 7. Hydraulic filter element
3. Sight gauge 8. Spring
4. Cover 9. Suction valve
5. Hydraulic tank 10. Strainer
11. Drain plug
12. Drain valve
2 D475A, D475ASD-5E0
Specified value
Tank capacity (l) 310
Hydraulic High (l) 210

tank Level inside
Center (l) 170
tank
Low (l) 140
Cracking pressure 38.2 ± 6.9
(kPa {kg/cm2}) {0.39 ± 0.07}
Breather
cap Vacuum valve
0 – 0.49
actuating pressure
{0 – 0.005 }
(kPa {kg/cm2})
Specified value
Cracking pressure 150 ± 30
(kPa {kg/cm2}) {1.53 ± 0.3}
Hydraulic Mesh size (µm) 30/8
filter
Filtering area (cm )
2
17,600
Filtering oil flow (l/min) 703
Mesh size (µm) 105
Strainer 2
Filtering area (cm ) 3,600
D475A, D475ASD-5E0 3
Accumulator 1
For PPC valve Operation
q After the engine is stopped, when the PPC
valve is at neutral, chamber (A) inside the blad-
der is compressed by the oil pressure in cham-
ber (B).
q When the PPC valve is operated, the oil pres-
sure in chamber (B) goes below 2.9 MPa {30
kg/cm2}, and the pressure of the nitrogen gas
in chamber (A) expands the bladder, so the oil
in chamber (B) acts as the pilot pressure and
actuates the main control valve.
1. Glass plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications:
Type of gas:Nitrogen
Gas volume:300 cc
Max. actuation pressure:3.1 MPa {32 kg/cm2}
Min. actuation pressure: 1.2 MPa {12 kg/cm2}
Function
q The accumulator is installed between the pres-
sure reducing valve and the PPC valve. Even if
the engine is stopped with the work equipment
still raised, the pressure of the nitrogen gas
compressed inside the accumulator sends the
pilot pressure to the main control valve to actu-
ate it and enable the work equipment to move
down under its own weight.
4 D475A, D475ASD-5E0
D475A, D475ASD-5E0 5
Work equipment cylinder 1

q Blade lift cylinder
q Blade tilt cylinder, superdozer pitch cylinder
q Ripper lift cylinder, ripper tilt cylinder
6 D475A, D475ASD-5E0
q Pin puller cylinder
Unit: mm

size Shaft Hole clearance limit
–0.036 +0.261 0.083 –

Blade lift 110 0.65
–0.090 +0.047 0.351
–0.043 +0.263 0.090 –
Clearance Blade tilt 140 0.67
–0.106 +0.047 0.369
1 between piston
rod and bushing –0.036 +0.263 0.084 –
Ripper lift 120 0.65
–0.090 +0.048 0.353
–0.043 +0.263 0.090 –
Ripper tilt 140 0.67
–0.106 +0.047 0.369
–0.065 +0.133 0.072 –
Pin puller 30 0.55
–0.117 +0.007 0.250
+0.5
Blade lift 65 — — 1.0
+0.2
–0.300 +0.100 0.200 –
Blade tilt 90 1.0
–0.200 +0.013 0.400
Clearance
between piston +0.207 Replace
2 Ripper lift 110 1.0
rod support shaft +0.120
and bushing
+0.207
Ripper tilt 110 1.0
+0.120
Ball –0.100
Pin puller
29 –0.200
Clearance
between cylinder –0.145
3 Blade lift 145
support shaft –0.245
bushing and yoke
+0.457
Blade tilt 90 — — 1.0
+0.370
Clearance
between cylinder +0.207
4 Ripper lift 110 1.0
bottom support +0.120
shaft and bushing
+0.195
Ripper tilt 110 1.0
+0.122
Clearance between cylinder
5 26 +0.1
bottom support shaft and boss
D475A, D475ASD-5E0 7
Piston valve 1
For blade lift cylinder
Outline 2. When piston valve is “open”

q The piston valve is installed to the piston of the The end of valve (6) touches the cylinder bot-
blade lift cylinder. When the piston moves to tom before piston rod (1) reaches the stroke
the stroke end, the piston valve relieves the oil end, and then valve (6) and piston valve (3) do
sent from the work equipment pump to lower not move any more and only piston (2) contin-
the oil pressure applied to the piston. ues moving.
The piston valve also relieves the oil before the At this time, the oil on the cylinder head side
piston reaches the bottom or head of the cylin- which has been stopped by piston valve (3) is
der to reduce the impact made at the stroke relieved through piston valve seats (4) and (5),
end and lower the surge pressure generated thus the oil pressure in the cylinder does not
by the impact. rise any more.
Operation
1. When piston valve is “closed”
The oil from the work equipment pump acts on
piston (2) and piston valve (3).
Then, piston valve (3) is pushed to the right to
seal the tapered part of piston valve seat (4).
As a result, the oil pressure in the cylinder
rises to move piston (2) to the right.
8 D475A, D475ASD-5E0
D475A, D475ASD-5E0 9
Quick drop valve 1

For blade lift cylinder 2. While lowering blade
The oil pushed out of the cylinder head side
Outline flows through port (B) to port (C).
The quick drop valve is installed to each of the right At this time, a pressure difference is made
and left blade lift cylinders. It increases the lowering between before and after orifice (a).
speed of the blade and prevents a vacuum on the If the pressure difference becomes larger than
cylinder bottom side during the lowering stroke and the tension of spring (4), it compresses the
shortens the time lag in starting digging. The blade spring and moves spool (2) and check valve
lowering speed is almost determined by the pump (3) to the right.
delivery amount. It can be heightened, however, by Then, ports (B) and (A) are connected and a
the quick drop valve. part of the oil which has been flowing from the
head side to port (C) flows in port (A) on the
bottom side and merges with the oil from the
control valve and flows into the bottom side.
Accordingly, the blade lowering speed is
increased by the quantity of the oil flowing into
the cylinder bottom side and a vacuum on the
bottom side is prevented.
1. Valve body 3. Check valve

2. Spool 4. Spring
Operation
1. Start of lowering blade
If the blade control lever is set in the LOWER
position, the oil from the control valve flows
through port (A) to the cylinder bottom side and
pushes the piston.
The oil on the cylinder head side is pushed out
by the piston into port (B), and then flows
through port (C) and control valve to the
hydraulic tank.
10 D475A, D475ASD-5E0
Unit: mm

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

2 Valve spring length load load
136.3 N 122.6 N
75.2 55.9 67.7
{13.9 kg} {12.5 kg}
D475A, D475ASD-5E0 11
Blade control knob (Dual tilt specification) 1
1. Switch (dual-single selector switch) q If switch (2) is pressed and the lever is oper-
2. Switch (pitch) ated, the blade is pitched. If the lever is tilted to
3. Cover the left, the blade is pitched back. If the former
4. Connector (male) is tilted to the right, the latter is pitched for-
5. Connector (female) ward.
q If switch (1) is set to the “DUAL” position and
Outline the lever is operated, blade carries out dual tilt
q If the blade control knob is tilted forward, back- operation. If the lever is tilted to the left, the
ward, to the right, or to the left, the blade is blade carries out left dual tilt operation. If the
raised, lowered, tilted to the right, or tilted to the lever is tilted to the right, the blade carries out
left. If switch (1) is set to the “DUAL” position right dual tilt operation.
and the lever is tilted to the right or left, dual tilt q If switch (1) is set in either “DUAL” or
operation is carried out. If the lever is tilted to “SINGLE” position and the lever is tilted to the
the right or left while switch (2) is pressed and right or left while switch (2) is pressed and
held, pitching operation is carried out. held, the blade is pitched.
12 D475A, D475ASD-5E0
Blade control knob (Superdozer specification) 1
1. Forward pitch switch Outline

2. Rear pitch switch q The blade is raised and lowered by leaning the
3. Cover blade control knob forward and backward.
4. Connector (male) q If switch (1) is pressed, the blade is pitched for-
5. Connector (female) ward. If switch (2) is pressed, the blade is
pitched back.
D475A, D475ASD-5E0 13
Pitch and dual solenoid valve 1
1. Connector Outline
2. Solenoid (a) q The pitch and dual solenoid valve is installed
3. Valve between the PPC valve and main control valve
4. Solenoid (b) and used to select the PPC pilot pressure.
5. Manual push pin q Operation of the pitch switch of the blade con-
trol lever (or the rear pitch switch or forward
A: Port A pitch switch of the superdozer specification),
B: Port B pilot pressure can be applied so the right and
P: Port P left pitch cylinders will move similarly and the
T: Port T tilt operation can be changed to the pitch oper-
ation.
q If the dual tilt specification is installed and the
toggle switch of the blade control lever is set in
the "dual" position, the pilot pressure is applied
to both right and left tilt cylinder spools to
change the single tilt operation to the dual tilt
operation.
q The pitch and dual tilt solenoid valve is oper-
ated by the controller.
14 D475A, D475ASD-5E0
Pin puller hydraulic circuit diagram 1
1. Power train oil tank 8. Pin-puller cylinder

2. Oil strainer 9. Steering case
3. Power train pump 10. Scavenging pump
4. Oil filter
5. Main relief valve A: To transmission lubrication circuit
(Set pressure: 2.45 MPa {25 kg/cm2}) B: To torque converter circuit
6. Steering control valve C: To transmission valve circuit and torque
7. Pin-puller solenoid valve converter lockup circuit
D475A, D475ASD-5E0 15
Pin puller solenoid valve 1
1. Plug A. To pin puller cylinder head

2. Spring B. From power train pump
3. Spring retainer C. To pin puller cylinder bottom
4. Valve body D. To steering case
5. Spool
6. Spring retainer
7. Spring
8. Push pin
9. Solenoid assembly
16 D475A, D475ASD-5E0
Operation
1. Pin puller switch at PUSH IN position 2. Pin-puller switch at PULL OUT position
When the pin-puller switch is turned to the When the pin puller switch is turned to the
PUSH IN position, no current flows to solenoid PULL OUT position, current flows to solenoid
(9) and it is deactivated. (9) and it is excited.
When this happens, spool (5) opens ports (A) When this happens, the solenoid pushes out
and (B) and ports (C) and (D), and the oil from push pin (8), and spool (5) moves to the left in
the power train pump flows from port (A) to the direction of the arrow.
port (B) and enters the bottom of pin puller cyl- Ports (A) and (B) and ports (C) and (D) close,
inder (10). and ports (A) and (C) and ports (B) and (D)
The oil entering the bottom end of the cylinder open. The oil from the power train pump flows
increases the hydraulic pressure in the circuit from port (A) to port (C) and enters the head of
and extends the cylinder. Shank mounting pin pin puller cylinder (10).
(11) is pushed into shank (12). The oil entering the head end of the cylinder
increases the hydraulic pressure in the circuit
and retracts the cylinder. Shank mounting pin
(11) is pulled out of shank (12).
D475A, D475ASD-5E0 17
SEN00216-00

18
SEN00217-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up

Work equipment
Work equipment .............................................................................................................................................. 2
Cylinder stay ........................................................................................................................................ 2
Blade .................................................................................................................................................... 4
Ripper equipment................................................................................................................................. 8
D475A, D475ASD-5E0 1
Work equipment 1
Cylinder stay 1
Unit: mm

Clearance between cylinder size Shaft Hole clearance limit
1
yoke and bushing
–0.050 +0.167 0.145 –
210 0.5
–0.122 +0.005 0.289
Replace
Clearance between cylinder –0.043 +0.192 0.172 –
2 160 0.5
yoke and bushing –0.106 +0.129 0.298
Clearance between lift cylinder –0.145 +0.040 0.145 –
3 145 0.5
supporting shaft and bushing –0.245 +0.016 0.285
2 D475A, D475ASD-5E0
D475A, D475ASD-5E0 3
Blade 1
Full U-dozer, Semi U-dozer, Superdozer
Unit: mm
4 D475A, D475ASD-5E0

Clearance between brace pin size Shaft Hole clearance limit
1
and brace
–0.2 +0.3
90 0.3 – 0.6 2
–0.3 +0.1
Clearance between brace pin –0.2 +0.3 Replace
2 90 0.3 – 0.6 2
and bracket –0.3 +0.1
Clearance between brace pin –0.3 +0.1
3 90 0.3 – 0.5 1
and bracket –0.4 +0.6
Clearance between brace pin –0.3 +0.1
4 90 0.3 – 0.5 1
and bushing –0.4 +0.6
Clearance between center
–0.2 +0.3 Adjust shim
5 brace and cap spherical 200 0.2 – 0.6 1
–0.3 +0.6 or replace
surface
Clearance between joint and –0.2 +1.5
6 240 1.2 – 1.9 3
bracket –0.4 +1.0
Clearance between frame pin –0.3 +0.3
7 120 0.3 – 0.8 3
and joint –0.5 +0.6
Clearance between frame pin –0.3 +0.207 0.420 –
8 120 2
and bracket –0.5 +0.120 0.707
Clearance between straight +0.206 –0.014 –0.152 –
9 185 —
frame joint bushings +0.166 –0.060 –0.266
Clearance between trunnion –0.5 +1.0
10 250 0.5 – 2.0 8
and cap spherical surface –1.0 +0.6
Clearance between joint and –0.2 +0.3
11 240 0.3 – 0.7 3 Replace
bracket –0.4 +0.1
Clearance between blade pin –0.3 +0.3
12 120 0.3 – 0.8 3
and joint –0.5 +0.6
Clearance between blade pin –0.3 +0.208 0.418 –
13 120 2
and bracket –0.5 +0.118 0.708
Clearance between center –0.043 +0.225 0.149 –
14 145 2
link pin and blade bracket –0.108 +0.106 0.333
Clearance between center –0.043 +0.225 0.149 –
15 145 2
link pin and center link –0.108 +0.106 0.333
Clearance between center –0.2 +0.3
16 550 0.2 – 1.1 2
link and blade bracket –0.8 +0.6
Clearance between center –0.2 +0.3 Adjust shim
17 200 0.2 – 0.6 1
brace spherical surface and cap –0.3 +0.6 or replace
Clearance between lift –0.3 +0.5
18 65 0.5 – 1.0 2
cylinder head pin and cylinder –0.5 +0.2
Clearance between lift cylinder –0.3 +0.3
19 65 0.3 – 0.8 2
head pin and cross joint –0.5 +0.6
Replace
Clearance between bracket –0.3 +0.3
20 65 0.3 – 0.8 2
and lateral pin –0.5 +0.6
Clearance between cross –0.3 +0.5
21 65 0.5 – 1.0 2
joint and lateral pin –0.5 +0.2
D475A, D475ASD-5E0 5
Cutting edge, end bit
Unit: mm

1 Height of end bit outside
510 383
Replace
2 Width of end bit 720 635
3 Height of end bit inside 393 330
Replace or
4 Height of cutting edge 405 351 (240 after turned)
turn
6 D475A, D475ASD-5E0
D475A, D475ASD-5E0 7
Ripper equipment 1
Variable giant ripper
8 D475A, D475ASD-5E0
Unit: mm

Clearance between bushing size clearance limit
Shaft Hole
1 and bracket and arm mount
pin –0.043 +0.193 0.093 –
140 1.5
–0.106 +0.050 0.299
Clearance between bushing –0.043 +0.500 0.343 –
2 140 1.5
and beam and arm mount pin –0.106 +0.300 0.606
Clearance between cylinder –0.036 +0.289 0.159 – Replace
3 110 1.5
mount pin and bushing –0.090 +0.123 0.379
Outside diameter of shank Standard size Tolerance Repair limit

4
mount pin 100 ±0.3 —
5 Wear of point
460 300
6 Wear of protector 224 184
D475A, D475ASD-5E0 9
SEN00217-00
D475A, D475ASD-5 Bulldozer

10
SEN00218-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up

Cab and its attachments
Cab and its attachments ................................................................................................................................. 2
Cab mount............................................................................................................................................ 2
Cab....................................................................................................................................................... 3
Air conditioner ...................................................................................................................................... 6
D475A, D475ASD-5E0 1
Cab and its attachments 1

Cab mount 1
1. Support Outline
2. Damper mount (front) q Mounts are installed at two places at the front
3. Damper mount (rear) and two places at the rear to secure the floor
frame and cab.
q An oil-filled damper mount is used to absorb
the vibration.
2 D475A, D475ASD-5E0
Cab 1
Cab assembly
1. Front wiper
2. Front glass
3. Rear wiper
4. Door
D475A, D475ASD-5E0 3
ROPS guard
1. ROPS guard
4 D475A, D475ASD-5E0
D475A, D475ASD-5E0 5
Air conditioner 1
Air conditioner piping
6 D475A, D475ASD-5E0
1. Condenser
2. Air conditioner compressor
3. Refrigerant piping
4. Window defroster
5. Side defroster
6. Vent
7. Hot water pickup piping
8. Valve (hot water outlet)
9. Receiver tank
10. Hot water return piping
11. Valve (hot water inlet)
12. Air conditioner unit
13. Additional blower motor
A. Fresh air
B. Recirculated air
C. Hot air/cold air
D475A, D475ASD-5E0 7
SEN00218-00

8
SEN00219-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up

Electrical system
Electrical system ............................................................................................................................................. 2
Engine control ...................................................................................................................................... 2
Engine control system.......................................................................................................................... 3
Deceleration potentiometer .................................................................................................................. 4
CRI engine control system ................................................................................................................... 6
Monitor system..................................................................................................................................... 8
Monitor panel ......................................................................................................................................11
Sensors .............................................................................................................................................. 15
Mode selection system....................................................................................................................... 18
Electrical equipment........................................................................................................................... 24
Steering electronic control system ..................................................................................................... 27
VHMS controller ................................................................................................................................. 29
Communication (ORB: ORBCOMM) controller/antenna .................................................................... 35
D475A, D475ASD-5E0 1
Electrical system 1
Engine control 1
1. Battery relay (Right) Outline

2. Steering controller Engine control is carried out in the following two
3. Battery (Right) systems.
4. Transmission controller 1. When the fuel control dial and decelerator
5. Engine throttle controller pedal are operated, it controls the fuel injection
6. Decelerator pedal pump with an electric signal.
7. Starting switch 2. When mode selection system is actuated.
8. Decelerator pedal potentiometer 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 supply pump The electronic engine throttle controller con-
trols the fuel supply pump according to the
command.
This machine uses CRI system.
2 D475A, D475ASD-5E0
Engine control system 1
Outline
q The engine throttle controller receives the q The steering controller sends the most suitable
manual signals of the 1st throttle, 2nd throttle for engine speed from informations 1) and 2)
and the 3rd throttle signals which is the control and transmits it as the 3rd throttle to the engine
signals from the machine body, then selects throttle controller.
the lower engine speed and controls the fuel q Information of the engine throttle controller is
supply pump. commonly used by all the controllers through-
The 3rd throttle control signals contain the fol- out the network, for optimum control of the
lowing. engine and machine body.
1) High idle speed control q The automatic deceleration function sets the
2) SSC (Shoe Slip Control) engine speed to 1,000 rpm temporarily when
3) Automatic deceleration (F3, R3, R2) the travel direction is changed from F3, R3, or
R2 (to protect the transmission clutch).
D475A, D475ASD-5E0 3
Deceleration potentiometer 1
1. Connector Outline
2. Lever q The deceleration potentiometer is installed to
3. Body the front lower part of the operator’s cab and
4. Potentiometer connected to the decelerator pedal by linkage.
5. Coupling q If the decelerator pedal is pressed, the throttle
6. Shaft potentiometer shaft rotates by the linkage and
7. Stopper the potentiometer resistance changes.
Constant voltage is applied between pins (A)
and (C) of the potentiometer and an electric
signal is sent through pin (B) to the engine
throttle controller according to the position of
the decelerator pedal.
4 D475A, D475ASD-5E0
D475A, D475ASD-5E0 5
CRI engine control system 1

a CRI: Abbreviation for Common Rail Injection.
System diagram
Outline
q The signals detected by various sensors are
input to the engine throttle controller.
q The input signals are processed by the control-
ler and output to each actuator to control the
fuel injection rate and fuel injection timing.
6 D475A, D475ASD-5E0
1. Fuel tank System configuration

2. Fuel supply pump assembly q The CRI system consists of the fuel supply
2A. PCV pump (2), common rail (5), injector (8), engine
2B. High pressure pump throttle controller (9) to control them, and sen-
2C. Priming pump sors.
2D. Feed pump q The fuel supply pump generates fuel pressure
2E. Bypass valve in the common rail. The fuel pressure is con-
2F. G speed sensor trolled by the fuel discharge rate of the supply
3. Fuel filter pump.
4. Overflow valve The discharge rate is controlled by turning on
5. Common rail and off PCV (discharge control valve) (2A) of
6. Pressure limiter the fuel supply pump according to the electric
7. Flow damper signals from the engine throttle controller.
8. Injector assembly The common rail receives the pressurized fuel
8A. Orifice from the fuel supply pump and distributes it to
8B. Control chamber the cylinders.
8C. Hydraulic piston The fuel pressure is sensed by the common
8D. Injector rail fuel pressure sensor installed to the com-
8E. Nozzle mon rail and controlled by the feedback
9. Engine throttle controller method so that the actual fuel pressure will
10. NE speed sensor match to the command pressure set according
to the engine speed and the load on the
engine.
The fuel pressure in the common rail is applied
to nozzle (8E) side of the injector and control
chamber (8B) through the fuel injection pipe of
each cylinder.
q The injector controls the fuel injection rate and
fuel injection timing by turning on and off the
TWV (2-way solenoid valve). If the TWV is
turned on, the fuel circuit is so changed that
the high-pressure fuel in the control chamber
will flow through orifice (8A). The needle valve
is raised to start fuel injection by the nozzle
cracking pressure applied as the high-pressure
fuel on the nozzle side. If the TWV is turned
off, the fuel circuit is so changed that the high-
pressure fuel will be applied to the control
chamber through the orifice. As a result, the
needle valve lowers and finishes fuel injection.
Accordingly, the fuel injection timing and fuel
injection rate are controlled respectively by the
timing to turn on the TWV and the length of the
turn-on time of the TWV.
D475A, D475ASD-5E0 7
Monitor system 1
q The monitor system monitors the machine con- q In the monitor panel, there are various mode
dition with sensors installed to various parts of selector switches of the SSC (Shoe Slip Con-
the machine, and quickly processes and dis- trol), which are used to operate the machine
plays obtained information on the monitor control system (with SSC).
panel, to notify the operator of machine condi- q The monitor panel has the functions of display-
tion. ing data and selecting the SSC mode (with
The function of the monitor system is as fol- SSC).
lows. q The CPU (Central Processing Unit) in it pro-
1) Function which turns on the alarm when cesses, displays, and outputs the information.
the machine has a trouble on the monitor. The display unit is LCD (Liquid Crystal Display)
2) Function which constantly displays the and the switches are seat switches.
machine condition (coolant temperature,
torque converter oil temperature, fuel
level, hydraulic oil level, etc.) on the
gauge.
3) Function of displaying error codes.
4) Function of monitoring the current and
voltage of the sensors and solenoids.
8 D475A, D475ASD-5E0
Processing in monitor panel (Common to all specifications)

Display of monitor panel
1. Contents and conditions of processing 2. Method 3. Flow of signals
1) Display of travel direction and gear speed. Transmission controller o Steering
F1, R3, etc. are notified by CAN according to CAN controller o Monitor panel
information of transmission controller. (Controller
Area Network)
2) Display of engine speed in gauge number. CAN Engine speed sensor o Steering
The number of pulses the engine rotation is controller o Monitor panel
converted into a gauge number and notified to the
monitor panel by CAN.
3) Display of failure
When the machine has a failure, the corresponding CAN Engine sensor/solenoid o Steering
failure code is notified to the monitor panel by CAN. controller or transmission controller
Which one should be turned on, the buzzer or the o Monitor panel
caution lamp, is notified, too.
i) In normal state
User code
ii) In fault history display mode Sensors and solenoids o Engine
The service code (6-digit code) and the throttle controller o Steering
following items are displayed controller o Monitor panel
1. Time after first occurrence
2. Time after latest occurrence
3. Number of past occurrence
The monitor panel displays code on the hour meter
section.
Display of monitoring conditon

1) The communication conditions of each sensor, CAN Each sensor o Steering controller
each solenoid, and CAN are displayed. or transmission controller o Monitor
The item Nos. and device conditions are notified to panel
the monitor panel by CAN.
The monitor panel displays the items and each Sensors o Engine throttle controller
value on its multi-information section. o Steering controller o Monitor
panel
2) Each items is selected by using the cursor
switches, selector switches, buzzer cancel switch, Monitor panel o Controller o
and shift UP/DOWN switches. Monitor panel
Other items
1) Function selection mode (Displayed each time CAN Steeging controller o Monitor panel
cancel switch is turned to left)
i) Replacement periods of oil filter and oil are
displayed.
ii) Engine speed, oil pressure in work equipment
circuit, etc. are displayed.
iii) Failure codes related to electronic control are
displayed.
iv) Brightness of display, etc. are adjusted.
2) Mode to change replacement periods of
maintenance mode
3) Mode to display failure codes related to the
machine such as overheating, abnormal coolant
temperature, etc.
4) Mode to display service meter and information
related to load on machine
D475A, D475ASD-5E0 9
10 D475A, D475ASD-5E0
Monitor panel 1
Monitor portion
1. Engine coolant temperature gauge 14. Engine preheating pilot lamp

2. Power train oil temperature gauge 15. Maintenance caution lamp
3. Hydraulic oil temperature gauge 16. Warming lamp
4. Fuel gauge 17. Filter, oil change interval lamp
5. Radiator coolant level check lamp 18. Display panel A (Speed range, Engine speed)
6. Hydraulic oil level check lamp 19. Display panel B (Multi-information)
7. Engine oil level check lamp 20. Dual/single tilt selector display lamp
8. Charge level monitor 21. Lockup mode switch
9. Engine oil pressure caution lamp 22. Economy mode selector switch
10. Engine coolant temperature caution lamp 23. Reverse slow mode selector switch
11. Power train oil temperature caution lamp 24. Shoe slip selection mode switch (with SSC)
12. Hydraulic oil temperature caution lamp 25. Rock selection mode selector switch (with SSC)
13. Air cleaner clogging caution lamp 26. Fan operation confirmation lamp
Outline 2. Start-up inspection

q The monitor potion consists of a monitor that 1) After all lighting of Section 1 is terminated,
issues an alarm when an error occurred in a if there is an error in a start-up inspection
vehicle, a gauge that always displays the state item, the item flashes.
of the vehicle, and the service meter. 2) If the engine is started, the check items
The monitor portion installs a microcomputer before starting go off. (If the engine run-
and processes and displays signals from each ning is judged by the signal (CAN) from
sensor. the engine controller.)
Besides, the items displayed on the monitor 3. Cautions
portion and gauge portion are listed in the table Caution items are checked until the engine
on the next page. stops after the engine starts.
If an error occurs, the error is displayed by
Operation flashing and the alarm lamp synchronously
1. When the power turns on (When the start- flashes.
ing switch is ON) Further, if an emergency item flashes, the
1) All items of the gauge and monitor por- alarm buzzer also sounds synchronously.
tions come on for three seconds. a Flashing of the monitor and alarm lamp is
2) The alarm lamp comes on for two sec- repeated. They come on and off for about 0.8
onds. second.
a The flashing period of the monitor slightly
changes when atmospheric temperature is low
(below about –10°C), but this case is not
abnormal.
D475A, D475ASD-5E0 11
Monitor panel display

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

and starting switch is ON
Radiator coolant level Below low level
Display when normal: OFF
Display when abnormal: Flashes
When sensor is abnormal or

Check
Engine oil level when wiring harness is

disconnected
Display when abnormal: ON
Hydraulic oil level Below low level
Battery charge When charge is defective

Displays when starting switch is
Caution 1
SAP00522 ON and engine is running

Display when abnormal: Flashes
When clogged: Less than CAUTION lamp flashes
Air clever clogging
6.37 kPa {–650 mmH2O}
Engine oil pressure Below 49.0kPa {0.5kg/cm2}
Radiator coolant level Below low level
When at highest level (108°C or

Engine coolant
above) on engine coolant
temperature
temperature gauge
Displays when starting switch is
ON and engine is running
Caution 2
When at highest level (130°C or

Torque converter oil Display when normal: OFF
above) on engine coolant
temperature Display when abnormal: Flashes
temperature gauge
CAUTION lamp flashes
Alarm buzzer sounds
Hydraulic oil
105±3°C or above
temperature
Hydraulic oil level Below low level
When replacement time of filter

Maintenance
or oil has been passed
12 D475A, D475ASD-5E0
Display
Symbol Display item Display range Display method
category
Lights according to required time
determined by engine controller
based.
Preheating When preheating It also lights at the time of manual
preheat by setting starting switch
at preheat position (turning it
Pilot
counterclockwise).
Display lights at the time of

operation.
Dual tilt At the time of operation
It goes off at the time of non-
operation.
Engine coolant
temperature
Torque converter oil One place lights up to show

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

Fuel level
applicable level
information
Service meter Actuated when the engine is

Multi
From 0 to 99999
(Hours meter) rotating
D475A, D475ASD-5E0 13
Switch portion
1. Switch functions
1) ON-OFF switching in lockup mode
2) Economy mode setting – OFF, mode 1, mode 2
3) ON-OFF switching in reverse slow mode
4) ON-OFF switching in SSC mode
5) SSC mode level setting – Mode 1 to 5
a), b), and c) are mounted for all specifications and d) and e) are mounted for the SSC specifications.
q SSC specifications
q Without SSC specifications
2. Initial Setup at key ON Economy Mode Function

The function the operator desires according to In a field, such as a rock-bed place where many
the situation of an operating place is selected shoe slips are generated, the following power is
and all functions shall be set to the OFF state. output in each mode so that the frequency of decel-
erator operation can decrease.
q Economy mode 1 o Set to about 90% of the
full power.
q Economy mode 2 o Set to about 70% of the
full power.
q REVERSE slow mode o Set to about 80% of
the full travel speed at reverse time.
14 D475A, D475ASD-5E0
Sensors 1
Type of sensor Sensor method When normal When abnormal
Engine oil pressure Contact OFF ON
Engine coolant temperature Resistance — —
Torque converter oil temperature Resistance — —
Hydraulic oil temperature Resistance — —
Radiator coolant level Contact ON OFF
Fuel level Resistance — —
Engine oil level Contact ON OFF
All cleaner clogging Contact ON OFF
Engine oil pressure sensor
1. Plug 4. Diaphragm
2. Contact ring 5. Spring
3. Contact 6. Terminal
Engine coolant temperature sensor

Torque converter oil temperature sensor
Hydraulic oil temperature sensor
1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector
D475A, D475ASD-5E0 15
Radiator coolant level sensor
1. Float 4. Wire
2. Sensor 5. Connector
3. Tube
Fuel level sensor
1. Connector Function
2. Float q The fuel level sensor is installed to the side
3. Arm face of the fuel tank. The float moves up and
4. Body down according to the fuel level. This move-
5. Spring ment of the float is transmitted by the arm and
6. Contact actuates a variable resistance. This sends a
7. Spacer signal to the monitor panel to indicate the
remaining fuel level. When the display on the
monitor panel reaches a certain level, a warn-
ing lamp flashes.
16 D475A, D475ASD-5E0
Engine oil level sensor
1. Float 4. Wire
2. Sensor 5. Connector
3. Tube
Air cleaner clogging sensor
1. Boss 4. Wire
2. Switch 5. Connector
3. Conduit
D475A, D475ASD-5E0 17
Mode selection system 1

(SSC (Shoe Slip Control) System)
System diagram
Outline
q The mode selection system automatically car- q The lockup control mode is the same as the
ries out engine control to match the operating conventional lockup function. It cannot be
mode selected by the operator, and acts to selected in combination with the above modes.
reduce fuel consumption, extend the life of the
track shoes, and reduce the frequency of oper-
ation of the deceleration.
q The engine control modes consist of the econ-
omy mode control used when dozing, the SSC
(shoe slip control) used when ripping, and the
reverse slow mode control, which can be used
for either operation.
18 D475A, D475ASD-5E0
Function of mode selection system

The system consists of the mode selection panel
(containing a microcomputer) to select working
condition, steering controller (containing a micro-
computer) to control the engine, engine controller
to receive the commands from the steering control-
ler and controls the fuel injection pump, transmis-
sion controller to turn on and off the lockup system
of the torque converter according to the signals
from the transmission output speed sensor, and
various sensors.
The function of each controller is explained below.
Functions of steering controller and transmis-

sion controller
1. The steering controller calculates travel speed
of the ground from signals of the acceleration
sensor and inputs the transmission output
speed sensor signal to calculate the shoe
speed, then obtains the shoe slip rate.
2. If the engine speed sensor signal and trans-
mission output speed sensor signal are input,
the steering controller calculates the traction
force.
3. The steering controller calculates the optimum
engine speed from the results of 1 and 2
above, mode set signal of the monitor panel,
and speed information from the transmission
controller, then sends it as the SSC command
to the engine controller.
4. The transmission controller sends lockup sig-
nal to the lockup solenoid valve, judging from
input gear speed information from the trans-
mission controller.
a See "Operation of torque converter lockup
control system".
Function of engine controller

q The engine controller controls the fuel injection
pump according to the lowest engine speed
(highest voltage) in the 3 signals of the manual
command input from the deceleration potenti-
ometer, manual signal of the throttle dial, and
the SSC command signal.
D475A, D475ASD-5E0 19
Operation of mode selection system

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

Low ON 1,360 rpm or more mode
4. Suitable for dozing work of comparatively a few
T/C speed OFF 1,330 rpm or more load fluctuations.
output side
shaft High ON 2,570 rpm or more
speed speed
side OFF 2,600 rpm or more
Dozing
1. When F1 is shifted with the economy 1. When the economy mode (1 or 2) and SSC are
mode switch 1) or 2) ON set simultaneously, the F1 shift economy control
is performed. When the ripper lever is actuated
and the switch is turned on, the slip control is
Economy
performed.
2. The engine output can be suppressed in two
stages without performing the decelerator
operation of the engine.
Mode 1): 90% (at 1.5 km/h)
Mode 2): 65% (at 1.5 km/h)
3. At neutral time, the engine speed can be
suppressed partially.
1. When R1, R2, and R3 are shifted 1. The engine speed can be suppressed without
Reverse slow
performing the decelerator operation of the

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

output control in accordance with the index
Ripping
force characteristic (refer to the rock-bed

selection shown below) selected by the operator
among the index force characteristics set in five
stages and suppresses the generation of a slip.
3. The steering controller regards the index force
immediately before the slip (exceeding the shoe
slipping ratio of 30% is generated, as the
maximum, and performs the engine output
control. At this time, the steering controller
performs index characteristic down of about 30
to 80% and performs the engine output control
if a ripper tilt or ripper up signal is input.
4. At neutral time, the engine speed is suppressed
partially.
Rock-bed
selection
Set to ON in connection with SSC 1. When the SSC is set to ON, the selection mode
3 comes on.
2. 1 ⇔ 3 ⇔ 5 is selected in accordance with the
state and load of the rock-bed.
a When the above mode is set, the throttle lever and decelerator operations are enabled. In that case, the
engine output control is performed in accordance with the command having the smallest value among
the control command, throttle command, and decelerator command.
20 D475A, D475ASD-5E0
Sensors
Transmission output shaft speed sensor
1. Magnet 4. Boots
2. Terminal 5. Connector
3. Case
Torque converter speed sensor
1. Connector
2. Flange
3. Sensor
D475A, D475ASD-5E0 21
Acceleration sensor
1. Sensor portion
2. Wire
3. Connector
q The acceleration sensor is installed under the

front of the operator’s cab.
q With the acceleration sensor, the position of
the ball inside the sensor changes according to
the acceleration.
q Inside the sensor, there is a coil that detects
the position of the ball. This is amplified by the
amp and is sent as a voltage change to the
SSC controller.
q The input and output characteristics of the sen-
sor are shown in the diagram below.
22 D475A, D475ASD-5E0
Pitch angle sensor
1. Body
2. Tube
3. Wire
4. Connector
q The sensor is filled with electrolyte. If sensor

leans, the electrolyte surface slants. If electro-
lyte surface slants, the contact area of two
electrodes installed in the sensor with electro-
lyte changes. As a result, electrostatic capacity
between the two electrode changes. The
change of electrostatic capacity is output as a
change of voltage.
q The input and output characteristics of the sen-
sor are shown in the figure at right.
D475A, D475ASD-5E0 23
Electrical equipment 1
Relay box
24 D475A, D475ASD-5E0
Operation of lamp system
Lamp system circuit diagram
D475A, D475ASD-5E0 25
Preheating (Electrical intake air heater) control
Preheating circuit
26 D475A, D475ASD-5E0
Steering electronic control system 1
1. Monitor panel (Multi information) 6. Steering control valve

2. Auto shift down switch 7. Transmission output shaft speed sensor
3. Engine controller 8. Transmission control valve
4. Transmission controller 9. Engine speed sensor
5. Steering controller
D475A, D475ASD-5E0 27
Shift mode function Auto-shift-down function

Function Function
If you shift the lever to the forward or reverse, the If the load is increased while the machine is travel-
gear speed selected from the shift mode is turned ing or working at the 2nd or 3rd gear speed, the
on. gear speed is shifted down automatically.
q The drawbar pull (load on the machine) is cal-
Type of modes culated from the engine speed, travel speed,
q F1-R1 (Manual mode) and throttle information from the steering con-
q F1-R2 (Shift mode 1) troller, and the gear speed is shifted down
q F2-R2 (Shift mode 2) automatically according to the load and travel
speed.
Selecting method q Once the gear speed is automatically shifted
Shift the PCCS lever to “N”. down, it is not automatically shifted up to the
Select the shift mode using UP or DOWN switch. former position. (Gear speed can be shifted up
with the manual switch.)
Display q This function is applicable to both forward and
The selected shift mode is displayed on the monitor reverse travels.
panel.
How to use
Turn auto-shift-down switch (1) ON.
Manual mode
Down switch ON Up switch ON
Shift mode 1
Down switch ON Up switch ON
Shift mode 2
28 D475A, D475ASD-5E0
VHMS controller 1
D475A, D475ASD-5E0 29
Input and output signals

CN1 [CN 1] CN2 [CN2 A, B]
Input/ Input/
Pin No. Signal name Pin No. Signal name
Output Output
CN1-1 NC Input CN2-A1 Input
CN1-2 Sensor power supply (24V) Output CN2-A2 NC Input
CN1-3 Sensor power supply (12V) Output CN2-A3 Input
CN1-4 Sensor power supply (5V) Output CN2-A4 NC Input
CN1-5 Sensor power supply (5V) Output CN2-A5 Exhaust temperature (Right 1) Input
Power supply (Constant power supply) CN2-A6 Exhaust temperature (Left 2) Input
CN1-6 Input
(24V)
CN2-A7 Exhaust temperature (Left 1) Input
Power supply (Constant power supply)
CN1-7 Input CN2-A8 NC Input
(24V)
CN2-A9 NC Input
CN1-8 BR power supply (24V) Input
CN2-A10 Input
CN1-9 BR power supply (24V) Input
CN2-A11 NC Input
CN1-10 NC Input
CN2-A12 Sensor GND Input
CN1-11 GND Input
CN2-A13 Sensor GND Input
CN1-12 GND Input
CN2-A14 NC Input
CN1-13 NC —
CN2-A15 Transmission, main Input
CN1-14 NC Input
CN2-A16 Exhaust temperature (Right 2) Input
CN1-15 NC —
CN2-A17 WAKE UP (Low) —
CN1-16 NC —
CN2-A18 Blow-by pressure Input
CN1-17 Start signal Input
CN2-B1 NC —
CN1-18 NC —
CN2-B2 NC Input
CN1-19 GND Input
CN2-B3 NC —
CN1-20 GND Input
CN2-B4 NC Input
CN2-B5 NC Input
CN2-B6 Wake up HI —
CN2-B7 NC Input
CN2-B8 NC —
CN2-B9 GND Input
CN2-B10 NC Input
CN2-B11 NC Input
CN2-B12 CONNECTOR (GND) Input
30 D475A, D475ASD-5E0
CN3 [CN 3 A, B] CN4 [CN 4 A, B]

Input/ Input/
Pin No. Signal name Pin No. Signal name
Output Output
CN3-A1 Input CN4-A1 NC —
CN3-A2 CAB out D/L Sw Input CN4-A2 NC —
CN3-A3 NC Input Input/
CN4-A3 RS232C GND
Output
CN3-A4 NC Output
Input/
Model selection CN4-A4 CAN (1) H (KOM-NET/c)
CN3-A5 Input Output
(See ORB connection)
CN4-A5 CAN (0) shield CGC Input
CN3-A6 NC Input
Input/
CN3-A7 Input CN4-A6 CAN (0) H CGC
Output
Input/
CN3-A8 CN4-A7 NC —
Output
CN4-A8 NC —
CN3-A9 CONNECTOR SEL2 (OPEN) Input
CN4-A9 GND Input
CN3-A10 NC Input
CN4-A10 RS232C RX0 (PC Tool) Input
CN3-A11 NC Input
CN4-A11 RS232C TX0 (PC Tool) Output
CN3-A12 NC Input
Input/
CN3-A13 NC Input CN4-A12 CAN (1) L (KOM-NET/c)
Output
CN3-A14 NC Input
CN4-A13 CAN (1) SH (KOM-NET/c) Input
CN3-A15 NC Input
Input/
CN3-A16 NC Input CN4-A14 CAN (0) L CGC
Output
CN3-A17 NC Input CN4-B1 NC —
Input/ CN4-B2 NC —
CN3-A18 NC
Output
CN4-B3 RS232C GND Input
CN3-B1 NC Input
CN4-B4 RS232C TX1 (Orbcom) Output
CN3-B2 NC —
CN4-B5 NC —
CN3-B3 NC —
CN4-B6 NC —
CN3-B4 NC —
CN4-B7 NC —
CN3-B5 NC —
CN4-B8 NC —
CN3-B6 Snap shot Sw data clear —
CN4-B9 GND Input
CN3-B7 NC —
CN4-B10 RS232C RX1 (Orbcom) Input
CN3-B8 NC —
CN3-B9 NC —
CN3-B10 NC —
CN3-B11 NC —
CN3-B12 NC Input
D475A, D475ASD-5E0 31
Sensors
Engine oil temperature sensor Exhaust temperature sensor/amplifier
Specifications Specifications
Type of sensor: Thermistor Rated voltage: DC 24 V
Measurement range: 40 – 130°C Sensed temperature range: 100 – 1,000°C
80 – 130°C 300 – 800°C
(Assured accuracy: ±2°C) (Assured accuracy: ±10°C)
Max. power consumption: 0.5 mW Output voltage characteristics
Pressure resistance: 4.9 MPa {50 kg/cm2} (Ambient temperature: 20°C)
– Reference values
Using temperature: –30°C to +140°C
Sensed
Performance table
temperature 50 100 400 700 800
Temper- Resis- Temper- Resis- Temper- Resis- (°C)
ature tance ature tance ature tance
Output voltage
(°C) (kz) (°C) (kz) (°C) (kz) 1.191 1.397 2.626 3.899 4.316
(V)
30 35.27 80 6.571 110 2.887
40 24.28 85 5.682 115 2.544 Operating temperature range: –40 to +110°C
Current consumption: Max. 30 mA
50 17.05 90 4.931 120 2.248
a: Heat sensing part of sensor – Outside diame-
60 12.20 95 4.293 125 1.992
ter of mounting part: R1/8
70 8.884 100 3.750 130 1.769 b: Amplifier
a: Heat sensing part of sensor – Outside diame- c: Connector (Power supply side)
ter of mounting part: R1/4 d: Connector (Sensor side)
Function Function
The exhaust temperature sensor/amplifier is a ther-
The engine oil temperature sensor is installed to
mocouple-type temperature sensor, which is
the engine oil filter. It inputs the change of the tem-
installed to the turbocharger inlet. It outputs the
perature as the change of the thermistor resistance
exhaust temperature data to the VHMS controller.
to the VHMS controller.
32 D475A, D475ASD-5E0
Atmospheric temperature sensor

Specifications
Power consumption: Max. 0.5 mW
Pressure resistance: 0.98 MPa {10 kg/cm2}
Sensed temperature range (ambient):
–30 to +120°C
Storage temperature range: –50 to +140°C
Performance table
Sensed
temperature –20 –10 0 10 20 50
(°C)
Resistance
30.32 18.58 11.74 7.623 5.077 1.712
(kz)
a. Heat sensing part of sensor – Outside diame-

ter of mounting part: 16 x 1.5
Function
The atmospheric temperature sensor inputs the
change of the atmospheric temperature as the
change of the thermistor resistance to the VHMS
controller.
D475A, D475ASD-5E0 33
Engine blow-by pressure sensor
1. Sensor Specifications and function

2. Connector Pressure range: 0 – 20 kPa
3. Atmospheric pressure intake tube {0 – 2,040 mmH2O}
Allowable pressure: –20 to 100 kPa
A. GND (Black) {–2,040 to 10,200 mmH2O}
B. Power supply (Red)
Source voltage: 5 ± 0.25 V
C. Output (White)
Output characteristics:See graph.
q The blow-by pressure sensor is a fine relative
pressure sensor which measures the differ-
ence between the pressure in the crankcase
and the atmospheric pressure.
q The pressure in the crankcase is applied to the
tip side of the sensor and the atmospheric
pressure is applied to the wiring harness side.
Transmission main oil pressure sensor

1. Sensor
2. Connector
34 D475A, D475ASD-5E0
Communication (ORB: ORBCOMM) controller/antenna 1

Controller Antenna
Specifications Specifications
Source voltage: DC 12 V – DC 30 V Type: Helical whip antenna (1)
Size: W306 x D152 x H52 (mm) Impedance: 50 z
Connectors Input terminal:N-P type
CN1A (ORB-A): AMP070-14 Length: 165 ± 20 mm
CN1B (ORB-B): AMP070-10 a. Communication antenna mounting part
CN2: Communication antenna cable connector
Function
The communication controller transmits the data
collected and stored by the VHMS controller to the
computer center via the communication satellite.
D475A, D475ASD-5E0 35
SEN00219-00

36
SEN00225-00
D475A-5E0
D475ASD-5E0
Machine Model Serial Number

D475A-5E0 30001 and up
90 Diagrams and drawings 1

Hydraulic diagrams and drawings
Hydraulic diagrams and drawings................................................................................................................... 3
Power train hydraulic circuit diagram ................................................................................................... 3
Hydraulic circuit diagram (1/3) ............................................................................................................. 5
D475A, D475ASD-5E0 1
SEN00225-00 90 Diagrams and drawings
2 D475A, D475ASD-5E0
Hydraulic diagrams and drawings Power train hydraulic circuit diagram

D475A, D475ASD-5E0
Power train hydraulic circuit diagram
D475A, D475ASD-5E0 3
Hydraulic circuit diagram (1/3) Hydraulic circuit diagram (1/3)
D475A, D475ASD-5E0
SEN00225-00
D475A, D475ASD-5E0 5
D475A, D475ASD-5E0
SEN00225-00
D475A, D475ASD-5E0 7
D475A, D475ASD-5E0
SEN00225-00
D475A, D475ASD-5E0 9
D475A, D475ASD-5E0 11
SEN00225-00

12
SEN00226-00
D475A-5E0
D475ASD-5E0
Machine Model Serial Number

D475A-5E0 30001 and up
90 Diagrams and drawings 1

Electrical diagrams and drawings
Electrical diagrams and drawings ................................................................................................................... 3
Electrical circuit diagram (1/13)............................................................................................................ 3
Electrical circuit diagram (5/13)...........................................................................................................11
Electrical circuit diagram (6/13).......................................................................................................... 13
Electrical circuit diagram (10/13)........................................................................................................ 21
Electrical circuit diagram (11/13) ........................................................................................................ 23
Electrical circuit diagram of inside cab ............................................................................................... 29
D475A, D475ASD-5E0 1
SEN00226-00 90 Diagrams and drawings
2 D475A, D475ASD-5E0
Electrical diagrams and drawings Electrical circuit diagram (1/13)
D475A, D475ASD-5E0
Electrical circuit diagram (1/13)
SEN00226-00
D475A, D475ASD-5E0 3
Electrical circuit diagram (2/13) Electrical circuit diagram (2/13)
D475A, D475ASD-5E0
SEN00226-00
D475A, D475ASD-5E0 5
D475A, D475ASD-5E0
SEN00226-00
D475A, D475ASD-5E0 7
D475A, D475ASD-5E0
SEN00226-00
D475A, D475ASD-5E0 9
D475A, D475ASD-5E0
SEN00226-00
D475A, D475ASD-5E0 11
D475A, D475ASD-5E0
SEN00226-00
D475A, D475ASD-5E0 13
D475A, D475ASD-5E0
SEN00226-00
D475A, D475ASD-5E0 15
D475A, D475ASD-5E0
SEN00226-00
D475A, D475ASD-5E0 17
D475A, D475ASD-5E0
SEN00226-00
D475A, D475ASD-5E0 19
D475A, D475ASD-5E0
SEN00226-00
D475A, D475ASD-5E0 21
D475A, D475ASD-5E0
SEN00226-00
D475A, D475ASD-5E0 23
D475A, D475ASD-5E0
SEN00226-00
D475A, D475ASD-5E0 25
D475A, D475ASD-5E0
SEN00226-00
D475A, D475ASD-5E0 27
Electrical circuit diagram of inside cab Electrical circuit diagram of inside cab
D475A, D475ASD-5E0
D475A, D475ASD-5E0 29
D475A, D475ASD-5E0 31
SEN00226-00

32

Shop Manual KOMATSU D475A-EO

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Shop Manual KOMATSU D475A-EO

Uploaded by

Copyright:

Available Formats

SEN00203-00

Copyright 2006 Komatsu

BULLDOZER 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

Organization list of the shop manual.................................................................................................... 2

Organization list of the shop manual 1

Section Title Form Number

Shop Manual, contents binder, binder label and tabs SEN00203-00

00 Index and foreword SEN00204-00

10 Structure, function and maintenance standard SEN00209-00

90 Diagrams and drawings SEN00224-00

Foreword and general information SEN00206-00

10 Structure, function and maintenance standard

Cab and its attachments SEN00218-00

90 Diagrams and drawings

D475A, D475ASD-5E0 Bulldozer

BULLDOZER 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

Foreword and general information (Rev. 2005/11)

1. General precautions 7) If welding repairs are needed, always

4. Precautions for sling work and making

How to read the shop manual 1

1. Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

2. Revision and distribution

q Revised edition mark

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving stan-

2 Coat Places to be coated with adhesives, etc. during assembly.

Explanation of terms for maintenance standard 1

1. Standard size and tolerance

a The tolerance may be indicated in the text

q Usually, the size of a hole and the size of

2. Standard clearance and standard value 5. Clearance limit

4. Repair limit and allowable value

Handling electric equipment and hydraulic component 1

Points to remember when handling electric

2. Main failures occurring in wiring harness

2) Defective crimping or soldering of connec-

4) High-pressure water entering connector

5) Oil or dirt stuck to connector

3. Removing, installing, and drying connec-

2] When removing from clips

q When removing a connector from a

3] Action to take after removing connec-

4) Drying wiring harness

5. Points to remember when troubleshooting

Points to remember when handling hydraulic equipment

1. Be careful of the operating environment.

2. Disassembly and maintenance work in the

4. Do not let any dirt or dust get in during

5. Change hydraulic oil when the temperature

How to read electric wire code 1

Indicates size of wire by nominal No.

Indicates type of wire by symbol.

1. Type, symbol, and material