Serviços 02 Ingles Sen06650-02

SEN06650-02
MOTOR GRADER GD535 -5

Hydraulic drive fan specification
SERIAL NUMBERS 1001 and up

Notice of revision
Notice of revision
2nd revision 2017/11
The affected pages are indicated by the use of the
Mark Indication Action required
following marks. It is requested that necessary ac-
tions must be taken to these pages according to the Q Page to be newly added Add
list below.
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List of revised pages

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Q 50-164 (02) Q 50-216 (02) Q 50-268 (02) 60-15
Q 50-165 (02) Q 50-217 (02) Q 50-269 (02) 60-16
Q 50-166 (02) Q 50-218 (02) Q 50-270 (02) 60-17
Q 50-167 (02) Q 50-219 (02) Q 50-271 (02) 60-18
Q 50-168 (02) Q 50-220 (02) Q 50-272 (02) 60-19
Q 50-169 (02) Q 50-221 (02) Q 50-273 (02) 60-20
Q 50-170 (02) Q 50-222 (02) Q 50-274 (02) 60-21
Q 50-171 (02) Q 50-223 (02) Q 50-275 (02) 60-22
Q 50-172 (02) Q 50-224 (02) Q 50-276 (02) 60-23
Q 50-173 (02) Q 50-225 (02) Q 50-277 (02) 60-24
Q 50-174 (02) Q 50-226 (02) Q 50-278 (02) 60-25
Q 50-175 (02) Q 50-227 (02) Q 50-279 (02) 60-26
Q 50-176 (02) Q 50-228 (02) Q 50-280 (02) 60-27
Q 50-177 (02) Q 50-229 (02) Q 50-281 (02) 60-28
Q 50-178 (02) Q 50-230 (02) Q 50-282 (02) 60-29
Q 50-179 (02) Q 50-231 (02) Q 50-283 (02) 60-30
Q 50-180 (02) Q 50-232 (02) Q 50-284 (02) 60-31
Q 50-181 (02) Q 50-233 (02) Q 50-285 (02) 60-32
Q 50-182 (02) Q 50-234 (02) Q 50-286 (02) 60-33
Q 50-183 (02) Q 50-235 (02) Q 50-287 (02) 60-34
Q 50-184 (02) Q 50-236 (02) Q 50-288 (02) 60-35
Q 50-185 (02) Q 50-237 (02) Q 50-289 (02) 60-36
Q 50-186 (02) Q 50-238 (02) Q 50-290 (02) 60-37
Q 50-187 (02) Q 50-239 (02) Q 50-291 (02) 60-38
Q 50-188 (02) Q 50-240 (02) Q 50-292 (02) 60-39
Q 50-189 (02) Q 50-241 (02) Q 50-293 (02) 60-40
Q 50-190 (02) Q 50-242 (02) Q 50-294 (02) 60-41
Q 50-191 (02) Q 50-243 (02) Q 50-295 (02) 60-42
Q 50-192 (02) Q 50-244 (02) Q 50-296 (02) 60-43
Q 50-193 (02) Q 50-245 (02) Q 50-297 (02) 60-44
Q 50-194 (02) Q 50-246 (02) Q 50-298 (02) 60-45
Q 50-195 (02) Q 50-247 (02) Q 50-299 (02) 60-46
Q 50-196 (02) Q 50-248 (02) Q 50-300 (02) 60-47
GD535-5 7
(02)
Notice of revision
Revision Revision Revision

Mark Page Mark Page Mark Page
number number number
60-48 80-41 (01) 90-19
60-49 80-42 (01) 90-20
60-50 80-43 (01) 90-21
60-51 80-44 (01) 90-23
60-52 80-45 (01) 90-25
60-53 80-46 (01) 90-27
60-54 80-47 (01) 90-29
60-55 80-48 (01) 90-31
60-56 80-49 (01) 90-33
60-57 80-50 (01) 90-35
60-58 80-51 (01) 90-37
80-52 (01) 90-39
80-1 (01) 80-53 (01) 90-41
80-2 (01) 80-54 (01) 90-43
80-3 (01) 80-55 (01)
80-4 (01) 80-56 (01) q 1 (02)
80-5 (01) 80-57 (01) q 2 (02)
80-6 (01) 80-58 (01) q 3 (02)
80-7 (01) 80-59 (01) q 4 (02)
80-8 (01) 80-60 (01) q 5 (02)
80-9 (01) 80-61 (01) q 6 (02)
80-10 (01) 80-62 (01) q 7 (02)
80-11 (01) 80-63 (01) q Colophon (02)
80-12 (01) 80-64 (01)
80-13 (01) 80-65 (01)
80-14 (01) 80-66 (01)
80-15 (01) 80-67 (01)
80-16 (01) 80-68 (01)
80-17 (01) 80-69 (01)
80-18 (01) 80-70 (01)
80-19 (01) 80-71 (01)
80-20 (01) 80-72 (01)
80-21 (01) 80-73 (01)
80-22 (01) 80-74 (01)
80-23 (01) 80-75 (01)
80-24 (01) 80-76 (01)
80-25 (01)
80-26 (01) 90-1
80-27 (01) 90-2
80-28 (01) 90-3
80-29 (01) 90-4
80-30 (01) 90-5
80-31 (01) 90-6
80-32 (01) 90-7
80-33 (01) 90-8
80-34 (01) 90-9
80-35 (01) 90-10
80-36 (01) 90-11
80-37 (01) 90-13
80-38 (01) 90-15
80-39 (01) 90-17
80-40 (01) 90-18
8 GD535-5
(02)
00 Index and foreword
GD535-5 00-1
Table of contents 00 Index and foreword
Table of contents 1
00 Index and foreword
Table of contents ......................................................................................................................................... 00-2
Acronyms .................................................................................................................................................. 00-12
Foreword and general information ............................................................................................................ 00-17
Safety notice .......................................................................................................................................... 00-17
How to read the shop manual ................................................................................................................ 00-22
Explanation of terms for maintenance standard .................................................................................... 00-24
Handling of electric equipment and hydraulic components.................................................................... 00-26
Handling of connectors newly used for engines .................................................................................... 00-35
How to read electric wire code............................................................................................................... 00-38
Precautions when carrying out work ...................................................................................................... 00-41
Method of disassembling and connecting push-pull type coupler.......................................................... 00-44
Standard tightening torque table ............................................................................................................ 00-47
Conversion table .................................................................................................................................... 00-51
01 Specification
Acronyms .................................................................................................................................................... 01-3
Specifications .............................................................................................................................................. 01-8
Specification drawing ............................................................................................................................... 01-8
Specifications ......................................................................................................................................... 01-10
Weight table ........................................................................................................................................... 01-16
Table of fuel, coolant, and lubricants...................................................................................................... 01-17
10 Structure and function

Acronyms .................................................................................................................................................... 10-4
Engine and cooling system ......................................................................................................................... 10-9
Cooling system ........................................................................................................................................ 10-9
Cooling fan motor................................................................................................................................... 10-11
Power train system ................................................................................................................................... 10-19
Power train system drawing................................................................................................................... 10-19
Power train piping drawing..................................................................................................................... 10-20
Transmission control .............................................................................................................................. 10-21
Torque converter .................................................................................................................................... 10-22
Transmission.......................................................................................................................................... 10-25
Transmission control valve..................................................................................................................... 10-44
ECMV..................................................................................................................................................... 10-46
Main relief valve and torque converter relief valve................................................................................. 10-53
Front axle ............................................................................................................................................... 10-55
Rear axle................................................................................................................................................ 10-58
Differential (Non-differential specification) ............................................................................................. 10-59
Differential (Differential lock specification) ............................................................................................. 10-61
Differential lock solenoid valve............................................................................................................... 10-64
Final drive .............................................................................................................................................. 10-65
Tandem drive ......................................................................................................................................... 10-67
Steering system ........................................................................................................................................ 10-69
Steering piping drawing.......................................................................................................................... 10-69
Priority valve .......................................................................................................................................... 10-70
Steering valve ........................................................................................................................................ 10-75
Brake system ............................................................................................................................................ 10-82
Hydraulic piping drawing of brake system ............................................................................................. 10-82
Brake valve ............................................................................................................................................ 10-83
Brake circuit accumulator....................................................................................................................... 10-88
Brake circuit accumulator charge valve ................................................................................................. 10-89
Wheel brake........................................................................................................................................... 10-95
Parking brake solenoid valve and lifter lock pin solenoid valve ............................................................. 10-96
Parking brake......................................................................................................................................... 10-97
00-2 GD535-5
(01)
00 Index and foreword Table of contents
Undercarriage and frame .......................................................................................................................... 10-98

Frame..................................................................................................................................................... 10-98
Tire......................................................................................................................................................... 10-99
Hydraulic system..................................................................................................................................... 10-100
Hydraulic system.................................................................................................................................. 10-100
Hydraulic piping drawing of work equipment ....................................................................................... 10-102
Work equipment control ....................................................................................................................... 10-104
Hydraulic tank ...................................................................................................................................... 10-105
Work equipment pump and steering pump .......................................................................................... 10-106
Power train pump................................................................................................................................. 10-107
Power train pump and differential lock pump....................................................................................... 10-108
Brake and cooling fan pump ................................................................................................................ 10-109
Control valve .........................................................................................................................................10-110
Functions and valve operations ............................................................................................................10-112
Hydraulic cylinder..................................................................................................................................10-113
Swivel joint ............................................................................................................................................10-114
Pilot check valve ...................................................................................................................................10-115
Work equipment system ......................................................................................................................... 10-124
Circle and drawbar............................................................................................................................... 10-124
Blade.................................................................................................................................................... 10-126
Lifter ..................................................................................................................................................... 10-128
Circle rotation motor............................................................................................................................. 10-130
Circle rotation gear............................................................................................................................... 10-132
Ripper .................................................................................................................................................. 10-134
Cab and its attachments ......................................................................................................................... 10-135
ROPS cab ............................................................................................................................................ 10-135
Electrical system ..................................................................................................................................... 10-136
Layout drawing of electrical system ..................................................................................................... 10-136
System operating lamp system............................................................................................................ 10-138
Battery disconnect switch .................................................................................................................... 10-139
Machine monitor .................................................................................................................................. 10-140
Automatic gear shift control system ..................................................................................................... 10-151
Transmission controller ........................................................................................................................ 10-156
Engine controller .................................................................................................................................. 10-159
KOMTRAX system............................................................................................................................... 10-162
KOMTRAX terminal ............................................................................................................................. 10-163
Rearview monitor system..................................................................................................................... 10-165
Rearview monitor ................................................................................................................................. 10-166
Rearview camera ................................................................................................................................. 10-167
Engine starting circuit........................................................................................................................... 10-168
Engine stop circuit................................................................................................................................ 10-170
Preheating circuit ................................................................................................................................. 10-171
Sensors................................................................................................................................................ 10-172
Engine power mode selector circuit ..................................................................................................... 10-181
Cooling fan control system................................................................................................................... 10-182
20 Standard value table

Acronyms .................................................................................................................................................... 20-3
Standard value table ................................................................................................................................... 20-8
Standard value table for engine ............................................................................................................... 20-8
Standard value table for machine .......................................................................................................... 20-10
30 Testing and adjusting

Acronyms .................................................................................................................................................... 30-4
Tools for testing, adjusting, and troubleshooting......................................................................................... 30-9
Tools for testing, adjusting, and troubleshooting...................................................................................... 30-9
Engine and cooling system ....................................................................................................................... 30-16
Testing engine speed ............................................................................................................................. 30-16
Testing boost pressure........................................................................................................................... 30-18
GD535-5 00-3
(01)
Testing exhaust gas temperature........................................................................................................... 30-20

Testing exhaust gas color ...................................................................................................................... 30-22
Adjusting valve clearance ...................................................................................................................... 30-24
Testing compression pressure ............................................................................................................... 30-26
Testing blowby pressure ........................................................................................................................ 30-29
Testing engine oil pressure .................................................................................................................... 30-30
Handling fuel system devices ................................................................................................................ 30-31
Releasing remaining pressure from fuel system.................................................................................... 30-32
Testing fuel pressure.............................................................................................................................. 30-33
Bleeding air from fuel circuit................................................................................................................... 30-34
Testing fuel circuit for leakage................................................................................................................ 30-35
Handling cylinder cutout mode operation............................................................................................... 30-36
Handling no-injection cranking operation............................................................................................... 30-37
Handling voltage circuit of engine controller .......................................................................................... 30-38
Testing muffler (main body) and stacked muffler for looseness and damage ........................................ 30-39
Testing muffler function .......................................................................................................................... 30-40
Testing installed condition of cylinder heads and manifolds .................................................................. 30-41
Testing of engine piping for damage and looseness.............................................................................. 30-42
Testing fuel discharge, return rate, and leakage .................................................................................... 30-43
Testing and adjusting air conditioner compressor belt tension .............................................................. 30-47
Checking and replacing alternator belt .................................................................................................. 30-49
Checking and replacing auto-tensioner ................................................................................................. 30-51
Power train ................................................................................................................................................ 30-54
Testing power train oil pressure ............................................................................................................. 30-54
Adjusting transmission speed sensor .................................................................................................... 30-68
Retrieval of disabled machine due to transmission valve failure ........................................................... 30-71
Flushing procedure for torque converter and transmission circuits........................................................ 30-74
Testing and adjusting toe-in ................................................................................................................... 30-76
Testing and adjusting differential lock oil pressure (differential lock specification)................................. 30-78
Steering system ........................................................................................................................................ 30-80
Testing and adjusting steering oil pressure............................................................................................ 30-80
Testing oil leakage of steering cylinder .................................................................................................. 30-81
Bleeding air from steering circuit............................................................................................................ 30-82
Brake system ............................................................................................................................................ 30-83
Releasing remaining pressure from brake circuit................................................................................... 30-83
Testing and adjusting brake oil pressure................................................................................................ 30-84
Bleeding air from brake circuit ............................................................................................................... 30-87
Testing wear of wheel brake disc ........................................................................................................... 30-88
Testing and adjusting parking brake pad................................................................................................ 30-89
Releasing parking brake manually ......................................................................................................... 30-92
Charging brake accumulator with gas.................................................................................................... 30-93
Hydraulic system....................................................................................................................................... 30-95
Testing work equipment oil pressure...................................................................................................... 30-95
Testing lifter lock pin circuit pressure ..................................................................................................... 30-97
Testing cooling fan speed ...................................................................................................................... 30-99
Testing cooling fan circuit oil pressure ................................................................................................. 30-100
Testing oil leakage of work equipment cylinder.................................................................................... 30-102
Bleeding air from work equipment circuit ............................................................................................. 30-105
Work equipment ...................................................................................................................................... 30-106
Adjusting drawbar ball joint clearance ................................................................................................. 30-106
Testing and adjusting circle guide clearance ....................................................................................... 30-107
Testing and adjusting slip clutch type circle drive ................................................................................ 30-109
Electrical system ......................................................................................................................................30-111
Procedure for testing diodes .................................................................................................................30-111
Special functions of machine monitor .................................................................................................. 30-113
Handling high-voltage circuit of engine controller ................................................................................ 30-162
KOMTRAX terminal start-up procedure ............................................................................................... 30-163
Adjusting rearview camera angle......................................................................................................... 30-167
Handle battery disconnect switch ........................................................................................................ 30-169
00-4 GD535-5
(01)
Preparatory work for troubleshooting of electrical system failure ........................................................ 30-170

Pm Clinic................................................................................................................................................. 30-172
Pm Clinic.............................................................................................................................................. 30-172
40 Troubleshooting
Acronyms .................................................................................................................................................... 40-8
Information related to troubleshooting ...................................................................................................... 40-13
Points to remember when troubleshooting ............................................................................................ 40-13
How to proceed in troubleshooting ........................................................................................................ 40-14
Checks before troubleshooting .............................................................................................................. 40-15
Inspection procedure before troubleshooting......................................................................................... 40-17
Troubleshooting procedure .................................................................................................................... 40-32
Failure code list...................................................................................................................................... 40-34
Symptoms and troubleshooting numbers .............................................................................................. 40-42
Information described in troubleshooting table ...................................................................................... 40-45
Diagnosis of open harness in pressure sensor system ......................................................................... 40-47
Connector list and layout ....................................................................................................................... 40-49
Connector pin layout .............................................................................................................................. 40-63
T-box and T-adapter list ......................................................................................................................... 40-99
Locations of fuses ................................................................................................................................ 40-104
Troubleshooting by failure code (display of code)................................................................................... 40-107
Failure code [1500L0] Double Engagement of T/M Clutches .............................................................. 40-107
Failure code [15G0MW] Failure of R-Clutch System ........................................................................... 40-108
Failure code [15H0MW] Failure of Clutch System (FH)....................................................................... 40-109
Failure code [15J0MW] Failure of Clutch System (FL) .........................................................................40-110
Failure code [15K0MW] Failure of Clutch System (1st) ........................................................................40-111
Failure code [15L0MW] Failure of Clutch System (2nd) .......................................................................40-112
Failure code [15M0MW] Failure of Clutch System (3rd) .......................................................................40-113
Failure code [15N0MW] Failure of Clutch System (4th)........................................................................40-114
Failure code [15SBL1] Release Trouble of ECMV (R)..........................................................................40-115
Failure code [15SBMA] Malfunction of ECMV (R) ................................................................................40-117
Failure code [15SCL1] Release Trouble of ECMV (FH) .......................................................................40-119
Failure code [15SCMA] Malfunction of ECMV (FH)............................................................................. 40-121
Failure code [15SDL1] Release Trouble of ECMV (FL) ....................................................................... 40-123
Failure code [15SDMA] Malfunction of ECMV (FL) ............................................................................. 40-125
Failure code [15SEL1] Release Trouble of ECMV (1st) ...................................................................... 40-127
Failure code [15SEMA] Malfunction of ECMV (1st) ............................................................................. 40-129
Failure code [15SFL1] Release Trouble of ECMV (2nd) ..................................................................... 40-131
Failure code [15SFMA] Malfunction of ECMV (2nd) ............................................................................ 40-133
Failure code [15SGL1] Release Trouble of ECMV (3rd)...................................................................... 40-135
Failure code [15SGMA] Malfunction of ECMV (3rd) ............................................................................ 40-137
Failure code [15SHL1] Release Trouble of ECMV (4th) ...................................................................... 40-139
Failure code [15SHMA] Malfunction of ECMV (4th)............................................................................. 40-141
Failure code [15SJMA] Malfunction of ECMV (L/U)............................................................................. 40-143
Failure code [15U0NT] Overload of Inching Clutch ............................................................................. 40-144
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) ........................................................... 40-145
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear)............................................................ 40-147
Failure code [989L00] Engine Controller Lock Caution 1 .................................................................... 40-149
Failure code [989M00] Engine Controller Lock Caution 2 ................................................................... 40-150
Failure code [989N00] Engine Controller Lock Caution 3.................................................................... 40-151
Failure code [AB00KE] Charge Voltage Low ....................................................................................... 40-152
Failure code [AB00KY] Hot Short of Alternator R Terminal.................................................................. 40-153
Failure code [B@BAZG] Derating in speed due to engine oil pressure drop....................................... 40-154
Failure code [B@BCNS] Engine Overheat .......................................................................................... 40-155
Failure code [B@CENS] T/C Oil Temp. Overheat ............................................................................... 40-156
Failure code [B@CKNS] DIFF Oil Temp. Overheat ............................................................................. 40-157
Failure code [B@HANS] HYD Oil Temp. Overheat.............................................................................. 40-159
Failure code [CA111] Engine NE, controller internal error ................................................................... 40-161
Failure code [CA115] Engine NE, Bkup speed sensor error................................................................ 40-162
GD535-5 00-5
(01)
Failure code [CA122] Charge pressure sensor high error ................................................................... 40-163
Failure code [CA123] Charge pressure sensor low error..................................................................... 40-165
Failure code [CA131] Throttle sensor high error .................................................................................. 40-167
Failure code [CA132] Throttle sensor low error ................................................................................... 40-169
Failure code [CA144] Coolant sensor high error.................................................................................. 40-172
Failure code [CA145] Coolant sensor low error ................................................................................... 40-174
Failure code [CA153] Charge temperature sensor high error .............................................................. 40-176
Failure code [CA154] Charge temperature sensor low error ............................................................... 40-178
Failure code [CA155] Speed derating error by high charge temperature ............................................ 40-180
Failure code [CA187] Sensor power supply 2 low error....................................................................... 40-181
Failure code [CA221] Atmospheric pressure sensor high error ........................................................... 40-183
Failure code [CA222] Atmospheric pressure sensor low error ............................................................ 40-185
Failure code [CA227] Sensor power supply 2 high error ..................................................................... 40-187
Failure code [CA234] Engine overspeed ............................................................................................. 40-188
Failure code [CA238] Ne speed sensor power supply error ................................................................ 40-189
Failure code [CA271] IMV short-circuit error........................................................................................ 40-190
Failure code [CA272] IMV open circuit ................................................................................................ 40-192
Failure code [CA322] Injector #1 (L/B #1) open/short.......................................................................... 40-194
Failure code [CA342] Data compatibility error in engine controller ...................................................... 40-206
Failure code [CA351] Injector drive circuit error................................................................................... 40-207
Failure code [CA352] Sensor power supply 1 low error....................................................................... 40-208
Failure code [CA386] Sensor power supply 1 high error ..................................................................... 40-210
Failure code [CA428] Water-in-fuel sensor high error.......................................................................... 40-211
Failure code [CA429] Water-in-fuel sensor low error ........................................................................... 40-213
Failure code [CA431] Idle validation switch error................................................................................. 40-215
Failure code [CA432] Idle validation action error ................................................................................. 40-219
Failure code [CA435] Engine oil pressure switch error ........................................................................ 40-222
Failure code [CA441] Power supply voltage low error ......................................................................... 40-223
Failure code [CA442] Power supply voltage high error........................................................................ 40-225
Failure code [CA449] Common rail pressure high error 2 ................................................................... 40-226
Failure code [CA451] Common rail pressure sensor high error........................................................... 40-227
Failure code [CA452] Common rail pressure sensor low error ............................................................ 40-229
Failure code [CA488] Torque derating error by high charge temperature............................................ 40-231
Failure code [CA553] Common rail pressure high error 1 ................................................................... 40-232
Failure code [CA559] Supply pump pressure low error 1 .................................................................... 40-233
Failure code [CA689] Engine Ne speed sensor error .......................................................................... 40-235
Failure code [CA731] Engine Bkup speed sensor phase error............................................................ 40-237
Failure code [CA757] All continuous data lost error............................................................................. 40-239
Failure code [CA778] Engine Bkup speed sensor error....................................................................... 40-240
Failure code [CA1633] KOMNET (CAN communication) error ............................................................ 40-244
Failure code [CA2185] Throttle sensor power supply high error.......................................................... 40-248
Failure code [CA2186] Throttle sensor power supply low error ........................................................... 40-250
Failure code [CA2249] Supply pump pressure low error 2 .................................................................. 40-252
Failure code [CA2311] Abnormality in IMV (IMA) solenoid .................................................................. 40-253
Failure code [CA2555] Intake heater relay open circuit ....................................................................... 40-254
Failure code [CA2556] Intake heater relay short circuit ....................................................................... 40-256
Failure code [D160KA] Disconnection of Backup Light Relay ............................................................. 40-258
Failure code [D160KB] Ground Fault of Backup Light Relay............................................................... 40-260
Failure code [D160KY] Hot Short of Back Lamp Relay Output............................................................ 40-262
Failure code [D19JKZ] Personal Code Relay Abnormality .................................................................. 40-264
Failure code [D19KKZ] Failure of Diff Control Relay............................................................................ 40-266
Failure code [D1EHKA] Disconnection of Engine Start Relay ............................................................. 40-268
Failure code [D1EHKB] Ground Fault of Engine Start Relay ............................................................... 40-269
Failure code [D1EHKY] Hot Short of Engine Start Relay ..................................................................... 40-270
00-6 GD535-5
(01)
Failure code [D1FBKB] Ground Fault of Sol. Self-Holding Relay ........................................................ 40-271
Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 ......................................................................... 40-273
Failure code [D8AQKR] CAN2 Discon (KOMTRAX)............................................................................ 40-274
Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON)................................................... 40-276
Failure code [DAF0MB] Monitor ROM Abnormality ............................................................................. 40-277
Failure code [DAF0MC] Monitor Error ................................................................................................. 40-278
Failure code [DAF3KK] Controller Power Source Low (MON)............................................................. 40-279
Failure code [DAFLKA] Op Lamp Open Cir (Mon)............................................................................... 40-281
Failure code [DAFLKB] Op Lamp Shrt Cir (Mon)................................................................................. 40-283
Failure code [DAQ0KK] Controller Power Source Low (T/M) .............................................................. 40-285
Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M) .................................................... 40-287
Failure code [DAQ0MC] T/M Con Error ............................................................................................... 40-288
Failure code [DAQ1KA] Disconnection of Key SW ACC ..................................................................... 40-289
Failure code [DAQ2KK] Solenoid Power Source Low (T/M)................................................................ 40-291
Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M) ........................................................ 40-293
Failure code [DAQLKA] Op Lamp Open Cir (T/M Cont) ...................................................................... 40-294
Failure code [DAQLKB] Op Lamp Shrt Cir (T/M Cont) ........................................................................ 40-296
Failure code [DAQQKR] CAN2 Discon (Transmission Con)................................................................ 40-298
Failure code [DAQRMA] Inconsistency of Option Selection (T/M)....................................................... 40-299
Failure code [DB2QKR] CAN2 Discon (Engine Con)........................................................................... 40-300
Failure code [DD1PKB] Abnormality of RPM Switch ........................................................................... 40-304
Failure code [DD1QKB] Abnormality of RPM Set Mode Switch .......................................................... 40-306
Failure code [DDB6L4] Parking brake signal error .............................................................................. 40-308
Failure code [DDTHKA] Disconnection of Fill Switch (FH) .................................................................. 40-310
Failure code [DDTJKA] Disconnection of Fill Switch (FL).....................................................................40-311
Failure code [DDTKKA] Disconnection of Fill Switch (1st)................................................................... 40-312
Failure code [DDTLKA] Disconnection of Fill Switch (2nd).................................................................. 40-313
Failure code [DDTMKA] Disconnection of Fill Switch (3rd).................................................................. 40-314
Failure code [DDTNKA] Disconnection of Fill Switch (R)..................................................................... 40-315
Failure code [DDTPKA] Disconnection of Fill Switch (4th) .................................................................. 40-316
Failure code [DF10KA] Disconnection of Shift Lever Input.................................................................. 40-317
Failure code [DF10L4] Gear Speed/Travel Direction Signal Error ....................................................... 40-321
Failure code [DGF1KX] Out of Range of T/M Oil Temp. Sensor.......................................................... 40-324
Failure code [DGH2KB] Ground Fault of Hydraulic Oil Temp. S.......................................................... 40-326
Failure code [DGT1KX] Out of Range of T/C Oil Temp. Sensor .......................................................... 40-328
Failure code [DGT7KB] Ground Fault of Diff Oil Temp. S.(C).............................................................. 40-330
Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor .................................................. 40-331
Failure code [DHT5L6] Failure of T/C Oil Press Sensor ...................................................................... 40-333
Failure code [DJF1KA] Disconnection of Fuel Level Sensor ............................................................... 40-335
Failure code [DK70KX] Out of Range of Inching Potentio. .................................................................. 40-337
Failure code [DKD0KX] Out of Range of Articulated Angle Sensor..................................................... 40-339
Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor ..................................................... 40-341
Failure code [DLF1LC] Failure of T/M Input Speed Sensor ................................................................. 40-343
Failure code [DLF2KA] Disconnection of T/M Inter. Speed Sensor ..................................................... 40-345
Failure code [DLF2LC] Failure of T/M Intermediate Speed Sensor ..................................................... 40-347
Failure code [DLM3KA] Rad Fan Spd Sen Opn/Shrt Cir ..................................................................... 40-349
Failure code [DLM3LC] Rad Fan Spd Sen Sig Error ........................................................................... 40-351
Failure code [DLM3MB] Rad Fan Spd Sen Error................................................................................. 40-352
Failure code [DLT3KA] Disconnection of T/M output Speed Sensor ................................................... 40-353
Failure code [DW4BKA] Disconnection of Parking Brake Valve .......................................................... 40-355
Failure code [DW4BKB] Ground Fault of Parking Brake Valve............................................................ 40-357
Failure code [DW4BKY] Hot Short of Parking Brake Solenoid ............................................................ 40-359
Failure code [DW7BKA] Rad Fan R Sol Opn Cir ................................................................................. 40-361
Failure code [DW7BKB] Rad Fan R Sol Gnd Flt.................................................................................. 40-363
Failure code [DW7BKY] Rad Fan R Sol Shrt Cir ................................................................................. 40-365
Failure code [DX16KA] Rad Fan Pump EPC Sol Opn Cir ................................................................... 40-367
Failure code [DX16KB] Rad Fan Pump EPC Sol Gnd Flt.................................................................... 40-369
Failure code [DX16KY] Rad Fan Pmp EPC Sol Shrt Cir ..................................................................... 40-371
Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup)................................................... 40-373
GD535-5 00-7
(01)
Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup) .................................................... 40-375
Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup) .......................................................... 40-377
Failure code [DXH2KA] Disconnection of ECMV Solenoid (High) ....................................................... 40-379
Failure code [DXH2KB] Ground Fault of ECMV Solenoid (High)......................................................... 40-381
Failure code [DXH2KY] Hot Short of ECMV Solenoid (High) .............................................................. 40-383
Failure code [DXH3KA] Disconnection of ECMV Solenoid (Low) ........................................................ 40-385
Failure code [DXH3KB] Ground Fault of ECMV Solenoid (Low) ......................................................... 40-387
Failure code [DXH3KY] Hot Short of ECMV Solenoid (Low) ............................................................... 40-389
Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st).......................................................... 40-391
Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st) ........................................................... 40-393
Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st) ................................................................. 40-395
Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd) ........................................................ 40-397
Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd) .......................................................... 40-399
Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd) ................................................................ 40-401
Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd) ......................................................... 40-403
Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd) ........................................................... 40-405
Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd)................................................................. 40-407
Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse) ................................................. 40-409
Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse)................................................... 40-411
Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse) ........................................................ 40-413
Failure code [DXHHKA] Disconnection of ECMV Solenoid (4th) ......................................................... 40-415
Failure code [DXHHKB] Ground Fault of ECMV Solenoid (4th) .......................................................... 40-417
Failure code [DXHHKY] Hot Short of ECMV Solenoid (4th) ................................................................ 40-419
Troubleshooting of electrical system (E-mode)....................................................................................... 40-421
E-1 Engine does not start (Starting motor does not rotate).................................................................. 40-421
E-2 Manual preheating system does not work ..................................................................................... 40-425
E-3 When starting switch is turned ON, machine monitor displays nothing......................................... 40-431
E-4 LCD panel backlight of machine monitor fails (goes out or flickers).............................................. 40-434
E-5 LCD display failure of machine monitor......................................................................................... 40-435
E-6 The switch of machine monitor switch panel does not work.......................................................... 40-436
E-7 Two-switch operation of switch panel on machine monitor does not function. .............................. 40-437
E-8 Machine monitor buzzer does not sound. ..................................................................................... 40-438
E-9 Some gauges or caution lamps of machine monitor do not work normally. .................................. 40-439
E-10 Rearview monitor does not light up or backlight flickers. ............................................................ 40-440
E-11 Rearview monitor images are not displayed clearly .................................................................... 40-442
E-12 Rearview monitor brightness cannot be adjusted ....................................................................... 40-444
E-13 Night lighting lamp of rearview monitor is abnormal.................................................................... 40-447
E-14 Speedometer or engine speed display is abnormal. ................................................................... 40-449
E-15 Engine coolant temperature is displayed abnormally. ................................................................. 40-450
E-16 Articulated meter display is abnormal. ........................................................................................ 40-452
E-17 Torque converter oil temperature is displayed abnormally. ......................................................... 40-454
E-18 Fuel gauge is displayed abnormally. ........................................................................................... 40-456
E-19 Centralized warning lamps do not light or do not go out. ............................................................ 40-458
E-20 Alarm buzzer does not sound or does not stop sounding. .......................................................... 40-459
E-21 Transmission mode cannot be switched. .................................................................................... 40-461
E-22 Engine mode cannot be switched. .............................................................................................. 40-463
E-23 Differential gear lock function does not operate or is not canceled (for differential gear lock model). .40-465
E-24 Cannot be locked or canceled by the lifter lock pin. .................................................................... 40-467
E-25 Horn does not sound or does not stop sounding......................................................................... 40-469
E-26 Backup alarm does not sound or does not stop sounding. ......................................................... 40-471
E-27 Headlamps, clearance lamps, and tail lamps do not light up or go out. ...................................... 40-474
E-28 Working lamps do not light up or go out. ..................................................................................... 40-482
E-29 Turn indicator light or emergency flashing light does not flash.................................................... 40-487
E-30 Stop lamp does not light up or does not go out. .......................................................................... 40-496
E-31 Backup lamp does not light up or does not go out ...................................................................... 40-498
E-32 All wipers do not operate............................................................................................................. 40-500
E-33 Front wiper does not operate ...................................................................................................... 40-502
E-34 Rear wiper does not operate ....................................................................................................... 40-506
E-35 Left and right door wiper does not operate.................................................................................. 40-509
00-8 GD535-5
(01)
E-36 Left door wiper does not operate................................................................................................. 40-512

E-37 Right door wiper does not operate .............................................................................................. 40-514
E-38 Front or door washer does not operate ....................................................................................... 40-516
E-39 Rear washer does not operate .................................................................................................... 40-518
E-40 KOMTRAX system does not operate normally............................................................................ 40-520
Troubleshooting of hydraulic and mechanical system (H-mode) ............................................................ 40-522
How to use troubleshooting table......................................................................................................... 40-522
H-1 Engine speed drops significantly or engine stalls ......................................................................... 40-528
H-2 Machine does not move off. .......................................................................................................... 40-529
H-3 Gear speed does not shift. ............................................................................................................ 40-530
H-4 Travel speed or power is low......................................................................................................... 40-531
H-5 Torque converter lockup does not operate or is not canceled....................................................... 40-534
H-6 Machine starts or gear speed shifts with long time lag.................................................................. 40-535
H-7 Torque converter oil temperature is high....................................................................................... 40-538
H-8 Differential gear lock function does not operate or is not canceled............................................... 40-541
H-9 Steering speed or power is insufficient.......................................................................................... 40-542
H-10 Steering wheel does not move .................................................................................................... 40-543
H-11 Wheel brakes do not work or are weak ....................................................................................... 40-544
H-12 Wheel brakes are not released or drag....................................................................................... 40-545
H-13 Parking brake does not work or it is weak................................................................................... 40-546
H-14 Parking brake (including emergency release system) is not released or drags.......................... 40-547
H-15 All work equipment operates slowly or lacks power.................................................................... 40-548
H-16 Work equipment does not operate. ............................................................................................. 40-549
H-17 Unusual noise is heard from around hydraulic pump.................................................................. 40-550
H-18 Blade lift speed or power is low................................................................................................... 40-551
H-19 Hydraulic drift of lifted blade is large. .......................................................................................... 40-552
H-20 Drawbar side shift speed or power is low.................................................................................... 40-553
H-21 Blade side shift speed or power is low. ....................................................................................... 40-554
H-22 Power tilt speed or power is low.................................................................................................. 40-555
H-23 Articulate speed or power is low.................................................................................................. 40-556
H-24 Leaning speed or power is insufficient. ....................................................................................... 40-557
H-25 Hydraulic drift (tilting) of leaning is large. .................................................................................... 40-558
H-26 Blade does not rotate. ................................................................................................................. 40-559
H-27 Lifter lock pin is not locked or is not canceled............................................................................. 40-560
H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats)....... 40-561
Troubleshooting of engine (S-mode)....................................................................................................... 40-563
How to read matrix............................................................................................................................... 40-563
S-1 Engine startability is poor. ............................................................................................................. 40-566
S-2 Engine does not start. ................................................................................................................... 40-567
S-3 Engine does not pick-up smoothly................................................................................................. 40-570
S-4 Engine stops during operation....................................................................................................... 40-571
S-5 Engine runs rough or is unstable................................................................................................... 40-572
S-6 Engine lacks power. ...................................................................................................................... 40-573
S-7 Exhaust smoke is black (Incomplete combustion) ........................................................................ 40-574
S-8 Large oil consumption (or blue exhaust gas) ................................................................................ 40-575
S-9 Oil becomes contaminated early. .................................................................................................. 40-576
S-10 Fuel consumption is excessive.................................................................................................... 40-577
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) .......................................... 40-578
S-12 Oil pressure drops. ...................................................................................................................... 40-579
S-13 Oil amount increases (due to water or fuel mixing). .................................................................... 40-580
S-14 Coolant temperature rises too high (overheating). ...................................................................... 40-581
S-15 Unusual noise is heard................................................................................................................ 40-582
S-16 Vibration is excessive.................................................................................................................. 40-583
50 Disassembly and assembly

Acronyms .................................................................................................................................................... 50-4
Related information on disassembly and assembly.................................................................................... 50-9
How to read this manual .......................................................................................................................... 50-9
Coating materials list...............................................................................................................................50-11
GD535-5 00-9
(02)
Special tool list ....................................................................................................................................... 50-15

Sketches of special tools ....................................................................................................................... 50-23
Engine and cooling system ....................................................................................................................... 50-51
Removal and installation of supply pump assembly .............................................................................. 50-51
Removal and installation of injector assembly ....................................................................................... 50-55
Removal and installation of cylinder head assembly ............................................................................. 50-64
Removal and installation of air conditioner compressor belt.................................................................. 50-82
Removal and installation of alternator belt ............................................................................................. 50-83
Removal and installation of engine front oil seal.................................................................................... 50-85
Removal and installation of engine rear oil seal .................................................................................... 50-88
Removal and installation of cooling fan pump assembly ....................................................................... 50-91
Removal and installation of cooling fan and fan motor assembly .......................................................... 50-93
Removal and installation of radiator assembly ...................................................................................... 50-97
Removal and installation of aftercooler assembly................................................................................ 50-101
Removal and installation of power train oil cooler assembly................................................................ 50-105
Removal and installation of fuel tank assembly ................................................................................... 50-108
Removal and installation of engine hood assembly ............................................................................. 50-112
Removal and installation of air conditioner compressor assembly ...................................................... 50-114
Power train .............................................................................................................................................. 50-116
Removal and installation of engine, transmission, and torque converter assembly............................. 50-116
Disconnection and connection of engine, transmission, and torque converter assembly.................... 50-124
Disassembly and assembly of torque converter assembly .................................................................. 50-126
Disassembly and assembly of transmission assembly ........................................................................ 50-137
Removal and installation of tandem drive and final drive assembly..................................................... 50-172
Disassembly and assembly of tandem drive assembly........................................................................ 50-175
Disassembly and assembly of differential assembly............................................................................ 50-181
Disassembly and assembly of final drive assembly ............................................................................. 50-194
Steering system ...................................................................................................................................... 50-203
Removal and installation of Orbitrol valve assembly............................................................................ 50-203
Brake system .......................................................................................................................................... 50-208
Disassembly and assembly of wheel brake assembly......................................................................... 50-208
Undercarriage and frame ........................................................................................................................ 50-216
Removal and installation of center hinge pin ....................................................................................... 50-216
Hydraulic system..................................................................................................................................... 50-227
Removal and installation of hydraulic tank, battery, and frame assembly............................................ 50-227
Removal and installation of hydraulic tank assembly........................................................................... 50-234
Removal and installation of control valve assembly............................................................................. 50-238
Disassembly and assembly of hydraulic cylinder assembly ................................................................ 50-243
Work equipment ...................................................................................................................................... 50-247
Removal and installation of blade assembly ........................................................................................ 50-247
Removal and installation of circle drawbar assembly .......................................................................... 50-248
Removal and installation of circle rotation gear assembly ................................................................... 50-250
Disassembly and assembly of circle rotation gear assembly............................................................... 50-252
Cab and its attachments ......................................................................................................................... 50-257
Removal and installation of operator's cab assembly .......................................................................... 50-257
Removal and installation of operator cab glass (adhered glass) ......................................................... 50-266
Removal and installation of floor frame assembly................................................................................ 50-276
Removal and installation of operator's cab and floor frame assembly................................................. 50-280
Removal and installation of air conditioner unit assembly ................................................................... 50-287
Removal and installation operator's seat ............................................................................................. 50-293
Removal and installation seat belt ....................................................................................................... 50-294
Electrical system ..................................................................................................................................... 50-296
Removal and installation of engine controller assembly ...................................................................... 50-296
Removal and installation of machine monitor assembly ...................................................................... 50-298
Removal and installation of transmission controller assembly............................................................. 50-299
Removal and installation of rearview camera ...................................................................................... 50-301
Removal and installation of KOMTRAX terminal assembly ................................................................. 50-303
00-10 GD535-5
(02)
60 Maintenance standard
Acronyms .................................................................................................................................................... 60-3
Engine and cooling system ......................................................................................................................... 60-8
Engine mount and transmission mount.................................................................................................... 60-8
Cooling system ........................................................................................................................................ 60-9
Cooling fan motor................................................................................................................................... 60-10
Power train system ................................................................................................................................... 60-12
Torque converter .................................................................................................................................... 60-12
Transmission.......................................................................................................................................... 60-14
Main relief valve and torque converter relief valve................................................................................. 60-23
Front axle ............................................................................................................................................... 60-24
Rear axle................................................................................................................................................ 60-26
Differential (Non-differential specification) ............................................................................................. 60-27
Differential (Differential lock specification) ............................................................................................. 60-28
Final drive .............................................................................................................................................. 60-30
Differential lock solenoid valve............................................................................................................... 60-31
Tandem drive ......................................................................................................................................... 60-32
Steering system ........................................................................................................................................ 60-33
Steering cylinder .................................................................................................................................... 60-33
Brake system ............................................................................................................................................ 60-34
Wheel brake........................................................................................................................................... 60-34
Parking brake......................................................................................................................................... 60-35
Undercarriage and frame .......................................................................................................................... 60-36
Frame and center hinge pin ................................................................................................................... 60-36
Hydraulic system....................................................................................................................................... 60-37
Hydraulic tank ........................................................................................................................................ 60-37
Work equipment pump and steering pump ............................................................................................ 60-38
Power train pump................................................................................................................................... 60-39
Power train pump and differential lock pump......................................................................................... 60-40
Parking brake solenoid valve and lifter lock pin solenoid valve ............................................................. 60-41
Leaning cylinder..................................................................................................................................... 60-42
Articulate cylinder................................................................................................................................... 60-43
Blade lift cylinder.................................................................................................................................... 60-44
Drawbar shift cylinder ............................................................................................................................ 60-45
Blade side shift cylinder ......................................................................................................................... 60-46
Power tilt cylinder................................................................................................................................... 60-47
Scarifier cylinder .................................................................................................................................... 60-48
Ripper cylinder ....................................................................................................................................... 60-49
Work equipment........................................................................................................................................ 60-50
Circle and drawbar................................................................................................................................. 60-50
Blade...................................................................................................................................................... 60-52
Lifter ....................................................................................................................................................... 60-54
Circle rotation gear................................................................................................................................. 60-55
Ripper .................................................................................................................................................... 60-57
80 Appendix
Acronyms .................................................................................................................................................... 80-3
Air conditioner system................................................................................................................................. 80-8
Precautions for refrigerant ....................................................................................................................... 80-8
Air conditioner component ....................................................................................................................... 80-9
Specifications of air conditioner ............................................................................................................. 80-12
Configuration and function of refrigeration cycle.................................................................................... 80-13
Outline of refrigeration cycle .................................................................................................................. 80-14
Component parts of air conditioner system............................................................................................... 80-16
Air conditioner unit ................................................................................................................................. 80-16
Component parts of air conditioner unit ................................................................................................. 80-19
Compressor ........................................................................................................................................... 80-21
Condenser ............................................................................................................................................. 80-22
Receiver drier......................................................................................................................................... 80-23
GD535-5 00-11
(02)
Explanation of procedure for testing and troubleshooting of air conditioner .......................................... 80-24
Circuit diagram and arrangement of connector pins for air conditioner ................................................. 80-26
Air conditioner system diagram.............................................................................................................. 80-28
Input and output signals of air conditioner control panel........................................................................ 80-29
Installation locations of air conditioner parts and arrangement of connectors ....................................... 80-32
Testing air leakage (duct) .......................................................................................................................... 80-37
Method for testing air leakage (duct) ..................................................................................................... 80-37
Testing air conditioner using self-diagnosis function.............................................................................. 80-39
Check temperature control function .......................................................................................................... 80-40
Method for checking temperature control function ................................................................................. 80-40
Testing fresh/recirc air changeover ........................................................................................................... 80-41
Method for testing fresh/recirc air changeover....................................................................................... 80-41
Test evaporator temperature sensor ......................................................................................................... 80-42
Method for checking evaporator temperature sensor ............................................................................ 80-42
Test relays ................................................................................................................................................. 80-43
Method for testing relays........................................................................................................................ 80-43
Check blower AMP ................................................................................................................................... 80-44
Method for checking blower AMP .......................................................................................................... 80-44
Air conditioner troubleshooting chart 1 .................................................................................................. 80-46
Air conditioner troubleshooting chart 2 .................................................................................................. 80-48
Information described in troubleshooting table ...................................................................................... 80-51
A-1 Troubleshooting for power supply system (air conditioner does not operate) ................................. 80-52
A-2 Troubleshooting for compressor and refrigerant system (air is not cooled) .................................... 80-54
A-3 Troubleshooting for blower motor system (no air comes out or air flow is abnormal) ..................... 80-57
A-4 Troubleshooting for temperature control function............................................................................ 80-60
A-5 Troubleshooting for fresh/recirc air changeover .............................................................................. 80-63
A-6 Troubleshooting for hot water cut valve........................................................................................... 80-66
Troubleshooting using gauge pressure.................................................................................................. 80-68
Connection of service tool......................................................................................................................... 80-70
Method for connecting service tool ........................................................................................................ 80-71
Precautions for disconnecting and connecting hoses and tubes in air conditioner pipings ................... 80-72
Handle compressor oil ........................................................................................................................... 80-74
90 Diagrams and drawings

Acronyms .................................................................................................................................................... 90-3
Hydraulic diagrams and drawings ............................................................................................................... 90-8
Symbols used in hydraulic circuit diagrams ............................................................................................. 90-8
Hydraulic circuit diagram........................................................................................................................ 90-11
Power train hydraulic circuit diagram ..................................................................................................... 90-15
Electrical diagrams and drawings ............................................................................................................. 90-17
Symbols used in electric circuit diagrams .............................................................................................. 90-17
Chassis electric circuit diagram ............................................................................................................. 90-21
Floor electric circuit diagram .................................................................................................................. 90-31
Index ................................................................................................................................................................ 1
00-11-1 GD535-5
(02)
GD535-5 00-11-2
(02)
Acronyms 00 Index and foreword
Acronyms 1
q The abbreviations of unknown parts, equipment and functions have been extracted from the Shop Manual,
and their official names and details are defined in this Acronyms.
q Abbreviations that are commonly used in society might not be described.
q Special and rarely used abbreviations are described in the supplementary explanation in the text.
q The acronyms consist of two parts: the list of abbreviations that are used in the text, and the list of abbrevia-
tions that are used in circuit diagrams.
Abbreviations that are used in the text 1
Application (Applicable
Abbreviations Official name Explanation
models (*1) and equipment)
Traveling, brake With this function, when the tires skid (wheels stop
ABS Antilock Brake System rotating), the brakes are released, and when the
(HD series, HM series) wheels start to rotate, the brakes are applied again.
Automatic Idling Setting
AISS Engine This function automatically sets the idle speed.
System
Steering A lever is used to perform the steering operations
Advanced Joystick
AJSS instead of a steering wheel. Moreover, it shifts gear
Steering System (WA series) and changes direction (FORWARD or REVERSE).
Traveling, brake When the accelerator pedal is released while the
Automatic Retarder machine is traveling downhill, this function
ARAC
Accelerator Control (HD series, HM series) automatically applies the retarder with a constant
braking force.
machine is traveling downhill, this function
Automatic Retarder
ARSC automatically applies the retarder to ensure that the
Speed Control (HD series, HM series) machine speed does not accelerate above the
speed set by the operator.
Traveling, brake When the tires spin on soft ground surfaces, this
Automatic Spin
ASR function automatically uses the optimum braking
Regulator (HD series, HM series) force to drive both wheels.
The function or parts which are attached to the
ATT Attachment Work equipment
standard model and used
Brake When the retarder is not being used, this valve
Brake Cooling oil
BCV bypasses part of the brake cooling oil to reduce the
control Valve (HD series) load on the hydraulic pump.
Communication, electronic One of communication standards that is used in the
CAN Controller Area Network
control network on the machine
A regulator valve which is installed to KCCV
Crankcase Depression
CDR Engine ventilator. It is written as CDR valve and it is not
Regulator
used independently.
This system can simultaneously actuate multiple
Closed-center Load
CLSS Hydraulic system actuators regardless of the load (provides better
Sensing System
combined operation than OLSS).
Engine controller electronically controls supply
pump, common rail, and injector. This function
CRI Common Rail Injection Engine
maintains optimum fuel injection amount and fuel
injection timing.
Electronic control device that receives signals from
Electronic Control each sensor of the machine and that specifies the
ECM Electronic control
Module optimum operation to the actuators. (Same as
ECU)
00-12 GD535-5
(01)
00 Index and foreword Acronyms
Transmission Proportional solenoid valve that reduces the
Electronic Control
ECMV (D series, HD series, WA connection shock by gradually increasing the
Modulation Valve
series and others) hydraulic pressure to engage the clutch.
Electronically Traveling This system ensures smooth high-speed travel by

ECSS Controlled Suspension absorbing vibration of machine during travel with
System (WA series) hydraulic spring effect of accumulator.
each sensor of the machine and that specifies the
ECU Electronic Control Unit Electronic control
optimum operation to the actuators. (Same as
ECM)
This function recirculates part of exhaust gas to the
Exhaust Gas
EGR Engine combustion chamber in order to reduce combustion
Recirculation
temperature and control the emission of NOx.
This system allows data (filter, oil replacement
Equipment
interval, malfunctions on machine, failure code, and
EMMS Management Machine monitor
failure history) from each sensor on the machine to
Monitoring System
be checked on the monitor.
Electromagnetic proportional control This
Electromagnetic
EPC Hydraulic system mechanism allows actuators to be operated in
Proportional Control
proportion to the current supplied.
This structure protects the operator's head from
Falling Object falling objects. (Falling Object Protective Structure)
FOPS Operator's cab, canopy
Protective Structure
This performance is standardized as ISO 3449.
Forward-Neutral-Rever
F-N-R Operation Forward-Neutral-Reverse
se
Communication Global positioning system The satellite positioning
Global Positioning
GPS (KOMTRAX, KOMTRAX system to determine the current position on the
System
Plus) earth
Communication Global navigation satellite system A general term

Global Navigation
GNSS (KOMTRAX, KOMTRAX for positioning system using satellites such as
Satellite System
Plus) GPS, GALILEO, etc.
Steering This function uses a combination of hydraulic motor

Hydrostatic Steering and bevel shaft to control difference in travel speed
HSS
System (D series) of right and left tracks. Accordingly machine can
turn without using steering clutch.
Transmission This function uses a combination of hydraulic pump
Hydro Static
HST and hydraulic motor to shift the speed range
Transmission (D series, WA series) steplessly without using gears.
Information and A general term for the engineering and its socially
Communication, electronic
ICT Communication applied technology of information processing and
control
Technology communication.
Valve that adjusts fuel intake amount at inlet port of
IMA Inlet Metering Actuator Engine pump in order to control fuel discharged volume of
supply pump. (Same as IMV)
This is a device to detect the angle (or angular
Inertial Measurement
IMU Engine velocity) and acceleration of the 3 axes that control
Unit
motions.
Valve adjusting fuel intake amount at inlet port of
IMV Inlet Metering Valve Engine pump in order to control fuel discharged volume of
supply pump. (Same as IMA)
GD535-5 00-13
(01)
The mechanism for oil separation from gas in order
KOMATSU Closed
KCCV Engine to re-burn the blow-by gas and for oil return to the
Crankcase Ventilation
intake system. It is mainly composed of filters.
KOMATSU Catalyzed The filter to capture the soot from exhaust gas.
KCSF Engine
Soot Filter It is built in the KDPF.
The catalyst for exhaust gas purification.
KOMATSU Diesel
KDOC Engine It may be built in the KDPF or combined with the
Oxidation Catalyst
muffler.
This component is used to purify the exhaust gas.
KOMATSU Diesel KDOC (catalyst) and KCSF (filter to capture soot)
KDPF Engine are built-in it.
Particulate Filter
It is used instead of the conventional muffler.
Traveling, brake This function recovers the drive force of the wheels
by braking automatically with the optimum force
KOMATSU Traction
KTCS and at the same time activates the inter-axle
Control System (HM series) differential lock when the wheels idle while the
machine travels on the soft ground road.
The liquid crystal display panel. Image display
LCD Liquid Crystal Display Machine monitor device such as a monitor which assembles in the
liquid crystal element.
Light emitting diode It refers to semiconductor
LED Light Emitting Diode Electronic components element that emits light when the voltage is applied
in forward direction.
Local Interconnect Communication, electronic One of communication standards that is used in the
LIN
Network control network on the machine
Function that detects differential pressure of pump
LS Load Sensing Hydraulic system and controls discharged volume corresponding to
load.
Low Voltage Differential Communication, electronic One of communication standards that is used in the
LVDS
Signaling control network on the machine
The intake airflow rate of the engine. It is not used
alone, but used in combination with sensors. The
MAF Mass Air Flow Engine
intake airflow sensor may be called the MAF
sensor.
The service to allow transmission and reception of
Multimedia Messaging
MMS Communication short messages such as characters, voice and
Service
images between mobile phones.
The characteristics of an electric or hydraulic circuit
Electric system, hydraulic that is normally closed when the system is not
NC Normally Closed
system operating, and that is normally opened when the
system is operating.
Electric system, hydraulic that is normally opened when the system is not
NO Normally Open
system operating, and that is normally closed when the
Open-center Load The hydraulic system that can simultaneously
OLSS Hydraulic system
Sensing System operate multiple actuators regardless of the load.
Pressure The function to compensate for the hydraulic
PC Hydraulic system
Compensation pressure.
00-14 GD535-5
(01)
00 Index and foreword Acronyms
Steering The function to make the controller analyze the
Palm Command Control lever, pedal, and dial data instantaneously, and to
PCCS
System (D series) allow the electronic control of engine, transmission
and others appropriately.
This valve is installed at inlet port of pump and it
Pre-stroke Control
PCV Engine adjusts fuel intake amount in order to control fuel
Valve
discharged volume of supply pump.
Used for controlling proportional pressure. This
Proportional Pressure
PPC Hydraulic system system moves actuators in proportion to the
Control
hydraulic pressure.
Hydraulic system
PPM Piston Pump and Motor Piston hydraulic pump and motor.
(D series, PC series, others)
PTO Power Take Off Power transmission Power take-off mechanism
Power Tilt and power Work equipment This function performs hydraulic control of the tilt
PTP
Pitch dozer (D series) and pitch of the bulldozer blade.
The structure to protect the operator (fastened with

Roll-Over Protective seat belt) if the machine falls. (Roll-over protective
ROPS Operator's cab, canopy structure for operator)
Structure
The exhaust gas purification device, that uses urea
water and converts the nitrogen oxides (NOx) into
Selective Catalytic
SCR Urea SCR system harmless nitrogen and water (by reduction
Reduction
reaction). It may be called part of the exhaust gas
purifying catalyst or the related device name.
Le SystÐ®me Abbreviated for the "International System of Units".
SI International d‚Äô Unit It is the universal unit system and "A single unit for
UnitÐ©s a single quantity" is the basic principle applied.
It refers to an actuator consisting of a solenoid and
SOL Solenoid Electrical system an iron core that is moved by the magnetic force
when the solenoid is energized.
TWV 2-Way Valve Hydraulic system Solenoid valve that switches over direction of flow.
Variable Geometry Turbocharger having the variable geometry of
VGT Engine
Turbocharger exhaust passage
*1: Applicable model codes

D: Bulldozer
HD: Dump truck
HM: Articulated dump truck
PC: Hydraulic excavator
WA: Wheel loader
GD535-5 00-15
(01)
Abbreviations used in circuit diagrams 1

Abbreviations Official name
A/C Air Conditioner
A/D Analogue-to-Digital
A/M Air Mix damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
CCW Counter Clockwise
ECU Electronic Control Unit
ECM Electronic Control Module
ENG Engine
EXGND External Ground
F.G. Frame Ground
GND Ground
IMA Inlet Metering Actuator
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/C Torque Converter
T/M Transmission
00-16 GD535-5
(01)
00 Index and foreword Safety notice
Foreword and general information 1

Safety notice 1
(Rev. 2009/9)
Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair tech-
niques 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 cau-
tions accompanying these symbols should always be followed carefully. If any dangerous situation arises
or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.
1. General precautions
k Mistakes in operation are extremely danger- 9) Avoid continuing work for long hours and take
ous. Read the Operation and Maintenance rests at proper intervals to keep your body in
Manual carefully before operating the ma- good condition.
chine. In addition, read this manual and un- Take rests in specified safe places.
derstand its contents before starting the
work. Safety points
1) Before carrying out any greasing or repairs, 1 Good arrangement
read all the safety labels stuck to the machine. 2 Correct work clothes
For the locations of the safety labels and 3 Following work standard
detailed explanation of precautions, see the 4 Making and checking signals
Prohibition of operation and handling by unli-
Operation and Maintenance Manual. 5
censed workers
2) Decide a place in the repair workshop to keep 6 Safety check before starting work
tools and removed parts. Always keep the tools Wearing protective goggles(for cleaning or grind-
and parts in their correct places. Always keep 7
ing work)
the work area clean and make sure that there is Wearing shielding goggles and protectors(for
8
no dirt, water, or oil on the floor. Smoke only in welding work)
the areas provided for smoking. Never smoke 9 Good physical condition and preparation
while working. Precautions against work which you are not used
10
3) When carrying out any operation, always wear to or you are used to too much
safety shoes and helmet. Do not wear loose
work clothes, or clothes with buttons missing.
q Always wear safety glasses when hitting
parts with a hammer.
q Always wear safety glasses when grinding
parts with a grinder, etc.
4) When carrying out any operation with 2 or more
workers, always agree on the operating proce-
dure before starting. Always inform your fellow
workers before starting any step of the opera-
tion. Before starting work, hang UNDER
REPAIR warning tag in the operator's compart-
ment.
5) Only qualified workers must carry out work and
operation which require license or qualification.
6) Keep all tools in good condition, learn the
correct way to use them, and use the proper
ones. Before starting work, thoroughly check
the tools, machine, forklift, service car, etc.
7) If welding repairs are needed, always have a
trained and experienced welder carry out the
work. When carrying out welding work, always
wear welding gloves, apron, shielding goggles,
cap and other clothes suited for welding work.
8) Before starting work, warm up your body thor-
oughly to start work under good condition.
GD535-5 00-17
(01)
Safety notice 00 Index and foreword
2. Preparation work 7) When removing components, be careful not to

1) Before adding oil or making any repairs, park break or damage the electrical wiring.
the machine on a hard and level ground, and Damaged wiring may cause electrical fires.
apply the parking brake and block the wheels or 8) When removing piping, stop the fuel or oil from
tracks to prevent the machine from moving. spilling out. If any fuel or oil drips onto the floor,
2) Before starting work, lower the work equipment wipe it up immediately. Fuel or oil on the floor
(blade, ripper, bucket, etc.) to the ground. If this can cause you to slip and can even start fires.
is not possible, insert the lock pin or use blocks 9) As a general rule, do not use gasoline to wash
to prevent the work equipment from falling. In parts. Do not use it to clean electrical parts, in
addition, be sure to lock all the control levers particular.
and hang warning tag on them. 10)Be sure to assemble all parts again in their orig-
3) When disassembling or assembling, support inal places. Replace any damaged parts and
the machine with blocks, jacks, or stands parts which must not be reused with new parts.
before starting work. When installing hoses and wires, be sure that
4) Remove all mud and oil from the steps or other they will not be damaged by contact with other
places used to get on and off the machine. parts when the machine is operated.
Always use the handrails, ladders or steps 11)When installing high pressure hoses and tubes,
when getting on or off the machine. Never jump make sure that they are not twisted. Damaged
on or off the machine. If it is impossible to use hoses and tubes are dangerous, so be
the handrails, ladders or steps, use a stand to extremely careful when installing hoses and
provide safe footing. tubes for high pressure circuits. In addition,
check that connections of them are correct.
3. Precautions during work 12)When assembling or installing parts, always
1) Before disconnecting or removing components tighten them to the specified torques. When
of the oil, water, or air circuits, first release the installing protective parts such as guards, or
pressure completely from the circuit. When parts which vibrate violently or rotate at high
removing the oil filler cap, a drain plug, or an oil speeds, be particularly careful to check that
pressure pickup plug, loosen it slowly to prevent they are installed correctly.
the oil from spurting out. 13)When aligning 2 holes, never insert your fingers
2) The coolant and oil in the circuits are hot when or hand. Be careful not to get your fingers
the engine is stopped, so be careful not to get caught in a hole.
scalded. Wait for the oil and coolant to cool 14)When measuring hydraulic pressure, check
before carrying out any work on the oil or water that the measuring tools are correctly installed.
circuits. 15)Take care when removing or installing the
3) Before starting work, stop the engine. When tracks of track-type machines. When removing
working on or around a rotating part, in partic- the track, the track separates suddenly, so
ular, stop the engine. When checking the never let anyone stand at either end of the
machine without stopping the engine track.
(measuring oil pressure, revolving speed, 16)If the engine is operated for a long time in a
temperature, etc.), take extreme care not to get place which is not ventilated well, you may
caught in rotating parts or moving parts. suffer from gas poisoning. Accordingly, open
4) Before starting work, remove the leads from the the windows and doors to ventilate well.
battery. Always remove the lead from the nega-
tive (-) terminal first.
5) When raising a heavy component (heavier than
25kg), use a hoist or crane. Before starting
work, check that the slings (wire ropes, chains,
and hooks) are free from damage. Always use
slings which have ample capacity and install
them to proper places. Operate the hoist or
crane slowly to prevent the component from
hitting any other part. Do not work with any part
still raised by the hoist or crane.
6) When removing a cover which is under internal
pressure or under pressure from a spring,
always leave 2 bolts in diagonal positions.
Loosen those bolts gradually and alternately to
release the pressure, and then remove the
cover.
00-18 GD535-5
(01)
4. Precautions for sling work and making signals

1) Only one appointed worker must make signals
and co-workers must communicate with each
other frequently. The appointed signaler must
make specified signals clearly at a place where
he is well seen from the operator's seat and
where he can see the working condition easily.
The signaler must always stand in front of the
load and guide the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling work.
3) Keep putting on gloves during sling work. (Put
on leather gloves, if available.)
4) Measure the weight of the load by the eye and 8) When installing wire ropes to an angular load,
check its center of gravity. apply pads to protect the wire ropes. If the load
5) Use proper sling according to the weight of the is slippery, apply proper material to prevent the
load and method of slinging. If too thick wire wire rope from slipping.
ropes are used to sling a light load, the load 9) Use the specified eyebolts and fix wire ropes,
may slip and fall. chains, etc. to them with shackles, etc.
6) Do not sling a load with 1 wire rope alone. It 10)Apply wire ropes to the middle portion of the
may rotate and may slip out of the rope. Install hook.
2 or more wire ropes symmetrically.
k Slinging with 1 rope may cause turning
q Slinging near the tip of the hook may cause
the rope to slip off the hook during hoisting.
of the load during hoisting, untwisting of The hook has the maximum strength at the
the rope, or slipping of the rope from its middle portion.
original winding position on the load,
which can result in a dangerous acci-
dent.
7) Limit the hanging angle to 60 °, as a rule.
Do not sling a heavy load with ropes forming a
wide hanging angle from the hook.
When hoisting a load with 2 or more ropes, the
force subjected to each rope will increase with
the hanging angle. The table below shows the
variation of allowable load in kN {kg} when
hoisting is made with 2 ropes, each of which is
allowed to sling up to 9.8kN {1,000kg} verti-
cally, at various hanging angles. When the 2
ropes sling a load vertically, up to 19.6kN
{2,000kg} of total weight can be suspended. 11)Do not use twisted or kinked wire ropes.
This weight is reduced to 9.8kN {1,000kg} when 12)When lifting a load, observe the following.
the 2 ropes make a hanging angle of 120 °. If q Wind in the crane slowly until wire ropes are
the 2 ropes sling a 19.6kN {2,000kg } load at a stretched. When settling the wire ropes with
lifting angle of 150 ° , each of them is subjected the hand, do not grasp them but press them
to a force as large as 39.2kN {4,000kg}. from above. If you grasp them, your fingers
may be caught.
q After the wire ropes are stretched, stop the
crane and check the condition of the slung
load, wire ropes, and pads.
GD535-5 00-19
(01)
Safety notice 00 Index and foreword
If the load is unstable or the wire rope or

q 13)If the hoist stops because of a power failure,
chains are twisted, lower the load and lift it turn the power switch OFF. When turning on a
up again. switch which was turned OFF by the ground
q Do not lift up the load at an angle. fault circuit interrupter, check that the devices
13)When lowering a load, observe the following. related to that switch are not in operation state.
q When lowering a load, stop it temporarily at 14)If you find an obstacle around the hoist, stop the
30cm above the floor, and then lower it operation.
slowly. 15)After finishing the work, stop the hoist at the
q Check that the load is stable, and then re- specified position and raise the hook to at least
move the sling. 2m above the floor. Do not leave the sling
q Remove kinks and dirt from the wire ropes installed to the hook.
and chains used for the sling 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 the
a Read the Operation and Maintenance Manual table below.
of the crane carefully in advance and operate Wire ropes
the crane safely. (Standard "Z" twist ropes without galvanizing)
(JIS G3525, No. 6, Type 6X37-A)
6. Precautions for using overhead hoist crane Nominal diameter
Allowable load
kWhen raising a heavy part (heavier than 25),
of rope
mm kN ton
use a hoist, etc. In Disassembly and assem-
10 8.8 0.9
bly, the weight of a part heavier than 25 is in- 12 12.7 1.3
dicated after the mark of 4. 14 17.3 1.7
1) Before starting work, inspect the wire ropes, 16 22.6 2.3
brake, clutch, controller, rails, over wind stop 18 28.6 2.9
device, ground fault circuit interrupter, crane 20 35.3 3.6
collision prevention device, and power applica- 25 55.3 5.6
30 79.6 8.1
tion warning lamp, and check safety.
40 141.6 14.4
2) Observe the signals for sling work. 50 221.6 22.6
3) Operate the hoist at a safe place. 60 318.3 32.4
4) Check the direction indicator plates (east, west,
a The allowable load is one-sixth of the break-
south, and north) and the directions of the
ing strength of the rope used (Safety coeffi-
control buttons without fail.
cient: 6).
5) Do not sling a load at an angle. Do not move the
crane while the slung load is swinging.
6) Do not raise or lower a load while the crane is
moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting a load, stop it just after it leaves the
ground and check safety, and then lift it up.
9) Consider the travel route in advance and lift up
a load to a safe height.
10)Place the control switch on a position where it
will not be an obstacle to work and passage.
11)After operating the hoist, do not swing the
control switch.
12)Remember the position of the main switch so
that you can turn off the power immediately in
an emergency.
00-20 GD535-5
(01)
8. Precautions for disconnecting and connecting

hoses and tubes in air conditioner circuit
1) Disconnection
k For the environment, the air conditioner
of this machine uses the refrigerant (air
conditioner gas: R134a) which has fewer
factors of the depletion of the ozone lay-
er. However, it does not mean that you
may discharge the refrigerant into the at-
mosphere as it is. Be sure to recover the
refrigerant when disconnecting the re-
frigerant gas circuit and then reuse it.
a Ask professional traders for collecting and
filling operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to the
atmosphere.
k If the refrigerant gas gets in your eyes or
contacts your skin, you may lose your
sight and your skin may be frozen. Ac-
cordingly, put on safety glasses, safety
gloves and safety clothes when recover-
ing or adding the refrigerant.
Refrigerant gas must be recovered and
added by a qualified person.
2) Connection
1] When installing the air conditioner circuit
hoses and tubes, take care that dirt, dust,
water, etc. will not enter them.
2] When connecting the air conditioner hoses
and tubes, check that O-rings (1) are fitted
to their joints.
3] Check that each O-ring (1) is not damaged
or deteriorated.
4] When connecting the refrigerant piping,
apply compressor oil for refrigerant (R134a)
(DENSO: ND-OIL8, VALEO THERMAL
SYSTEMS: ZXL100PG (equivalent to
PAG46)) to its O-rings (1).
a Example of O-ring (Fitted to every joint
of hoses and tubes)
a For tightening torque, see the precau-

tions for installation in each section of
"Disassembly and assembly".
GD535-5 00-21
(01)
How to read the shop manual 00 Index and foreword
How to read the shop manual
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.
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 contains table of contents, and safety and basic information. If any revision of the shop manual is
made, the LIST OF REVISED PAGES will be added.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard

This section explains the structure and function of each component. It serves not only to give an understanding
of the structure, but also serves as reference material for troubleshooting.
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 judgment criteria for testing and adjusting are explained in Test-
ing 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.
60. Maintenance standard

This section gives maintenance standard values of each component. The maintenance standard sub-section
explains the criteria and remedies for disassembly and service.
80. Appendix
The section explains the equipment which can not be included in the other sections. This section explains the
structure, function, testing, adjusting, and troubleshooting of the equipment.
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 remanufacturing and repairing engine and replacing parts.
00-22 GD535-5
(01)
00 Index and foreword How to read the shop manual
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.
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 standards are neces-
a Caution
sary when performing work.
4
Weight of parts of component or parts. Caution necessary when selecting hoisting wire,
Weight
or when working posture is important, etc.
3 Tightening torque Places that require special attention for tightening torque during 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.
Units
In this shop manual, the units are indicated with International System of units (SI).
For reference, conventionally used Gravitational System of units is indicated in parentheses { }.
GD535-5 00-23
(01)
Explanation of terms for maintenance standard 00 Index and foreword
Explanation of terms for maintenance standard

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

q To be accurate, the finishing size of parts is a
little different from one to another.
q To specify a finishing size of a part, a temporary
standard size is set and an allowable difference
from that size is indicated.
q The above size set temporarily is called the
"standard size" and the range of difference from
the standard size is called the "tolerance".
q The tolerance with the symbols of + or - is indi-
cated 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 toler-
ance/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 indicated by the
same standard size and different tolerances of
the hole and shaft. The tightness of fit is decid-
ed by the tolerance.
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
00-24 GD535-5
(01)
00 Index and foreword Explanation of terms for maintenance standard
2. Standard clearance and standard value 5. Clearance limit

q The clearance made when new parts are as- q Parts can be used until the clearance between
sembled is called the "standard clearance", them is increased to a certain limit. The limit at
which is indicated by the range from the mini- which those parts cannot be used is called the
mum clearance to the maximum clearance. "clearance limit".
q When some parts are repaired, the clearance is q If the clearance between the parts exceeds the
generally adjusted to the standard clearance. clearance limit, they must be replaced or re-
q A value of performance and function of new paired.
products or equivalent is called the "standard
value", which is indicated by a range or a target 6. Interference limit
value. q The allowable maximum interference between
q When some parts are repaired, the value of the hole of a part and the shaft of another part
performance/function is set to the standard val- to be assembled is called the "interference lim-
ue. it".
q The interference limit shows the repair limit of
3. Standard interference the part of smaller tolerance.
q When the diameter of a hole of a part shown in q If the interference between the parts exceeds
the given standard size and tolerance table is the interference limit, they must be replaced or
smaller than that of the mating shaft, the differ- repaired.
ence between those diameters is called the "in-
terference".
q The range (A - B) from the difference (A) be-
tween 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 inter-
ference".
q After repairing or replacing some parts, mea-
sure the size of their hole and shaft and check
that the interference is in the standard range.
4. Repair limit and allowable value or allowable

dimension
q The size of a part changes because of wear
and deformation while it is used. The limit of
changed size is called the "repair limit".
q If a part is worn to the repair limit, it must be re-
placed or repaired.
q The performance and function of a product low-
ers while it is used. A value which the product
can be used without causing a problem is called
the "allowable value" or "allowable dimension".
q If a product is worn to the allowable value, it
must be checked or repaired. Since the permis-
sible value is estimated from various tests or
experiences in most cases, however, it must be
judged after considering the operating condi-
tion and customer's requirement.
GD535-5 00-25
(01)
Handling of electric equipment and hydraulic components 00 Index and foreword
Handling of electric equipment and hydraulic components

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
components" (particularly gear oil and hydraulic oil).
Points to remember when handling electric equip-

ment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wires connecting one
component to another component, connectors
used for connecting and disconnecting one wire
from another wire, and protectors or tubes used for
protecting the wires.
Compared with other electrical components fitted
in boxes or cases, wiring harnesses are more likely
to be affected by the direct effects of rain, water,
heat, or vibration. Furthermore, during inspection
and repair operations, they are frequently removed
and installed again, so they are likely to suffer
deformation or damage. For this reason, it is
necessary to be extremely careful when handling
wiring harnesses.
2. Main failures occurring in wiring harness
1) Defective contact of connectors (defective
contact between male and female connectors)
Problems with defective contact are likely to
occur because the male connector is not prop-
erly fitted into the female connector, or because
one or both of the connectors is deformed or
the position is not correctly aligned, or because
there is corrosion or oxidization of the contact
surfaces. The corroded or oxidized contact
surfaces may become shiny again (and contact
may become normal) by connecting and
disconnecting the connector about 10 times.
2) Defective crimping or soldering of connectors

The pins of the male and female connectors are
connected to wires by crimping or soldering. If
excessive force is applied to the wire, the joint
is separated to cause defective contact or the
wire is broken.
00-26 GD535-5
(01)
00 Index and foreword Handling of electric equipment and hydraulic components
3) Disconnections in wiring
If the harness is pulled to disconnect, or compo-
nents are lifted with a crane with the harness
still connected, or a heavy object hits the
harness, the crimping of the connector may
separate, or the soldering may be damaged, or
the harness may be broken.
4) High-pressure water entering connector

The connector is designed to make it difficult for
water to enter (drip-proof structure), but if
high-pressure water is sprayed directly on the
connector, water may enter the connector,
depending on the direction of the water jet.
Accordingly, take care not to splash water over
the connector.
The connector is designed to prevent water
from entering, but at the same time, if water
does enter, it is difficult for it to be drained.
Therefore, if water should get into the
connector, the pins will be short-circuited by the
water, so if any water gets in, immediately dry
the connector or take other appropriate action
before passing electricity through it.
5) Oil or dirt stuck to connector
If oil or grease are stuck to the connector and
an oil film is formed on the mating surface of the
male and female pins, the oil will not let the
electricity pass, so there will be defective
contact. If there is oil or grease stuck to the
connector, wipe it off with a dry cloth or blow it
dry with compressed air and spray it with elec-
tric contact cleaner.
a When wiping the joint portion of the connec-
tor, be careful not to apply excessive force
or deform the pins.
a If there is oil or water in the compressed air,
the contacts will become even dirtier, so re-
move the oil and water from the com-
pressed air completely before cleaning with
compressed air.
GD535-5 00-27
(01)
3. Removing, installing, and drying connectors

and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when disconnecting.
When disconnecting the connectors, hold
the connectors. For connectors held by a
screw, loosen the screw fully, then hold the
male and female connectors in each hand
and pull apart. For connectors which have a
lock stopper, press down the stopper with
your thumb and pull the connectors apart.
a Never pull with one hand.
2] 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 stoppers.
a If the connector is twisted up and down
or to the left or right, the housing may
break.
3] Action to take after removing connectors

After removing any connector, cover it with
a vinyl bag to prevent any dust, dirt, oil, or
water from getting in the connector portion.
a If the machine is left disassembled for a
long time, it is particularly easy for im-
proper contact to occur, so always cover
the connector.
00-28 GD535-5
(01)
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, defec-
tive contact, corrosion, or damage to the
connector pins.
Check that there is no damage or breakage
to the outside of the connector.
a If there is any damage or breakage, re-
place the connector.
a If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry cloth.
If any water has got inside the connec-
tor, warm the inside of the connector and
harness with a dryer, but be careful not
to make them too hot as this will cause
short circuits.
2] Fix the connector securely.

Position the connector correctly, and then fit
them securely. For connectors with the lock
stopper, push in the connector until the
stopper clicks into position.
3] Correct any protrusion of the boot and any
misalignment of the wiring harness.
For connectors fitted with boots, correct any
protrusion of the boot. In addition, if the
wiring harness is misaligned, or the clamp is
out of position, adjust it to its correct posi-
tion.
a If the connector cannot be corrected
easily, remove the clamp and adjust the
position.
q If the connector clamp has been re-
moved, be sure to return it to its original
position. Check also that there are no
loose clamps.
GD535-5 00-29
(01)
3) DT connector (DT 8-pole, 12-pole)

Disconnection (Left of figure) q Disconnection q Connection (Example of
While pressing both locks (a) and (b), pull out incomplete setting of
female connector (2). ((a))
Connection (Right of figure)
1] Push in female connector (2) horizontally
until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector (2)
while moving it up and down until the locks
are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled down
(not set completely) and lock (b) is set
completely.
(1): Male connector
(2): Female connector
(a),(b): Locks
00-30 GD535-5
(01)
4) Drying wiring harness

If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in
water or using steam. If the connector must be
washed in water, do not use high-pressure
water or steam directly on the wiring harness. If
water gets directly on the connector, do as
follows.
1] Disconnect the connector and wipe off the
water with a dry cloth.
a If the connector is blown dry with com-
pressed air, there is the risk that oil in the
air may cause defective contact, so re-
move all oil and water from the com-
pressed air before blowing with air.
2] Dry the inside of the connector with a dryer.

If water gets inside the connector, use a
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 re-
lated parts too hot, as this will cause de-
formation or damage to the connector.
3] Carry out a continuity test on the connector.

After drying, leave the wiring harness
disconnected and carry out a continuity test
to check for any short circuits between pins
caused by water.
a After completely drying the connector,
blow it with electric contact cleaner and
reassemble.
GD535-5 00-31
(01)
4. Handling controller
1) The controller contains a microcomputer and
electronic control circuits. These control all of
the electronic circuits on the machine, so be
extremely careful when handling the controller.
2) Do not place objects on top of the controller.
3) Cover the control connectors with tape or a
vinyl bag. Never touch the connector contacts
with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to rain.
5) Do not place the controller on oil, water, or soil,
or in any hot place, even for a short time. (Place
it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the machine
body, disconnect all wiring harness connectors
connected to the controller. Fit an arc welding
ground close to the welding point.
5. Points to remember when troubleshooting electric circuits

1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check all
the related connectors for half fit.
a Disconnect and connect the related connec-
tors several times to check.
3) Always connect any disconnected connectors
before going on to the next step.
a If the power is turned ON with the connec-
tors still disconnected, unnecessary abnor-
mality warning will be issued.
4) When carrying out troubleshooting of circuits
(measuring the voltage, resistance, continuity,
or current), wag the related wiring harnesses
and connectors several times and check that
there is no change in the reading of the tester.
a If there is any change, there is probably de-
fective contact in that circuit.
00-32 GD535-5
(01)
Points to remember when handling hydraulic components

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (for-
eign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic
components, 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 components in the field, there is
danger of dust entering the components. It is also
difficult to check the performance after repairs, so
it is desirable to use unit exchange. Disassembly
and maintenance of hydraulic components should
be carried out in a specially prepared dustproof
workshop, and the performance should be
checked with special test equipment.
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from entering.
If the opening is left open or is blocked with a rag,
there is danger of dirt entering or of the
surrounding area being made dirty by leaking oil so
never do this. Do not simply drain oil out onto the
ground, but collect it and ask the customer to
dispose of it, or take it back with you for disposal.
4. Do not let any dirt or dust get in during refilling operations

Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil filler
and the area around it clean, and also use clean
pumps and oil containers. If an oil cleaning device
is used, it is possible to filter out the dirt that has
collected during storage, so this is an even more
effective method.
GD535-5 00-33
(01)
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 components (pump,
control valve, etc.) or when running the machine,
carry out oil cleaning to remove the sludge or
contaminants in the hydraulic oil circuit. The oil
cleaning components is used to remove the ultra
fine (about 3 m) particles that the filter built in the
hydraulic equipment cannot remove, so it is an
extremely effective device.
00-34 GD535-5
(01)
00 Index and foreword Handling of connectors newly used for engines
Handling of connectors newly used for engines

a Mainly, following engines are object for following connectors.
q 95E-5
q 107E-1
q 114E-3
q 125E-5
q 140E-5
q 170E-5
q 12V140E-3
Slide lock type Pull lock type (PACKARD-2)

(FRAMATOME-3,FRAMATOME-2) q 95-170,12V140 engines
q 95-170,12V140 engines q Various temperature sensors
q Various pressure sensors and NE speed sen- Examples)
sor Intake air temperature sensor in intake mani-
Examples) fold: TIM
Intake air pressure sensor in intake manifold: Fuel temperature sensor: TFUEL
PIM (125,170,12V140 engines) Oil temperature sensor: TOIL
Oil pressure sensor: POIL (125,170,12V140 Coolant temperature sensor: TWTR, etc.
engines)
Oil pressure switch (95,107,114 engines) Disconnect
Ne speed sensor of flywheel housing: Disconnect the connector by pulling lock (B) (on the
NE (95-170,12V140 engines) wiring harness side) of connector (2) outward.
Ambient pressure sensor:
PAMB (125,170,12V140 engines)
Disconnect
1) Slide lock L1 to the right.
2) While pressing lock L2, pull out connector(1)
toward you.
a Even if lock L2 is pressed, connector(1)
cannot be pulled out toward you, if part A
does not float. In this case, float part A with
a small screwdriver while press lock L2 ,
and then pull out connector(1) toward you.
Connect
Insert the connector straight until it "clicks".
Connect
GD535-5 00-35
(01)
Handling of connectors newly used for engines 00 Index and foreword
Push lock type (1)

q 95, 107, 114 engines While pressing up lock (C)of the connector with
Example) Fuel pressure sensor in common rail flat-head screwdriver [1], pull out connector (3) in the
(BOSCH-03) direction of the arrow.
Disconnect
While pressing lock (C), pull out connector (3) in the di-
rection of the arrow.
q 114 engine
Connect
Push lock type (2)

q 107, 114 engines
Example) Intake air pressure/temperature sensor
q 107 engine in intake manifold(SUMITOMO-04)
Disconnect
While pressing lock (D), pull out connector (4) in the di-
rection of the arrow.
a If the lock is on the underside, use flat-head screw-

driver[1]since you cannot insert your fingers.
Connect
00-36 GD535-5
(01)
00 Index and foreword Handling of connectors newly used for engines
Push lock type (3) Turn-housing type (Round green connector)

q 95, 125 - 170, 12V140 engines q 140 engine
Example) Intake air pressure sensor in intake
Disconnect manifold.
While pressing lock (E) of the connector, pull out con- (CANNON-04): PIM etc.
nector (5) in the direction of the arrow.
Disconnect
Example) Fuel pressure sensor in common rail: 1) Turn housing (H1) in the direction of the arrow.
PFUEL etc. (AMP-3) a When connector is unlocked, housing
(H1)becomes heavy to turn.
2) Pull out housing (H1)in the direction of the
arrow.
a Housing (H1)is left on the wiring harness
side.
Example) Injection pressure control valve of fuel sup-

ply pump: PCV (SUMITOMO-2)
Connect
1) Insert the connector to the end, while setting its
groove.
2) Turn housing (H1)in the direction of the arrow
until it "clicks".
Examples) Speed sensor of fuel supply pump: G

(SUMITOMO-3)
a Pull the connector straight up.
Connect
GD535-5 00-37
(01)
How to read electric wire code 00 Index and foreword
How to read electric wire code

a The information about the wires unique to each machine model is described in Troubleshooting section, Rela-
tional information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The
electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L --- Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No.
of 0.85
Indicates color of wire by color code.

Color codes are shown in Table 3.
Indicates size of wire by nominal No.

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

Type, symbol, and material of wire are shown in Table 1.
(Since the use of AV and AVS wires depends on size (nominal No.), their symbols
are not indicated on the diagram.)
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 and different from AV and AVS in material of the cover.
(Table 1)
Using tem-
Type Symbol Material perature Example of use
range (°C)
Annealed copper for electric
Low-voltage Conductor
appliance General wiring
wire for automo- AV
(nominal No. 5 and above.)
bile Insulator Soft polyvinyl chloride
-30 to +60
Thin-cover Conductor
appliance General wiring
low-voltage wire AVS
(nominal No. 3 and below.)
for automobile Insulator Soft polyvinyl chloride
Heat-resistant Conductor General wiring in extremely cold dis-
appliance
low-voltage wire AEX -50 to +110 trict, wiring at high ambient temperature
Heat-resistant crosslinked
for automobile Insulator place
polyethylene
00-38 GD535-5
(01)
00 Index and foreword How to read electric wire code
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/Diame- 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
ter 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-er D
AV Standard — — — — — — — 4.6
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/Diame- 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
ter 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-er D
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
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".
GD535-5 00-39
(01)
How to read electric wire code 00 Index and foreword
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 cir-
Br BrW BrR BrY BrB — — —
cuit
Lg LgR LgY LgB LgW — — —
O — — — — — — —
Others Gr — — — — — — —
P — — — — — — —
Sb — — — — — — —
Dg — — — — — — —
Ch — — — — — — —
00-40 GD535-5
(01)
00 Index and foreword Precautions when carrying out work
Precautions when carrying out work

When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general pre-
cautions given below when carrying out the work.
1. Precautions when carrying out removal work

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

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379 - 00400 07378 - 10400 07371 - 30400
05 07379 - 00500 07378 - 10500 07371 - 30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part No.
number D d L
06 07049 - 00608 6 5 8
08 07049 - 00811 8 6.5 11
10 07049 - 01012 10 8.5 12
12 07049 - 01215 12 10 15
14 07049 - 01418 14 11.5 18
16 07049 - 01620 16 13.5 20
18 07049 - 01822 18 15 22
20 07049 - 02025 20 17 25
22 07049 - 02228 22 18.5 28
24 07049 - 02430 24 20 30
27 07049 - 02734 27 22.5 34
GD535-5 00-41
(01)
Precautions when carrying out work 00 Index and foreword
2. Precautions when carrying out installation work

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

1) Refilling with coolant, oil and grease
q If the coolant has been drained, close the drain valve, and add coolant to the specified level. Run the
engine to circulate the coolant through the system . Then check the coolant level again.
q If the hydraulic component has been removed and installed again, add engine oil to the specified level.
Run the engine to circulate the oil through the system. Then check the oil level again.
q If the piping or hydraulic component have been removed, always bleed the air from the system after
reassembling the parts.
a For details, see Testing and adjusting, "Bleeding air".
q Add the specified amount of grease (molybdenum disulfide grease) to the work equipment parts.
2) Checking cylinder head and manifolds for looseness

Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loose, retighten it.
q For the tightening torque, see "Disassembly and assembly" .
3) Checking engine piping for damage and looseness

Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air suction and
exhaust gas leakage.
If any part is loose or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for coolant leak-
age.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage.
00-42 GD535-5
(01)
00 Index and foreword Precautions when carrying out work
4) Checking muffler, exhaust pipe and their mounts for damage and looseness
1] Visually check the muffler, exhaust pipe and their mounts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounts for looseness.
If any part is loose, retighten it.
5) Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to "Troubleshooting" and "Disassembly and
assembly".
GD535-5 00-43
(01)
Method of disassembling and connecting push-pull type coupler 00 Index and foreword
Method of disassembling and connecting push-pull type coupler

k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to re-
lease 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 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 approximate-
ly 3.5 mm.
a Do not hold rubber cap portion (4).
2) With hose joint (2) 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 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 approx-
imately 3.5 mm. This does not indicate ab-
normality, however.
00-44 GD535-5
(01)
00 Index and foreword Method of disassembling and connecting push-pull type coupler
Type 2
1. Disconnection
1) Hold the tightening portion and push body (7)
straight until sliding prevention ring (6) contacts
contact surface (a) of the hexagonal portion at
the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1) and 2),
pull out whole body (7) to disconnect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body (7)
contact surface (a) of the hexagonal portion at
GD535-5 00-45
(01)
Method of disassembling and connecting push-pull type coupler 00 Index and foreword
Type 3
1. Disconnection
1) Hold the tightening portion and push body (9)
contact surface (b) of the hexagonal portion at
2) While holding the condition of Step 1), push
cover (10) straight until it contacts contact
surface (b) of the hexagonal portion at the male
end. (Fig. 11)
3) While holding the condition of Steps 1) and 2),
pull out whole body (9) to disconnect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body (9)
straight until the sliding prevention ring (8) con-
tacts contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 13)
00-46 GD535-5
(01)
00 Index and foreword Standard tightening torque table
Standard tightening torque table

1. Table of tightening torques for bolts and nuts
a Unless there are special instructions, tighten metric nuts and bolts to the torque below.
a The following table applies to the bolts in Fig. A.

Thread diame- Width across
Tightening torque
ter of bolt flats
mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5
8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6.0 – 7.5
12 19 98 – 123 10.0 – 12.5
14 22 157 –196 16 – 20
16 24 245 – 309 25 – 31.5
18 27 343 – 427 35 – 43.5
20 30 490 – 608 50 – 62
22 32 662 – 829 67.5 – 84.5
24 36 824 – 1,030 84 – 105
27 41 1,180 – 1,470 120 – 150
30 46 1,520 – 1,910 155 – 195
33 50 1,960 – 2,450 200 – 250
36 55 2,450 – 3,040 250 – 310
39 60 2,890 – 3,630 295 – 370
a The following table applies to the bolts in Fig. B.

Tightening torque
ter of bolt flats
mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 12 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 17 74.5 – 90.2 7.6 – 9.2
a Fig. A a Fig. B
Remarks: The widths across flats by thread

diameter of flanged bolts (marked with "*") in
Fig. A are the ones indicated in the table for
bolts shown in Fig. B.
(Values of tightening torques shown in the table
for Fig. A are applied.)
GD535-5 00-47
(01)
Standard tightening torque table 00 Index and foreword
2. Table of tightening torques for split flanged bolts

a Unless there are special instructions, tighten split flanged bolts to the torque below.
Tightening torque
ter of bolt flats
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.
Tightening torque Nm {kgm}
Nominal No. ter flats
mm mm Range Target
02 14 35 – 63 {3.5 – 6.5} 44 {4.5}
Varies
03,04 20 84 – 132 {8.5 – 13.5} 103 {10.5}
depending on
05,06 24 128 – 186 {13.0 – 19.0} 157 {16.0}
type of con-
10,12 33 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 nector. 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.
Tightening torque Nm {kgm}
Nominal No. ter flats
mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.8 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0}
33 33 – 107.8 – 147.0 {11.0 – 15.0} 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}
00-48 GD535-5
(01)
00 Index and foreword Standard tightening torque table
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) (Refer-
hose flats (mm) threads, type of
ence)
thread
34 – 54 {3.5 – 5.5} 44 {4.5} – 9/16 – 18UNF 14.3
02 19
34 – 63 {3.5 – 6.5} 44 {4.5} 14 – –
22 54 – 93 {5.5 – 9.5} 74 {7.5} – 11/16 – 16UN 17.5
03
24 59 – 98 {6.0 – 10.0} 78 {8.0} 18 – –
04 27 84 – 132 {8.5 – 13.5} 103 {10.5} 22 13/16 – 16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1 – 14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1-3/16 – 12UN 30.2
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
6. Table of tightening torques for face seal joints

a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to be used
for engines etc. to the torque shown in the following table.
a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil (wet-
ted).
Tightening torque (Nm {kgm}) Face seal
Outer diame- Width across
Nominal No. –Num- Thread diameter
ter of pipe flats
Range Target ber of threads, type (mm)
(mm) (mm)
of thread (Reference)
8 19 14 – 16 {1.4 – 1.6} 15 {1.5} 9/16 – 18UN 14.3
10 22 24 – 27 {2.4 – 2.7} 25.5 {2.6} 11/16 – 16UN 17.5
12 24 (27) 43 – 47 {4.4 – 4.8} 45 {4.6} 13/16 – 16UN 20.6
15 (16) 30 (32) 60 – 68 {6.1 – 6.8} 64 {6.5} 1 – 14UN 25.4
22 (20) 36 90 – 95 {9.2 – 9.7} 92.5 {9.4} 1 – 3/16 – 12UN 30.2
Reference: The face seal joints of the dimensions in ( ) are slso used, depending on the specification.
GD535-5 00-49
(01)
Standard tightening torque table 00 Index and foreword
7. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114 engine series
to the torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 – –
8. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine series to
the torque below.
Thread size Tightening torque
mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
9. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114 engine
series to the torque below.
Tightening torque
Material In cast iron or steel In aluminum
Thread size (inch) Nm kgm Nm kgm
1/16 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
00-50 GD535-5
(01)
00 Index and foreword Conversion table
Conversion table
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the method
of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
1. Convert 55 mm into inches.

1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal line
from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from
(B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from millime-
ters 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 2.017 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 2.847 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
GD535-5 00-51
(01)
Conversion table 00 Index and foreword
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 5 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 2.017 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 2.847 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

1l= 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
00-52 GD535-5
(01)
Liters to U.K. Gallons

1l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 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
GD535-5 00-53
(01)
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
00-54 GD535-5
(01)
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade
temperature reading or vice versa is to enter the accompanying table in the center (boldface column) of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit tem-
peratures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade val-
ues, 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 47 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 127.4 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 68 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 69 154.4 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
GD535-5 00-55
(01)
00-56 GD535-5
(01)
01 Specification
GD535-5 01-1
Contents 01 Specification
Contents 1
Acronyms - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01-3
Specifications- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01-8
Specification drawing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01-8
Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01-10
Weight table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01-16
Table of fuel, coolant, and lubricants - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01-17
01-2 GD535-5
01 Specification Acronyms
Acronyms 1
System
Advanced Joystick
ARAC
braking force.
Automatic Retarder
Automatic Spin
Brake Cooling oil
Regulator
used independently.
Closed-center Load
Sensing System
injection timing.
ECU)
GD535-5 01-3
Acronyms 01 Specification
Electronic Control
Modulation Valve

ECM)
Exhaust Gas
Recirculation
Equipment
Monitoring System
Electromagnetic
Forward-Neutral-
Reverse
Global Positioning
System
Plus) earth

Global Navigation
Satellite System

HSS
Hydro Static
control
Unit
motions.
01-4 GD535-5
KOMATSU Closed
KCSF Engine
KOMATSU Diesel
Oxidation Catalyst
muffler.
Particulate Filter
KOMATSU Traction
LIN
load.
LVDS
sensor.
Service
NC Normally Closed
NO Normally Open
PC Hydraulic system
GD535-5 01-5
Acronyms 01 Specification
PCCS
Pre-stroke Control
Valve
Control
hydraulic pressure.
Hydraulic system
PTP

Structure
Selective Catalytic
Reduction
VGT Engine

D: Bulldozer
HD: Dump truck
WA: Wheel loader
01-6 GD535-5

A/C Air Conditioner
A/M Air Mix damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
ENG Engine
F.G. Frame Ground
GND Ground
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/M Transmission
GD535-5 01-7
Specification drawing 01 Specification
Specifications 1
Specification drawing 1
Machines without ripper
Machines with ripper
01-8 GD535-5
01 Specification Specification drawing
Item Unit GD535-5

Operating weight
kg 14,025 [15,600]
(including one operator weighing 75 kg)
Engine model Komatsu SAA6D107E-1 diesel engine
E mode P mode
Engine rated horsepower
q ISO 9249/SAE J1349 (net) 106 {142}/2,000 {2,000} 113 {151}/2,000 {2,000}
kW {HP}
q ISO 14396 - 115 {153}/2,000 {2,000}
min-1 {rpm}
q SAE J1995 (gross) 107 {143}/2,000 {2,000} 115 {154}/2,000 {2,000}
A Overall length mm 8,565 [9,880]
Overall height (including light diffusing type
B mm 3,250
warning lamp)
C Overall width mm 2,455
Min. ground clearance (to bottom surface of
mm 350
transmission undercover)
Min. turning radius
Without differential lock mm 7,000
With differential lock 6,900
Travel speed
1st (Forward/Reverse) 4.3/4.8
2nd (Forward/Reverse) 6.1/9.1
3rd (Forward/Reverse) 8.3/18.4
4th (Forward/Reverse) km/h 11.6/35.2
5th (Forward/Reverse) 16.2/-
a The engine rated horsepower is indicated in the net value and gross value. Gross denotes the rated horsepower measured
on the basic engine unit, while net denotes the measured value of an engine under conditions that are essentially the same
as those when it is installed on a machine.
a [ ]: with ripper
GD535-5 01-9
Specifications 01 Specification
Specifications 1
Item Unit GD535-5

Operating weight
kg 14,025 [15,600]
(including one operator weighing 75 kg)
Weight
Load on front axle kg 3,805 [4,610]

Load on rear axle kg 10,220 [10,990]
Travel speed
Forward 1st 4.3
Forward 2nd 6.1
Forward 3rd 8.3
Forward 4th 11.6
Forward 5th 16.2
Forward 6th km/h 22.7
Performance
Forward 7th 31.1

Forward 8th 43.4
Reverse 1st 4.8
Reverse 2nd 9.4
Reverse 3rd 18.4
Reverse 4th 35.2
Maximum rim pull kN {kgf} 80.1{8,176} [86.2{8,800}]
Gradeability deg. 24
Min. turning radius mm 6,900
Overall length mm 8,565 [9,880]
Overall height mm 3,250
Wheelbase mm 6,100
Dimensions
Tandem wheelbase mm 1,525

Tread
Front wheel 2,070
mm
Rear wheel 2,060
Blade base - 2,265
Min. ground clearance - 350
a [ ]: with ripper
01-10 GD535-5
(02)
01 Specification Specifications
Item Unit GD535-5

Model Komatsu SAA6D107E-1
4-cycle, water-cooled, in-line, vertical, direct
Type injection type, with turbocharger and air-cooled
aftercooler
No. of cylinders - bore x stroke mm 6 - 107×124
Total piston displacement l (cc) 6.69 (6,690)
E mode P mode
Engine rated horsepower
q ISO 9249/SAE J1349 (net) 106 {142}/2,000 {2,000} 113 {151}/2,000 {2,000}
kW {HP}/
q ISO 14396 - 115 {153}/2,000 {2,000}
min-1 {rpm}
Performance
Engine
q SAE J1995 (gross) 107 {143}/2,000 {2,000} 115 {154}/2,000 {2,000}

Nm {kgm}/
Max. torque 658 {67.1}/1,450 {1,450}
min-1 {rpm}
Fuel consumption ratio at rated horsepower g/kWh
236 {176}
(in high power mode) {g/HPh}
Max. speed with no load min-1 {rpm} 2.280 {2.280}
Min. speed with no load min-1 {rpm} 825 {825}
Starting motor 24 V, 4.5 kW
Alternator 24 V, 35 A or 60 A
Battery 12 V, 120 Ah
Radiator core type Corrugated (aluminum)
a The engine rated horsepower is indicated in the net value and gross value. Gross denotes the rated horsepower measured
on the basic engine unit, while net denotes the measured value of an engine under conditions that are essentially the same
as those when it is installed on a machine.
GD535-5 01-11
Item Unit GD535-5

Torque converter
3-element, 1-stage, 2-phase, with hydraulically
Type -
actuated wet type disc for lockup
Transmission
Counter-shaft type, full automatic electronically
Power train
Type - controlled automatic gear shift, pump feed

lubrication
Gear range - 8-forward and 4-reverse
Final drive
Spiral bevel gear and planet gear type, splash
Type -
lubrication
Tandem drive
Type - Double row, chain-drive type, splash lubrication
Front axle
Reverse Elliot type, angular type, hydraulic
Type -
leaning
Axle
Max. leaning angle deg. 16

Rear axle
Type - Full floating, tandem type
Size - 14.00-24-12PR
Rim size - 9.00/1.5×24
Tire
Inflation pressure
Front wheel 260 {2.6}
kPa {kg/cm2}
Rear wheel 260 {2.6}
Service brake
Braking method Rear 4-wheel braking
Brake type - Wet, multiple disc type
Operation method Hydraulically operated type
Brake
Parking brake
Braking method Final drive input shaft braking
Brake type - Dry, single disc type
Operation method Spring applied and hydraulically released
Type - Full hydraulic power steering
Steering
Steering angle - 49
Articulation angle - 25
01-12 GD535-5
Item Unit GD535-5

Work equipment and steering pump
Type - Gear type
Discharged volume cm /rev
3
40.2+20.4
Power train pump (*1)
Type - Gear type
Discharged volume cm3/rev 63.5
Power train pump and differential lock pump (*2)
Type - Gear type
Discharged volume cm3/rev 63.5+10.5
Brake and cooling fan pump
Type - Gear type
Discharged volume cm3/rev 29.9
Control valve
Type - 9-spool type
Hydraulic system
Set pressure MPa {kg/cm2} 19.6 {200}

Steering valve
Type - Orbitrol type
Set pressure MPa {kg/cm2} 18.1 {185}
Steering cylinder
Type - Double-acting piston type
Cylinder bore mm 50
Piston rod outer diameter mm 35
Stroke mm 330
Max. distance between pins mm 911.5
Min. distance between pins mm 581.5
Leaning cylinder
Cylinder bore mm 75
Stroke mm 160
*1: For machines with non-differential type rear axle

*2: For machines with differential lock type rear axle
GD535-5 01-13
Item Unit GD535-5

Articulate cylinder
Cylinder bore mm 75
Stroke mm 420
Max. distance between pins mm 1,131
Min. distance between pins mm 711
Blade lift cylinder
Cylinder bore mm 80
Stroke mm 1,000
Blade shift cylinder
Hydraulic system
Cylinder bore mm 80
Stroke mm 1,250
Min. distance between pins mm 1,539
Power tilt cylinder
Cylinder bore mm 80
Stroke mm 300
Max. distance between pins mm 890
Drawbar shift cylinder
Cylinder bore mm 80
Stroke mm 450
01-14 GD535-5
Item Unit GD535-5

Ripper cylinder
Hydraulic system
Cylinder bore mm 95
Stroke mm 300
Blade length mm 3,710
Blade height mm 645
Blade thickness mm 16
Cutting edge length mm 1,829
Cutting edge width mm 152
Cutting edge thickness mm 15.9
Max. lift above ground mm 500
Work equipment
Max. drop below ground mm 545

Blade load kW {kg} 59.3 [71.9]
Turning angle deg. 360
Blade side shift amount (move by cylinder + move
by bolt adjustment)
L.H. blade side shift mm 634±154
R.H. blade side shift 616±154
Blade tipping angle
Forward 40.5
deg.
Rearward 3.5
a [ ]: with ripper
GD535-5 01-15
Weight table 01 Specification
Weight table 1
k This weight table has been prepared for your reference when handling or transporting the compo-
nents.
k This weight table shows the dry weight.
Unit: kg
Item GD535-5
Engine assembly 585
Cooling system assembly 175
Transmission assembly 810
Power train pump and differential lock pump 11
Final drive assembly 825
Tandem drive assembly 761
Front axle assembly 413
Parking brake assembly (including disc) 23
Tire and rim assembly (14.00-24-12PR) (each) 144
q Tire (14.00-24-12PR) (each) 82
q Rim (9.00/1.5×24) (each) 62
Ripper assembly (3 shanks) 615
Work equipment and steering pump 15
Fuel tank 154
Hydraulic tank 66
Circle rotation gear 10
Steering cylinder assembly 11
Leaning cylinder assembly 14
Articulate cylinder assembly 21
Blade lift cylinder assembly 46
Blade side shift cylinder assembly 48
Power tilt cylinder assembly 19
Drawbar shift cylinder assembly 27
Ripper cylinder assembly 27
Blade assembly 609
Circle and drawbar assembly 440
Circle rotation gear assembly 107
Front frame assembly 1,598
Rear frame assembly 1,118
Operator's compartment assembly (including controls and operator's seat) 415
Cab assembly 825
01-16 GD535-5
01 Specification Table of fuel, coolant, and lubricants
Table of fuel, coolant, and lubricants 1
a For details of the notes (Note 1, Note 2...) in the table, see "Operation and Maintenance Manual".
GD535-5 01-17
Table of fuel, coolant, and lubricants 01 Specification
Unit: l
Subject component Specified capacity Refill capacity
Engine oil pan 25.4 23.1
Transmission case 60 45
Hydraulic oil system 104 [108.4] 48.5 [51.5]
Final drive case 14 14
Tandem case (each of R.H. and L.H. cases) 51 51
Circle rotation gear case 4.1 4.1
Cooling system 24 24
Fuel tank 271 -
a [ ]: with ripper
01-18 GD535-5
10 Structure and function
GD535-5 10-1
Contents 10 Structure and function
Contents 1
Acronyms - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-4
Engine and cooling system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-9
Cooling system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-9
Cooling fan motor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-11
Power train system- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-19
Power train system drawing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-19
Power train piping drawing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-20
Transmission control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-21
Torque converter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-22
Transmission - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-25
Transmission control valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-44
ECMV - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-46
Main relief valve and torque converter relief valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-53
Front axle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-55
Rear axle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-58
Differential (Non-differential specification) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-59
Differential (Differential lock specification) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-61
Differential lock solenoid valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-64
Final drive- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-65
Tandem drive - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-67
Steering system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-69
Steering piping drawing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-69
Priority valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-70
Steering valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-75
Brake system- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-82
Hydraulic piping drawing of brake system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-82
Brake valve- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-83
Brake circuit accumulator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-88
Brake circuit accumulator charge valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-89
Wheel brake - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-95
Parking brake solenoid valve and lifter lock pin solenoid valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-96
Parking brake - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-97
Undercarriage and frame - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-98
Frame - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-98
Tire - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-99
Hydraulic system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-100
Hydraulic system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-100
Hydraulic piping drawing of work equipment- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-102
Work equipment control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-104
Hydraulic tank - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-105
Work equipment pump and steering pump - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-106
Power train pump - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-107
Power train pump and differential lock pump - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-108
Brake and cooling fan pump - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-109
Control valve- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-110
Functions and valve operations- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-112
Hydraulic cylinder - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-113
Swivel joint - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-114
Pilot check valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-115
Work equipment system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-124
Circle and drawbar - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-124
Blade - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-126
Lifter- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-128
10-2 GD535-5
10 Structure and function Contents
Circle rotation motor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-130

Circle rotation gear - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-132
Ripper - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-134
Cab and its attachments- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-135
ROPS cab - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-135
Electrical system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-136
Layout drawing of electrical system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-136
System operating lamp system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-138
Battery disconnect switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-139
Machine monitor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-140
Automatic gear shift control system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-151
Transmission controller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-156
Engine controller- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-159
KOMTRAX system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-162
KOMTRAX terminal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-163
Rearview monitor system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-165
Rearview monitor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-166
Rearview camera - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-167
Engine starting circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-168
Engine stop circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-170
Preheating circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-171
Sensors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-172
Engine power mode selector circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-181
Cooling fan control system- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-182
GD535-5 10-3
Acronyms 10 Structure and function
Acronyms 1
System
Advanced Joystick
ARAC
braking force.
Automatic Retarder
Automatic Spin
Brake Cooling oil
Regulator
used independently.
Closed-center Load
Sensing System
injection timing.
ECU)
10-4 GD535-5
10 Structure and function Acronyms
Electronic Control
Modulation Valve

ECM)
Exhaust Gas
Recirculation
Equipment
Monitoring System
Electromagnetic
Forward-Neutral-
Reverse
Global Positioning
System
Plus) earth

Global Navigation
Satellite System

HSS
Hydro Static
control
Unit
motions.
GD535-5 10-5
KOMATSU Closed
KCSF Engine
KOMATSU Diesel
Oxidation Catalyst
muffler.
Particulate Filter
KOMATSU Traction
LIN
load.
LVDS
sensor.
Service
NC Normally Closed
NO Normally Open
PC Hydraulic system
10-6 GD535-5
10 Structure and function Acronyms
PCCS
Pre-stroke Control
Valve
Control
hydraulic pressure.
Hydraulic system
PTP

Structure
Selective Catalytic
Reduction
VGT Engine

D: Bulldozer
HD: Dump truck
WA: Wheel loader
GD535-5 10-7

A/C Air Conditioner
A/M Air Mix damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
ENG Engine
F.G. Frame Ground
GND Ground
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/M Transmission
10-8 GD535-5
10 Structure and function Cooling system
Engine and cooling system 1
Cooling system 1
GD535-5 10-9
Cooling system 10 Structure and function
A: Power train oil cooler inlet C: Hydraulic oil cooler inlet

B: Power train oil cooler outlet D: Hydraulic oil cooler outlet
1. Power train oil cooler 11. Aftercooler inlet hose

2. Aftercooler 12. Strainer
3. Radiator 13. Brake and cooling fan pump
4. Radiator cap 14. Aftercooler outlet hose
5. Reservoir tank 15. Cooling fan motor
6. Radiator outlet hose 16. Cooling fan
7. Drain valve 17. Fan guard
8. Hydraulic tank 18. Shroud
9. Condenser 19. Hydraulic oil cooler
10. Radiator inlet hose
Specifications
Power train
Radiator Aftercooler
oil cooler
Core type CF90-4 CF91-1 CF69
Fin pitch (mm) 3.5/2 3.5/2 4.0/2
Total heat dissipation area (m2) 49.19 4.51 20.91
Cracking pressure of pressure valve (kPa {kg/cm2}) 70 ± 15 - -

{0.7±0.15}
Cracking pressure of vacuum valve (kPa {kg/cm2}) 0 to 5 {0 to 0.05} - -
10-10 GD535-5
10 Structure and function Cooling fan motor
Cooling fan motor 1
Type: LMF16
P: From pump through charge valve Specifications

T: To hydraulic tank through return filter Type: LMF28
TC: To tank Capacity: 28 cm3/rev
Rated speed: 1,300 rpm
1. Terminal ER Rated delivery: 36.4 l/min
2. Terminal EF
3. Proportional solenoid pilot valve
4. ON/OFF pilot valve
GD535-5 10-11
Cooling fan motor 10 Structure and function
1. Output shaft
2. Case
3. Thrust plate
4. Shoe
5. Piston
6. Cylinder block
7. Valve plate
8. End cover
9. Bearing
10. Center spring
11. Retainer shoe
12. Retainer guide
13. Bearing
14. Oil seal
15. Flow control spool
16. Suction safety valve
17. Reversible spool
18. Speed sensor
10-12 GD535-5
1. Hydraulic motor
Function
q This hydraulic motor is called a swash plate-type
axial piston motor. It converts the energy of the
pressurized oil sent from the hydraulic pump into
rotary motion.
Principle of operation
q The pressurized oil sent from the pump flows
through valve plate (7) into cylinder block (5).
q This pressurized oil can flow on only to one side of
the (Y - Y) line connecting the top dead center and
bottom dead center of the stroke of piston (4).
q The pressurized oil sent to one side of cylinder
block (5) pushes piston (4) (two or three pistons).
q A single piston generates force F1 [F1 (kg) = P (kg/
cm2) x xD2/4 (cm2)].
q This force works on thrust plate (2).
q Since thrust plate (2) is fixed with the specific angle
(a) to output shaft (1), the force is divided into com-
ponents (F2) and (F3).
q Among them, radial component (F3) generates
torque (T = F3 x ri) against the (Y - Y) line connect-
ing the top dead center and bottom dead center.
q Total torque of the component force [T = s(F3 x ri)]
rotates cylinder block (5) through piston (4).
q This cylinder block (5) is connected to output shaft
(1) with the spline.
q Output shaft (1) rotates to transmit the torque.
GD535-5 10-13
2. Suction safety valve (2) When engine is stopped

q When the engine stops, the pump speed becomes
1) Suction function 0 rpm.
q The pressurized oil from the pump is not supplied
Function to port (P).
q If the fan pump stops, the pressurized oil does not q As the pressurized oil is not supplied to (MA) side
flow into the motor. of the motor, the motor speed decreases gradually
q Since the motor continues to rotate with the force to stop.
of inertia, the pressure on the outlet side of the mo- q If the motor shaft is rotated by the force of inertia
tor increases. while the oil flow in port (P) is reducing, the pres-
q When the pressurized oil stops flowing in from inlet surized oil in port (T) on the outlet side is sent by
port (P), suction safety valve (1) sucks in the pres- suction safety valve (1) to (MA) side to prevent cav-
surized oil on the outlet side and supplies it to port itation.
(MA) where there is not sufficient oil to prevent cav-
itation.
Operation
(1) When engine is started
q The pressurized oil from the pump is supplied to
port (P), increasing the (MA) side pressure.
q The starting torque is generated in the motor, and
the motor starts rotating.
q The pressurized oil on the motor outlet (MB) side
returns through port (T) to the tank.
10-14 GD535-5
2) Safety function
Function
q When the engine is started, the pressure in port (P)
of the fan motor is increased in some cases.
q Suction safety valve (1) is installed to protect the
fan system circuit.
Operation
q If the pressure in port (P) increases above the
opening pressure of suction safety valve (1), valve
(2) of suction safety valve (1) opens to release the
pressurized oil into port (T).
q By this operation, the generation of the abnormally
high pressure in port (P) is prevented.
GD535-5 10-15
3. Operation of reversible valve
1) When ON/OFF solenoid is de-energized 2) When ON/OFF solenoid is energized

q When ON/OFF solenoid (1) is "de-energized", the q When ON/OFF solenoid (1) is "energized", valve
pressurized oil from the pump is shut off by valve (2) is switched.
(2). q The pressurized oil from the pump flows to spool
q Port (C) opens for the hydraulic tank circuit. chamber (D) through port (C).
q Spool (3) is pushed to the right by spring (4). q The pressurized oil flowed in chamber (D) com-
q Port (MA) opens and pressurized oil flows in to ro- presses spring (4).
tate the motor in normal direction (clockwise). q Spool (3) moves to the left.
q Port (MB) opens and pressurized oil flows in to ro-
tate the motor in reverse direction (counterclock-
wise).
10-16 GD535-5
4. Flow control valve (continuously-variable type)
Function
This valve supplies the required pump delivery to the
motor, and returns the excessive oil to the hydraulic
tank.
q The motor speed increases in proportion to the in-

crease of the incoming oil (Q) as shown in Fig 1.
q When the incoming flow rate is (Q1), motor speed
becomes (B) rpm.
q In order to reduce noise and performance loss of
the motor, this valve keeps the fan speed constant
independent of the flow rate to the motor.
q Even if the flow rate is increased from (Q0) to (Q1),
the valve maintains the motor speed constant be-
tween points (A) and (C).
Operation
q For the flow control valve, the upstream pressure
through the orifice is applied to the right side of
spool (1) and the downstream pressure through
the orifice is applied to its left side.
q The differential pressure before and after orifice
(E) by the incoming flow rate to the motor works on
spring (2).
q In Fig. 1, when the incoming flow rate becomes
more than (Q0), the differential pressure before
and after spool (1) becomes larger than the in-
stalled load of spring (2).
q Spool (1) moves to the left and port (P) is connect-
ed to port (T).
q The excessive oil in (Z) portion of Fig 1 flows to the
hydraulic tank through the flow control valve, and
the motor speed is kept constant from (A) to (C).
q This flow control valve is a continuously-variable
type.
q As shown in Fig 2, it is possible to change the flow
control valve continuously while maintaining the
motor speed constant between (A') to (C') by
changing the command current between the motor
speed (A) and (C).
GD535-5 10-17
Cooling fan speed sensor
1. Speed sensor
2. O-ring
3. Connector
4. Wire
Function
q Cooling fan speed sensor which is installed to case
of the motor detects fan motor speed as pulse sig-
nals from cylinder block spline inside the motor and
sends them as converted electric signals to the
controller.
q Since the clearance between sensor and spline is
specified according to the parts dimensions, ad-
justment at installation is not necessary.
10-18 GD535-5
10 Structure and function Power train system drawing
Power train system 1
Power train system drawing 1
Outline
q Power from the engine is transmitted to transmis-
sion (2) through torque converter (1).
q Counter-shaft type transmission (2) is hydrauli-
cally controlled and can provide "8 forward and 4
reverse speeds".
q Power from transmission (2) is transmitted to dif-
ferential (4) through drive shaft (3).
q Differential (4) makes 90-degree directional
change of the power and transmit it to final drive
(5).
q Final drive (5) finally reduces the power and trans-
mits it to tandem drive (7) through shaft (6).
q Chain (8) in tandem drive (7) transmits the power
from shaft (6) to hub shaft (9).
q The power transmitted to hub shaft (9) drives tire
(10) to make the machine travel.
GD535-5 10-19
Power train piping drawing 10 Structure and function
Power train piping drawing 1
1. Differential lock pump (*1) 8. Power train oil filter

2. Power train pump 9. Differential lock pump outlet hose (*1)
3. Power train pump outlet tube 10. Differential lock pump inlet hose (*1)
4. Power train oil filter outlet hose 11. Power train pump inlet tube
5. Power train oil cooler 12. Transmission
6. Power train oil cooler inlet hose 13. Transmission oil filer/dipstick port
7. Power train oil cooler outlet hose 14. Differential lock solenoid valve (*1)
10-20 GD535-5
10 Structure and function Transmission control
Transmission control 1
1. Transmission controller
2. Gear shift lever
3. Transmission mode selector switch
GD535-5 10-21
Torque converter 10 Structure and function
Torque converter 1
1. PTO drive gear (number of teeth: 70) 13. Race

2. Pump 14. Guide
3. Drive case 15. Stator shaft
4. Stator
5. Turbine Specifications
6. Damper 3-element, 1-stage, 2-phase
7. Lockup clutch piston Type
With lockup clutch
8. Lockup clutch housing (number of teeth: 72)
9. Pilot Wet, single disc clutch
10. Boss Lockup clutch Hydraulically controlled
(With modulation mechanism)
11. Disc
12. One-way clutch Stall torque ratio 2.71
10-22 GD535-5
10 Structure and function Torque converter
Power transmission route
With lockup clutch disengaged With lockup clutch "engaged"
Because drive case (3) disconnected from boss (10) Since drive case (3) is connected to damper (8), boss
and turbine (9), the torque converter works as a nor- (10), and turbine (9), the torque converter provides
mal torque converter. lockup function.
Power generated in the engine Power generated in the engine
↓ ↓
Flywheel (1) Flywheel (1)
↓ ↓
Clutch housing (2) Clutch housing (2)
↓ ↓
Drive case (3), pump (5), and PTO drive gear (6) rotate Lockup clutch (4)
as a unit. ↓
↓ Damper (8)
Oil works as a power transmission medium. ↓
↓ Boss (10)
Turbine (9) and boss (10) ↓
↓ Transmission input shaft (11)
Transmission input shaft (11)
q The power transmitted to PTO drive gear (6) is

q The power transmitted to PTO drive gear (6) is used to drive the pump through PTO idler gear (7).
used to drive the pump through PTO idler gear (7).
GD535-5 10-23
Torque converter 10 Structure and function
Flow of oil
q The pressure of oil that has passed through the

main relief valve is regulated below the set pres-
sure by the torque converter relief valve. Then the
oil enters inlet port (A) and flows to pump (3)
through the oil paths of stator shaft (1) and guide
(2).
q The oil is moved via centrifugal force by pump (3)
and enters turbine (4) to power it.
q The oil from turbine (4) is sent to stator (5) and
enters pump (3) again. Some oil passes between
turbine (4) and stator (5) and flows from outlet port
(B) to lubricate the transmission through the oil
cooler.
10-24 GD535-5
10 Structure and function Transmission
Transmission 1
GD535-5 10-25
Transmission 10 Structure and function
A: From power train oil filter 1. Transmission control valve

B: To power train oil cooler 2. Main relief valve, torque converter relief valve
C: From power train oil cooler 3. Torque converter internal pressure sensor
D: To power train pump 4. Torque converter oil temperature sensor
E: Work equipment pump and steering pump mount- 5. Transmission case (rear)
ing location 6. Transmission case (front)
F: Power train pump mounting location (*1) 7. Transmission oil temperature sensor
G: Oil filer pipe mounting location 8. Transmission intermediate shaft speed sensor
9. Transmission output shaft speed sensor
10. Transmission input shaft speed sensor
*1. Power train pump and differential lock pump

mounting location for machines with differential
lock type rear axle
10-26 GD535-5
1. Torque converter 9. 4th clutch

2. Input shaft 10. Output shaft
3. FL clutch 11. 2nd clutch
4. Upper shaft 12. 1st clutch
5. FH clutch 13. R clutch
6. Lower shaft 14. PTO idler gear A (number of teeth: 61)
7. 3rd clutch 15. PTO driven gear A (number of teeth: 62)
8. Coupling
GD535-5 10-27
1. PTO driven gear B (number of teeth: 62)

2. PTO idler gear B (number of teeth: 61)
3. R idler gear (number of teeth: 35)
4. Strainer
5. Drain plug
6. Drain plug
7. Drain plug
10-28 GD535-5
Outline Number of plates and discs used

q The transmission is a combination of the counter-
Clutch No. Number of plates Number of discs
shaft type constant mesh gear mechanism and
disc clutches and provides "8 forward and 4 FL clutch 9 8
reverse speeds". FH clutch 12 11
q The transmission selects one rotation direction
and one gear speed by fixing 2 of the 7 disc R clutch 9 8
clutches hydraulically via the operation of the 1st clutch 7 6
ECMV in the counter-shaft type constant mesh
gear mechanism. 2nd clutch 12 11
q The transmission receives the power from the 3rd clutch 9 8
input shaft and transfers it to the output shaft while
4th clutch 7 6
changing its speed to the forward 1st to 8th or
reverse 1st to 4th by combining the FL, FH, and R
clutches and 4-speed clutches.
Table of clutch combination and reduction ratio
for each gear speed
Gear speed Clutches used Reduction ratio
Forward 1st FL and 1st 6.773
Forward 2nd FH and 1st 4.787
Forward 3rd FL and 2nd 3.499
Forward 4th FH and 2nd 2.473
Forward 5th FL and 3rd 1.771
Forward 6th FH and 3rd 1.251
Forward 7th FL and 4th 0.900
Forward 8th FH and 4th 0.636
NEUTRAL - -
Reverse 1st R and 1st 5.957
Reverse 2nd R and 2nd 3.077
Reverse 3rd R and 3rd 1.557
Reverse 4th R and 4th 0.791
GD535-5 10-29
FL and R clutches
A: FL clutch oil port C: Lubricating oil port

B: R clutch oil port D: Lockup clutch oil port
1. R clutch gear (number of teeth: 27) 5. FL clutch gear (number of teeth: 34)
2. R clutch 6. Input gear (number of teeth: 42)
3. FL and R cylinder 7. Input shaft
4. FL clutch
10-30 GD535-5
FH and 1st clutches
A: FH clutch oil port C: Lubricating oil port

B: 1st clutch oil port
1. Upper gear (number of teeth: 44) 5. FH clutch

2. 1st clutch gear (number of teeth: 28) 6. FH clutch gear (number of teeth: 55)
3. 1st clutch 7. Upper shaft
4. FH and 1st cylinder (number of teeth: 63)
GD535-5 10-31
2nd and 3rd clutches
A: 3rd clutch oil port C: Lubricating oil port

B: 2nd clutch oil port
1. 2nd clutch gear (number of teeth: 69) 4. 3rd clutch

2. 2nd clutch 5. 3rd clutch gear (number of teeth: 67 and 50)
3. 2nd and 3rd cylinder (number of teeth: 85 and 49) 6. Lower shaft
10-32 GD535-5
4th clutch
A: 4th clutch oil port

B: Lubricating oil port
1. 4th cylinder (number of teeth: 59) 3. 4th clutch gear (number of teeth: 41)
2. 4th clutch 4. Output shaft
GD535-5 10-33
Operation of disc clutch
When clutch is "engaged" (locked) When clutch is disengaged (released)
q The oil sent from the transmission valve flows q The oil sent from the transmission valve is blocked
through the oil path in shaft (1) to the backside of and the pressure of oil acting on the rear of piston
piston (5) and activates piston (5). (5) drops.
q When piston (5) is activated, it presses separator q Piston (5) is returned to the original position by
plate (2) against friction plate (3). This causes wave spring (6). This causes separation of shaft
integration of shaft (1) and clutch gear (4), allow- (1) and clutch gear (4).
ing the power to be transmitted. q Oil drain hole (a) serves to spin-drain the oil from
At this time, while some oil drains through oil drain the rear of the piston so that the clutch will not be
hole (a), the clutch operation is not affected left in a partially engaged state.
because the amount of oil drained is much less
than the oil supply. a The structure of oil drain hole (a) is that of the 2nd,
3rd, and 4th clutches.
10-34 GD535-5
Power transmission route

Forward 1st
FL clutch (3) and 1st clutch (11) are hydraulically locked.

Power from torque converter → (Continues from lower left)
↓ ↓
Input shaft (1) 1st clutch (11)
↓ ↓
FL and R cylinder (2) 1st clutch gear (14)
↓ ↓
FL clutch (3) 2nd and 3rd cylinder (20)
↓ ↓
FL clutch gear (5) 4th cylinder (25)
↓ ↓
FH and 1st cylinder (12) Output shaft (26)
↓
(Continues to top center) →
GD535-5 10-35
Forward 2nd
FH clutch (10) and 1st clutch (11) are hydraulically locked.

↓ ↓
Input shaft (1) 1st clutch gear (14)
↓ ↓
Input gear (7) 2nd and 3rd cylinder (20)
↓ ↓
FH clutch gear (9) 4th cylinder (25)
↓ ↓
FH clutch (10) Output shaft (26)
↓
FH and 1st cylinder (12)
↓
1st clutch (11)
↓
(Continues to upper right) →
10-36 GD535-5
Forward 3rd
FL clutch (3) and 2nd clutch (18) are hydraulically locked.

↓ ↓
Input shaft (1) Upper gear (15)
↓ ↓
FL and R cylinder (2) 2nd clutch gear (16)
↓ ↓
FL clutch (3) 2nd clutch (18)
↓ ↓
FL clutch gear (5) 2nd and 3rd cylinder (20)
↓ ↓
FH and 1st cylinder (12) 4th cylinder (25)
↓ ↓
Upper shaft (13) Output shaft (26)
↓
GD535-5 10-37
Forward 4th
FH clutch (10) and 2nd clutch (18) are hydraulically locked.

↓ ↓
Input shaft (1) Upper gear (15)
↓ ↓
Input gear (7) 2nd clutch gear (16)
↓ ↓
FH clutch gear (9) 2nd clutch (18)
↓ ↓
FH clutch (10) 2nd and 3rd cylinder (20)
↓ ↓
FH and 1st cylinder (12) 4th cylinder (25)
↓ ↓
Upper shaft (13) Output shaft (26)
↓
10-38 GD535-5
Forward 5th
FL clutch (3) and 3rd clutch (19) are hydraulically locked.

↓ ↓
Input shaft (1) 3rd clutch (19)
↓ ↓
FL and R cylinder (2) 2nd and 3rd cylinder (20)
↓ ↓
FL clutch (3) 4th cylinder (25)
↓ ↓
FL clutch gear (5) Output shaft (26)
↓
↓
3rd clutch gear (17)
↓
GD535-5 10-39
Forward 6th
FH clutch (10) and 3rd clutch (19) are hydraulically locked.

↓ ↓
Input shaft (1) 3rd clutch (19)
↓ ↓
Input gear (7) 2nd and 3rd cylinder (20)
↓ ↓
↓ ↓
↓
↓
↓
10-40 GD535-5
Forward 7th
FL clutch (3) and 4th clutch (24) are hydraulically locked.

↓ ↓
Input shaft (1) 4th clutch gear (23)
↓ ↓
FL and R cylinder (2) 4th clutch (24)
↓ ↓
FL clutch (3) 4th cylinder (25)
↓ ↓
FL clutch gear (5) Output shaft (26)
↓
↓
↓
GD535-5 10-41
Forward 8th
FH clutch (10) and 4th clutch (24) are hydraulically locked.

↓ ↓
Input shaft (1) 4th clutch gear (23)
↓ ↓
Input gear (7) 4th clutch (24)
↓ ↓
↓ ↓
↓
↓
↓
10-42 GD535-5
Reverse 1st
R clutch (4) and 1st clutch (11) are hydraulically locked.

Power from torque converter → (Continues from lower left) → (From lower center)
↓ ↓ ↓
Input shaft (1) Upper gear (15) 4th cylinder (25)
↓ ↓ ↓
FL and R cylinder (2) Upper shaft (13) Output shaft (26)
↓ ↓
R clutch (4) FH and 1st cylinder (12)
↓ ↓
R clutch gear (6) 1st clutch (11)
↓ ↓
R idler gear (8) 1st clutch gear (14)
(Through R idler gear (8), ↓
rotation direction of output power is
2nd and 3rd cylinder (20)
reversed.)
↓ ↓
(Continues to top center) → (Continues to upper right) →
GD535-5 10-43
Transmission control valve 10 Structure and function
Transmission control valve 1
Control valves for lockup control, directional change, and gear shifting
A: FL clutch pressure detection port 1. FL clutch ECMV

B: FH clutch pressure detection port 2. FH clutch ECMV
C: R clutch pressure detection port 3. R clutch ECMV
D: 1st clutch pressure detection port 4. 1st clutch ECMV
E: 2nd clutch pressure detection port 5. 2nd clutch ECMV
F: 3rd clutch pressure detection port 6. 3rd clutch ECMV
G: 4th clutch pressure detection port 7. 4th clutch ECMV
H: Lockup clutch pressure detection port 8. Lockup clutch ECMV
9. Seat
10. Last chance filter
10-44 GD535-5
10 Structure and function Transmission control valve
Outline
q The oil from the pump flows into the transmission case through the oil filter, and then divides into the main
relief circuit and clutch operation circuit.
q The oil, that has been pressure regulated by the main relief valve and branched off to the clutch operation cir-
cuit, passes through the last chance filter and activate the clutch. The oil that has been relieved by the main
relief valve is supplied to the torque converter.
q When the transmission gear is shifted, the ECMV smoothly increases the clutch oil pressure in line with the
command current received from the transmission controller to reduce the gear shifting shocks. The ECMV
keeps the clutch pressure constant during travel.
q When some ECMVs are selected and turned on from among those for FL, FH, and R clutches and 1st to 4th
clutches, pressure regulated oil is supplied to the selected clutches to realize required gear speed.
q This machine uses three types of ECMVs, which have the following identifications and differences.
Identification Fill switch

Print (A) on nameplate Clutches used
color (B) Operating pressure (MPa {kg/cm2})
OA2****** (*1) Yellow Provided (0.26 {2.7}) FL, FH, R, and 1st
0E1****** (*1) Pink Provided (0.26 {2.7}) 2nd, 3rd, and 4th
K7******* - None L/U
L/U: Denotes lockup clutch ECMV.

*1: ECMVs installed on the transmission assembly are coated with paint, which prevents them from being
distinguished by identification color.
(ECMVs can be distinguished by identification color
only when they are not installed and coated. ) ECMV operation table
ECMV
FL FH R 1st 2nd 3rd 4th
Gear speed
F1 Q Q
F2 Q Q
F3 Q Q
F4 Q Q
F5 Q Q
F6 Q Q
F7 Q Q
F8 Q Q
R1 Q Q
R2 Q Q
R3 Q Q
R4 Q Q
N
GD535-5 10-45
ECMV 10 Structure and function
ECMV 1
a ECMV: Stands for Electronic Control Modulation Valve.
For FL, FH, R, 1st, 2nd, 3rd, and 4th clutches

a Do not disassemble them. Doing so requires adjustment to keep their performances.
A: To clutch
P: From pump
T: Drain
DR: Drain
P1: Clutch pressure detection port
1. Fill switch connector

2. Proportional solenoid connector
3. Pressure detection valve
4. Fill switch
5. Proportional solenoid
6. Pressure control valve
7. Nameplate
10-46 GD535-5
10 Structure and function ECMV
Outline of ECMV ECMV and proportional solenoid

q An ECMV consists of two components, pressure q Each ECMV has one proportional solenoid.
control valve and fill switch. The proportional solenoid generates the level of
q Pressure control valve thrust shown below corresponding to the com-
This valve receives the current sent from the mand current from the controller.
transmission controller with its proportional sole- The thrust generated by the proportional solenoid
noid and converts the current to oil pressure. acts on the pressure control valve spool to pro-
q Fill switch duce the oil pressure shown below.
This switch determines at the clutch is filled with Therefore, control of the command current
oil and has the following functions. enables oil flow and oil pressure to be controlled
1. Outputs a signal (a fill signal) to the controller as because the thrust changes and activates the
notification that filling is complete when the clutch pressure control valve according to the current.
is filled with oil.
2. Continues to output a signal (a fill signal) to the Current - Thrust characteristics of proportional
controller while oil pressure is applied to the clutch solenoid
as notification that there is a certain degree of oil
pressure.
Thrust - Oil pressure characteristics of propor-

tional solenoid
Range A: Before gear shifting (when oil is being

ECMV and fill switch
drained)
q Each ECMV has one fill switch.
Range B: Filling in process
When the clutch is filled with oil, the fill switch is
Range C: Pressure regulation
turned ON by the pressure of the clutch. This sig-
Range D: Filling (triggering) in process
nal starts buildup of oil pressure.
Point E: Start of filling
Point F: End of filling
a The logic is designed so that the controller does
not recognize when filling is complete even if the
fill switch is turned ON during the triggering period
(Range D).
GD535-5 10-47
Operation of ECMV Before gear shifting (when oil is being drained)

q The ECMV is controlled with the command current (Range A in the diagram)
from the controller to the proportional solenoid and
the fill switch output signal
The relationships between ECMV proportional
solenoid command current, clutch input pressure,
and fill switch output signal are shown below.
q With proportional solenoid (1) is de-energized,

pressure control valve (3) drains the oil in clutch
port (A) through drain port (T).
At this time, fill switch (5) remains OFF because
no oil pressure applies to oil pressure detection
Range A: Before gear shifting (when oil is being valve (4).
drained)
Range B: Filling in process
Range C: Pressure regulation
Range D: Filling (triggering) in process
Point E: Start of filling
Point F: End of filling
a The logic is designed so that the controller does
not recognize when filling is complete even if the
fill switch is turned ON during the triggering period
(Range D).
10-48 GD535-5
Filling in process (Range B in the diagram) Pressure regulation (Range C in the diagram)
q When no oil is in the clutch, if proportional sole- q When proportional solenoid (1) is energized, the
noid (1) is energized, and pressure force that is solenoid generates a thrust proportional to the
equal to the solenoid force acts in chamber (B) current. The pressure is regulated so that the
and pushes pressure control valve (3) to the left. thrust of this solenoid balances with the sum of the
As a result, pump port (P) connects to clutch port thrust exerted by the clutch port pressure and
(A) and the clutch starts to be filled with oil. When repulsive force of pressure control valve spring
the clutch is filled up with oil, oil pressure detection (2).
valve (4) works to turn fill switch (5) ON.
GD535-5 10-49
For lockup clutch

a Do not disassemble them. Doing so requires adjustment to keep their performances.
A: To clutch
P: From pump
T: Drain
DR: Drain
P1: Clutch pressure detection port
1. Proportional solenoid connector

2. Sleeve
3. Proportional solenoid
4. Pressure control valve
5. Nameplate
10-50 GD535-5
Outline of ECMV Operation

q This valve regulates the clutch pressure to the set When clutch is disengaged (released)
pressure and switches the clutch function as well.
With modulation waveform clutch pressurization
characteristics, this valve realizes smooth lockup
clutch engagement and reduces gear shifting
shocks. In addition, this prevents generation of
peak torque in the power train. As a result, this
m a c h i n e p r o v i d e s a c o m f o r ta b l e r i d e a n d
increased power train durability.
Switching from torque converter drive to direct

drive
At gear shifting (in direct drive)
q With proportional solenoid (1) is de-energized,

pressure control valve (3) drains the oil in clutch
port (A) through drain port (T).
GD535-5 10-51
When clutch is engaged (locked)
q When proportional solenoid (1) is energized, an

pressure force that is equal to the solenoid force
acts on chamber (B) and pushes pressure control
valve (3) to the left. As a result, pump port (P) con-
nects to clutch port (A) and the clutch starts to be
filled with oil.
q When the clutch is filled up with oil, the pressure is
regulated so that the thrust of the solenoid bal-
ances with the sum of the thrust exerted by the
clutch port pressure and repulsive force of pres-
sure control valve spring (2).
10-52 GD535-5
10 Structure and function Main relief valve and torque converter relief valve
Main relief valve and torque converter relief valve 1
A: Drain (torque converter relief)

B: Drain
C: From pump
D: Drain
E: To torque converter
P1: Main relief pressure detection port
P2: Torque converter relief pressure detection port
1. Body
2. Piston
3. Torque converter relief valve
4. Piston
5. Main relief valve
GD535-5 10-53
Main relief valve and torque converter relief valve 10 Structure and function
Outline Operation of main relief valve
Torque converter relief valve

q The torque converter relief valve constantly regu-
lates the torque converter inlet circuit pressure be-
low the set pressure to protect the torque converter
from abnormally high pressure.
Set pressure: 1.02 MPa {10.4 kg/cm2}
(Cracking pressure)
Main relief valve

q The main relief valve regulates the pressure in the
transmission and parking brake hydraulic circuits
to the set pressure.
Set pressure: 2.73 MPa {27.9 kg/cm2}
(At rated engine speed) q The oil from the hydraulic pump flows to port (C)
through the filter. Then it flows to chamber (F)
Operation through orifice (a) in main relief valve (1).
Operation of torque converter relief valve
q When the oil pressure in the circuit increases be-

yond the set pressure, the oil in chamber (F) push-
q The oil relieved through the main relief valve flows es piston (2) and the resulting pushing force
through port (E) into the torque converter. against the spring force pushes main relief valve
It also flows through orifice (b) in torque converter (1) leftward. This connects ports (C) and (E).
relief valve (3) into chamber (G). Then, the oil from pump flows through port (E) into
q When the oil pressure to the torque converter ex- the torque converter.
ceeds the set pressure, the oil conducted to cham-
ber (G) pushes piston (4) and the resulting pushing
force pushes torque converter relief valve (3) to the
right. This connects ports (E) and (A).
Then, the oil in port (E) is drained through port (A).
10-54 GD535-5
10 Structure and function Front axle
Front axle 1
1. Tie rod Specifications

2. Leaning rod Toe-in angle (degrees) -5 to 0
3. Bracket
4. Support axle Camber angle (degrees) 0
5. Leaning cylinder Leaning angle (degrees) (*1) 16
6. Steering cylinder
7. Hub shaft
*1: Tilt angle of tire center to the normal from the axle
GD535-5 10-55
Front axle 10 Structure and function
Operation of front axle

1. Prevention of tilting and fluctuation of blade The blade can fluctuate while being kept horizon-
q The front axle is mounted on the frame at its tal if the front axle does not tilt to a degree that
center with the center pin and can oscillate 16 exceeds its oscillation range (16 degrees to the
degrees. In the same manner as the tandem right and left).
drive, this mechanism can reduce fluctuation of
the blade even when a wheel on one side runs
into a bump or falls into a hole.
As shown in the figure, the front axles rise by
H/2 at its center when either front wheel runs
into a bump.
Because the front axle can oscillate, the blade
moves by H/4 while being kept horizontal.
2. Prevention of side slipping of front wheel (leaning

device)
q Front wheels can lean to both sides. This
mechanism, called a leaning device, can pre-
vent side slipping of front wheels and reduce
the turning radius.
In many motor grader operations, a motor
grader is operated with the blade set at an
advancing angle. In such cases, as the
advancing angle increases, the force applied
to the blade, that can cause side slipping of
front wheels, becomes large.
q The mass distribution ratio to the front and rear

wheels is approximately 3:7. If the blade digs
into the ground, the load on the front axle is
reduced, causing the front wheels to side slip
easily.
To handle this side-slipping problem, motor
graders are designed with front wheels that
lean so that it can withstand side slipping and
move the center location of the load on the
front axle as well as the center of gravity of the
machine.
10-56 GD535-5
10 Structure and function Front axle
q A motor grader has a wide turning radius because

it has a long wheel base and also because the
driving mechanism does not have a differential.
So, as for the distance S = 2xr that is obtained
from tire rotation, if the wheels lean, the wheel
with larger loader loaded radius tends to advance
faster than the wheel with the smaller loaded
radius.
As a result, the machine tends to advance in the
direction in which wheels are leaning.
By using this characteristics, leaning operations

can facilitate smaller turning radii.
q In the reverse operation, the front wheels are

leaned in the direction opposite to that of steer-
ing wheel rotation (opposite direction to that of
forward movement).
GD535-5 10-57
Rear axle 10 Structure and function
Rear axle 1
1. Differential Outline
2. Tandem drive q When a motor grader is operated with the blade
3. Final drive set at an advancing angle or with the machine
body inclined, the front of the machine receives a
lateral force as a reaction and the machine tends
to turn to the right or left. To manage this prob-
lem, the machine is required to have straight-
travel capability. So, a motor grader usually has no
differential function in the rear axle structurally.
q When a motor grader conducts operations while it
is turning, the tire slip ratio of the rear wheels
becomes high due to trajectory differences.
In this case, machines with differential lock type
rear axles help extend the service lives of tires.
10-58 GD535-5
10 Structure and function Differential (Non-differential specification)
Differential (Non-differential specification) 1
(Machines with non-differential type rear axle)
1. Sun gear shaft (number of teeth: 18)

2. Bevel gear (number of teeth: 43)
3. Coupling
4. Bevel pinion (number of teeth: 12)
5. Cage
GD535-5 10-59
Differential (Non-differential specification) 10 Structure and function
Operation
q Power from the transmission is input to the cou-

pling, and then the power is transmitted to bevel
pinion (1) from the coupling.
q The power changes its direction by 90 degrees
and reduces its speed due to the combination of
bevel pinion (1) and bevel gear (2), and is then
transmitted to sun gear shaft (4) through cage (3).
q The power transmitted to the sun gear shaft is out-
put to the final drive.
10-60 GD535-5
10 Structure and function Differential (Differential lock specification)
Differential (Differential lock specification) 1
(Machines with differential lock type rear axle)
1. Sun gear shaft (number of teeth: 18) 7. Side gear (number of teeth: 24)
2. Bevel gear (number of teeth: 43) 8. Differential case
3. Coupling 9. Disc
4. Bevel pinion (number of teeth: 12) 10. Plate
5. Shaft 11. Differential lock solenoid valve
6. Pinion (number of teeth: 12)
GD535-5 10-61
Differential (Differential lock specification) 10 Structure and function
Outline
q The differential switches between ON and LOCK
(OFF) by hydraulically pressing disc (9) and plate
(10) simultaneously or separately.
q When the machine is in high-speed operation
(gear shift lever positioned at F8), the transmis-
sion controller automatically cancels the differen-
tial lock even if the differential lock switch is
switched to "ON".
10-62 GD535-5
10 Structure and function Differential (Differential lock specification)
Operation
At normal traveling At turning
q Power from the transmission is input to the cou- q While the machine is turning, the right and left
pling, and then the power is transmitted to bevel wheels rotate at different speeds. Pinion (1) and
pinion (1) from the coupling. side gear (2) inside the differential rotate and
q The power changes its direction by 90 degrees transmit the power of differential case (3) to the
and reduces its speed due to the combination of right and left sun gear shafts (4) according to the
bevel pinion (1) and bevel gear (2), and is then difference between the speeds of the right and
transmitted from side gear (4) to the sun gear left.
shaft through pinion (3).
q The power transmitted to the sun gear shaft is out- At differential lock
put to the final drive.
At straight traveling
q If either tire of the right or left tandem drive falls

into mud or similar substance and loses its load
resistance, the tire with the smaller load resistance
q While the machine is traveling straight, the right alone rotates and the power cannot be transmit-
and left wheels rotate at a same speed. So, pinion ted.
(1) inside the differential does not rotate and the q To enable the machine to travel even when the
power of differential case (2) is transmitted equally power cannot be transmitted, the differential lock
to the right and left sun gear shafts through pinion (1) is activated to stop the rotation of pinion (2)
(1) and side gear (3). and transmit the power equally to the right and left
sun gear shafts (3).
GD535-5 10-63
Differential lock solenoid valve 10 Structure and function
Differential lock solenoid valve 1
10-64 GD535-5
10 Structure and function Final drive
Final drive 1
a The figure shows the final drive for machines with differential lock type rear axle
1. Sprocket (number of teeth: 18)

2. Shaft
3. Planetary carrier
4. Planetary gear (number of teeth: 25)
5. Ring gear (number of teeth: 69)
GD535-5 10-65
Final drive 10 Structure and function
Operation
q The power from the differential is input to the final

drive through sun gear shaft (1).
q The power input to the final drive is reduced via
planet gear mechanism (2).
q The reduced power is input from sprocket (4) to
the tandem drive through shaft (3).
10-66 GD535-5
10 Structure and function Tandem drive
Tandem drive 1
1. Sprocket (number of teeth: 18)

2. Hub shaft
3. Breather
4. Oil level plug
5. Drain plug
GD535-5 10-67
Tandem drive 10 Structure and function
Outline
q The tandem drive transmits the power transmitted
from the final drive to the front/rear rear wheels
with chains.
q The tandem case can oscillate 11 degrees and 13
degrees in forwards upward and forwards down-
ward directions respectively. This allows the 4 rear
wheels to stay on the ground even when the
ground is uneven. So, fluctuation of the blade can
be minimized.
Operation
q If the rear wheels of the motor grader hit a bump in
the road, the blade moves as shown below.
1. If both the right and left wheels hit a bump (height

H), the rear axles rises by H/2 at its center as
shown in the figure. Because the blade is located
almost halfway between the front and rear axles,
the movement of the blade is further reduced to H/
4.
2. Among the rear wheels, if one wheel on the left

side alone hits a bump (height H), the rear axle
rises at its center by H/2, and the distance it rises
halves further to H/4 at the machine center point on
the rear axle as shown in the figure. The distance
the blade rises further halves to H/8 at its center.
10-68 GD535-5
10 Structure and function Steering piping drawing
Steering system 1
Steering piping drawing 1
1. Steering valve
2. Steering wheel
3. Steering cylinder
4. Hydraulic tank
5. Priority valve
6. Hydraulic oil line filter
7. Work equipment and steering pump
GD535-5 10-69
Priority valve 10 Structure and function
Priority valve 1
P: From pump
EF: To hydraulic tank
CF: To steering valve
LS: To pilot circuit
T: To hydraulic tank
10-70 GD535-5
10 Structure and function Priority valve
a: Orifice Outline
b: Orifice q This valve restricts flow rate to the steering circuit
c: Orifice to a minimum (approximately 1 l/min) when no
steering operations are performed. Thus, the load
1. Spring on the steering pump is minimized.
2. Relief valve q The relief valve built in this valve regulates the
3. Spool steering circuit pressure and prevents abnormally
high pressure from developing.
GD535-5 10-71
Operation
When engine is stopped
q Spool (1) is pushed to the right by the repulsive
force of spring (2). As a result, port (EF) is closed
and the opening area of port (CF) is maximized.
When engine is started

(Control valve and steering valve in neutral state)
q The oil from the main pump flows from port (A)
through port (CF) to the steering circuit.
q Because the steering valve is in neutral the posi-
tion, the oil pressure in port (CF) rises.
q The oil in chamber (A) enters chamber (B) through
orifice (a) and pushes spool (1) to the left.
q The oil in port (CF) drains through the steering
valve.
q The normal flow rate of the LS circuit is approxi-
mately 1 l/min.
q The differential pressure across orifice (b) is
approximately 0.98 MPa {10 kg/cm2} when oil flow
of the LS circuit passes through the orifice. The
formula Pressure in chamber (B) = Pressure in
chamber (C) + 0.98 MPa {10kg/cm2 } holds. So,
spool (1) moves to the left and starts to close part
(d).
q When the opening area of part (d) becomes
reduced, the drain amount through orifice (b) low-
ers and differential pressure across orifice (b)
falls.
q When spool (1) is pushed to the right by the repul-
sive force of spring (2), it opens part (d). As a
result, the flow rate increases and spool (1) is
pushed to the left again.
q These operations are repeated until the spool bal-
ances.
q Leftward force (reduced oil pressure)
: Pressure in chamber (B) (= 1.57 MPa {16 kg/
cm2})
q Rightward force
: Pressure in chamber (C) + 0.98 MPa {10 kg/
cm2}) (= 1.57 MPa {16 kg/cm2})
(0.98 MPa {10 kg/cm2} is reduced oil pressure of
spring (2))
10-72 GD535-5
10 Structure and function Priority valve
When machine is being steered

(Control valve in neutral state)
q When the steering wheel is operated, port (CF),
the steering cylinder, and port (LS) are intercon-
nected.
q Spool (1) is pushed to the right by the force
exerted by the increased pressure in chamber (C)
and the repulsive force of spring (2). As a result,
the opening area of part (d) becomes large.
q While the steering wheel is being operated, the oil
from the main pump flows from port (CF) through
the steering valve to the steering cylinder at a flow
rate corresponding to the steering wheel opera-
tion.
q When the steering wheel is operated quickly, the
throttle area of the variable throttle orifice of the
steering valve increases.
q When differential pressure across the variable
throttle orifice in the steering valve falls, the oil
pressure in (LS) circuit increases (oil pressure in
chamber (B) lowers) and oil pressure in chamber
(C) increases.
q So, spool (1) moves further to the right further and
the opening area of part (d) increases further,
resulting in increased oil flow to the steering cylin-
der.
q When the steering wheel is operated slowly, the
throttle area of the variable throttle orifice of the
steering valve decreases.
q As the throttle area becomes small, the differential
pressure across the variable throttle orifice in the
steering valve becomes high. As a result, the
pressure in chamber (C) becomes larger than that
in chamber (B).
q Spool (1) moves to the left and the opening area of
part (d) becomes small. So, the pol flow to the
steering cylinder is reduced.
q Spool (1) balances at a position corresponding to
the steering wheel operation.
q Spool (1) is controlled so that the opening area of
part (d) will correspond to the oil flow required by
port (CF) while the differential pressure between
chambers (A) and (B) is kept at 0.98 MPa {10 kg/
cm2},. (All oil other than that required for the steer-
ing operation returns from port (EF) to the hydrau-
lic tank .)
q As for the oil flowing from port (CF) to the steering
cylinder, if load is applied, the oil pressure in (PLS)
line increases.
GD535-5 10-73
When the steering cylinder is at the end of its

stroke
q When the steering cylinder has reached the end of
its stroke end if the steering wheel continues to be
operated, the oil flow from the steering valve to the
steering cylinder is stopped while the circuit
remains connected.
q When the oil flow is stopped, both (CF) and (LS)
circuit pressures increase to a level equivalent to
the pressure in pump port (P).
q Both pressures in chambers (B) and (C) increase
and spool (1) moves to the right.
q When the pressure in chamber (C) exceeds 15.2
MPa {155 kg/cm2}, the steering relief valve opens
to drain the oil in chamber (C).
q Differential pressure is developed across orifice
(b), and the pressure in chamber (C) lowers that in
chamber (B). So, spool (1) moves to the left.
q Spool (1) balances at a position where the open-
ing area of part (d) is throttled so that the flow rate
becomes 1 l/min. to prevent flow rate loss at
relief.
q When spool (1) moves to the left to an excessive
degree, part (d) is closed and no oil flows to orifice
(b).
q When the oil pressure in chamber (C) becomes
equal to that in chamber (B), spool (1) is moved to
the right by the repulsive force of spring (2) and
part (d) is connected.
q These operations are repeated to keep the steer-
ing circuit pressure below 15.2 MPa {155 kg/cm2}.
10-74 GD535-5
10 Structure and function Steering valve
Steering valve 1
(Q/Amp manual Orbitrol type)
1. Bushing Outline
2. Valve body q The Q/Amp manual Orbitrol consists of a direc-
3. Check valve tional control valve and a flow amplifier orifice.
4. Gerotor q This Orbitrol controls the steering discharge
5. Spacer according to the control speed of the steering
6. Cover wheel. It shows a flow characteristic that the oil
7. Spacer flow is amplified more than the flow metered by
8. Drive shaft gerotor especially in the high speed range. (Vari-
9. Sleeve able ratio steering function)
10. Spool q The Q/Amp manual Orbitrol has the following fea-
11. Center pin tures.
12. Center spring q Provides stable steering performance by allow-
ing fine steering correction during high-speed
travel.
q Allows flip turns during low-speed travel and
stationary steering.
q Allows secondary steering with Orbitrol alone.
GD535-5 10-75
Steering valve 10 Structure and function
Variable ratio steering function
q The steering discharge varies according to the q During high-speed travel, if the steering wheel is
control speed of the steering wheel. operated gently, the steering discharge decreases
q The steering discharge decreases in the low to allow fine steering correction, therefore creating
speed control range of the steering wheel and superior steering performance during high-speed
increases in the high speed control range. travel.
q During stationary steering or low-speed travel, if
the steering wheel is operated quickly, the steer-
ing discharge increases easily to allow flip turns.
Flow amplifier function

q The Orbitrol has a bypass flow control function via
a built-in flow amplifier orifice in addition to the pri-
mary metering function provided by the gerotor.
So, the Orbitrol can supply a large amount of oil to
the steering cylinder.
q In the high speed range, even a small Orbitrol can
supply a large amount of oil to the steering cylin-
der.
10-76 GD535-5
Q/Amp manual Orbitrol
q Q/Amp Orbitrol with secondary steering function is

called Q/Amp manual Orbitrol.
q The secondary steering function is realized by
closing the characteristics of bypass orifice (char-
acteristics of flow amplifier orifice (AA)), that does
not go through metering (gerotor), in a secondary
steering condition (with the valve in the maximum
displacement state).
q The Q/Amp manual Orbitrol will create a large
advantage if it is used for the steering system of
mid-sized machines.
q Actually, only the small-capacity Orbitrol can pro-
vide secondary steering function separately. If a
large-capacity Orbitrol is employed, a hydraulic
power source for secondary use is needed.
q Employment of Q/Amp manual Orbitrol helped
create a realized simplified system while also
improving reliability.
GD535-5 10-77
Structure
q Spool (10) is connected to the drive shaft of the
steering wheel, to sleeve (9) through center pin (7)
(not in contact with the spool steering wheel is in
the "Neutral" position), and centering spring (4).
q Drive shaft (3) meshes with center pin (7) at its top
and is united with sleeve (9). Its bottom is splined
to rotor (1) of the gerotor set (combination of rotor
(1) and stator (11)).
q The valve body has 4 ports that connect to the
pump circuit, tank circuit, steering cylinder head
side, and steering cylinder bottom side respec-
tively. The pump-side port and tank-side port are
connected through the check valve in the body. If
the pump or engine fails, this structure enables oil
to be sucked directly from the tank side through
the check valve.
10-78 GD535-5
Connection of hand pump with sleeve
q The above figure shows the connection between

the gerotor suction and discharge ports and con-
nection of sleeve ports that serves to connect the
suction and discharge ports.
q When the steering wheel is turned to the right,
ports (a), (c), (e), (g), (i), and (k) are connected to
the pump side through vertical grooves. Similarly,
ports (b), (d), (f), (h), (j), and (l) are connected to
the left steering cylinder head side.
q Under the condition of the left figure shown above,
ports (1), (2), and (3) are in the discharge state of
the gerotor set. At this time, they are connect to
ports (l), (b), and (d) respectively and cylinder oil is
supplied. In addition, ports (5), (6), and (7) are
connected, and oil flows in from the pump
q The figure on the right shown above shows the
condition when the steering wheel is turned 90
degrees from this position. At this time, ports (1),
(2), and (3) are in the suction state and connected
to ports (i), (k), and (c) respectively. Ports (5), (6),
and (7) are in the discharge state and connected
to ports (d), (f), and (h) respectively
q As described above, hand pump ports in the dis-
charge state are connected to respective ports
that lead to the steering cylinder, and those in the
suction state are connected to pump circuit.
q If the pump or engine fails, forcibly performing
suction and discharge of this hand pump allows
you to supply oil to the steering cylinder to carry
out steering operations.
GD535-5 10-79
q The discharge is adjusted according to the steering angle of the steering wheel. That is, oil from the pump
always passes through this hand pump. Because the hand pump advances its internal gear by one tooth for
each 1/7 turn of the steering wheel to discharge oil, the discharge is directly proportional to the steering angle
of the steering wheel.
q This applies even if the pump or engine fails, the same amount of discharge is obtained as that under normal
conditions.
Difference between trochoid pump and hand pump for steering pump
Trochoid pump
q The inlet port and outlet port are provided sepa-

rately. As shown in figures (2) to (6) above, the oil
is sucked in from the inlet side and discharged to
the outlet side as the shaft is rotated.
Hand pump for steering pump
q The hand pump has respective inlet/outlet ports at

the bottom of the stator internal gear teeth. When
the shaft rotates, as shown in figures (2) and (3)
above, the port connects to the steering pump
side and oil is sucked in.
When the shaft rotates further, as shown in figures
(5) and (6) above, the port connects to the steer-
ing cylinder side and oil is supplied to the cylinder.
Each port conducts this operation.
10-80 GD535-5
Role of center spring
q Center spring (2) consists of 4 X-shaped leaf

springs and 2 flat leaf springs, and as shown in the
figure, it is installed between spool (9) and sleeve
(8).
q When the steering wheel is turned, spool (9) com-
presses center spring (2) and angular displace-
ment (a) is generated between spool (9) and
sleeve (8).
As a results, ports in spool (9) interconnect to
ports in sleeve (8) and oil is supplied to the steer-
ing cylinder. When turning of the steering wheel is
stopped, the gerotor rotation is also stopped. So,
no oil is sent to the steering cylinder and the oil
pressure increases. To prevent this, when turning
of the steering wheel is stopped, the repulsive
force of center spring (2) turns the steering wheel
by angular displacement (a) between spool (9)
and sleeve (8) to return it to a neutral position.
GD535-5 10-81
Hydraulic piping drawing of brake system 10 Structure and function
Brake system 1
Hydraulic piping drawing of brake system 1
1. Parking brake solenoid valve, lifter lock pin sole- 8. Hydraulic tank
noid valve 9. Hydraulic oil line filter
2. Brake and cooling fan pump 10. Brake circuit accumulator charge valve
3. Wheel brake (rear) 11. Brake valve
4. Wheel brake (front) 12. Stop lamp oil pressure switch
5. Parking brake cylinder 13. Brake pedal
6. Brake circuit accumulator (left)
7. Brake circuit accumulator (right)
10-82 GD535-5
10 Structure and function Brake valve
Brake valve 1
PA: From ACC2 port of brake circuit accumulator B: To brake cylinder

charge valve TA: Drain
PB: From ACC1 port of brake circuit accumulator TB: Plug
charge valve SA: Plug
A: To brake cylinder SB: Stop lamp oil pressure switch
1. Piston 4. Spool
2. Spool 5. Cylinder
3. Cylinder
GD535-5 10-83
Brake valve 10 Structure and function
Outline
q The brake valve is installed at the bottom of the
front of the operator's seat. Pressing the brake
pedal supplies oil to the brake piston to apply the
brake.
Operation
When brake pedal is pressed
q When brake pedal (1) is pressed, the pressing

effort is transmitted to spool (5) through rod (2),
piston (3), and spring (4).
q When spool (5) is pushed to the right, port (TA) is
closed. The oil from the pump flows in port (PA)
through the accumulator, flows from port (A) to the
brake piston, and applies the brake [on port (A)
side].
q At the same time when spool (5) moves to the
right, spool (6) is also pushed to the right, and port
(TB) is closed. The oil from the pump flows in port
(PB) through the accumulator, flows from port (B)
to the brake piston, and applies the brake [on port
(B) side].
10-84 GD535-5
When brake on one side is applied

(When either brake failed)
q Even if an oil leak or the like occurs in the rear

brake system and a brake on either side alone can
work, the pressing effort on brake pedal (1)
mechanically moves spool (5) and spool (6) to the
right.
Therefore, the oil from the pump can flow to the
brake piston of the normal brake as usual and the
brake can be applied to stop the machine. Thus,
safety is improved.
GD535-5 10-85
Brake valve 10 Structure and function
When brake is balancing
q When the brake cylinder is filled with oil from port

(A) and the circuit pressure between port (PA) and
port (A) rises. The oil in chamber (E), that has
entered it through orifice (c) of spool (5), pushes
back spool (5) to the left against the repulsive
force of spring (4). As a result, port (PA) and port
(A) are blocked.
At this time, because port (TA) remains closed, the
oil from port (A) is held and the brake remains
applied.
q At the same time when spool (5) moves to the left,
the brake cylinder is filled with the oil from port (B)
and the circuit pressure between port (PB) and
port (B) rises. The oil in chamber (F), that has
entered it through orifice (d) of spool (6), pushes
back spool (6) to the left by the move distance of
spool (5). As a result, port (PB) and port (B) are
blocked
And because port (TB) remains closed, the oil
from port (B) is held and the brake remains
applied.
q The oil pressure of the brake circuit [on port (A)
side] balances with the brake pedal pressing
effort, and the oil pressure of the brake circuit [on
port (B) side] balances with that of the brake cir-
cuit [on port (A) side] .
When spools (5) and (6) move to the right by a full
stroke, the circuit between ports (PA) and (A) and
that between ports (PB) and (B) are completely
formed. The oil pressure of the brake circuit [on
port (B) side] and that of the brake circuit [on port
(B) side] are made equal to the oil pressure from
the brake pump.
Thus, the degree that the brake works can be
adjusted by adjusting brake pedal pressing effort
until spools (5) and (6) move to the right by a full
stroke.
10-86 GD535-5
When brake pedal is released
q When brake pedal (1) is returned, the brake pedal

pressing effort acting on spool (5) is released.
q When spool (5) is pushed back to the left by the
force exerted by the back pressure of the brake
piston [on port (A) side] and the repulsive force of
spring (7), port (PA) is closed and the oil in the
brake piston [on port (A) side] flows from port (A)
to port (TA). Then, the oil is drained from port (TB)
to the hydraulic tank. So, the brake [on port (A)
side] is released.
q At the same time when spool (5) moves to the left,
spool (6) is also pushed back to the left by the
force exerted by the back pressure of the brake
piston [on port (B) side] and the repulsive force of
spring (7), port (PB) is closed and the oil in the
brake piston [on port (B) side] flows from port (B)
to port (TB). Then, the oil is drained from port (TB)
to the hydraulic tank. So, the brake [on port (B)
side] is released.
GD535-5 10-87
Brake circuit accumulator 10 Structure and function
Brake circuit accumulator 1
1. Plug
2. Gas valve
3. Top cover
4. Cylinder
5. Free piston
6. End cover
Function
q The brake circuit accumulator is installed between
the brake circuit accumulator charge valve and the
brake valve.
q Cylinder (4) is charged with nitrogen gas. Free pis-
ton (5) uses the pressure of stored compressed
nitrogen gas to maintain the brake force even after
the engine is stopped.
Specifications
Gas to be used Nitrogen gas
Volume of gas (cc) 3,750
Gas charged pressure 3.4 ± 0.1 {35 ± 1.0}
(MPa {kg/cm2}) (at 20°C)
Max. operating pressure:
20.6 {210}
(MPa {kg/cm2})
10-88 GD535-5
10 Structure and function Brake circuit accumulator charge valve
Brake circuit accumulator charge valve 1
P: From pump
PA: To hydraulic oil cooler
ACC1: To brake valve port PA
ACC2: To brake valve port PB
T: Drain
GD535-5 10-89
Brake circuit accumulator charge valve 10 Structure and function
1. Valve body Function

2. Relief valve (R2) q The charge valve maintains the oil pressure from
3. Shuttle valve (S1) the pump to the set pressure and accumulates it in
4. Priority valve the accumulator.
5. Main relief valve (R1) q When the oil pressure rises above the preset pres-
sure, the oil from the pump is led to the drain circuit
to reduce the load on the pump.
10-90 GD535-5
Operation
When oil is not supplied to the accumulator (cut-out state)
q Plunger (1) is moved to the right direction by the

accumulator pressure, and maintains unload.
q The oil in the spring chamber of unload valve (3) is
drained to the hydraulic tank through the port.
q Since oil pressure in port (F) is reduced, unload
valve (3) moves to the right and is subjected to the
action of the oil from chamber (B).
q Port (C) and port (D) are opened, supplying most
of the oil from the pump to the hydraulic oil cooler
through port (P), ports (C) and (D), and port (PA).
GD535-5 10-91
When oil is supplied to the accumulator

q Cut-in state
q As the accumulator pressure falls, pressure on port

(E) goes low, allowing plunger (1) to move to the
left and unload relief valve (2) to close the drain cir-
cuit.
q Since the oil pressure in port (F) and the spring
chamber of unload valve (3) increases, unload
valve (3) moves to the left.
q Port (C) and port (B) are opened, conducting the oil
from the pump to port (B).
q As oil pressure in port (B) increases beyond the set
pressure of check valve (4), check valve opens, al-
lowing the oil to be supplied to the accumulator
through port (E). The pressure for supplying oil to
the accumulator depends on the set pressure of
check valve (4).
q The amount of oil supplied to the accumulator is
constant independent of the engine speed, thus
surplus oil flows to the hydraulic oil cooler through
port (PA).
q Inverse shuttle valve (5) supplies precedence to
the accumulator of lower pressure when supplying
oil.
10-92 GD535-5
2. When pressure reaches cut-out pressure
q As pressure in port (F) reaches the set pressure

(cut-out pressure of unload relief valve (2)), oil in
the spring chamber of unload valve (3) is drained
to the hydraulic tank through port (F), unload relief
valve (2) and port (T).
q Plunger (1) is moved to the right by the accumula-
tor pressure, and unload relief valve (2) remains
pushed open.
q Since oil pressure in port (F) is decreased, unload
valve (3) moves to the right and is subjected to the
action of the oil from chamber (B).
q Port (C) and port (D) are opened, supplying most
of the oil from the pump to the hydraulic oil cooler
through port (P), ports (C) and (D), and port (PA).
GD535-5 10-93
Main relief valve (R1) Shuttle valve (S1)
q If the pressure in port (P) (pump pressure) rises q When the pressure in port (ACC2) is higher than
above the set pressure, it compresses spring (1) that in port (ACC1), shuttle valve (1) moves to the
and moves ball (2) to the left. left to disconnect port (ACC2) from oil passage
q The pressure of the oil from the pump is reduced (B).
across orifice (a), and the resulting pressure differ- q The open area between port (ACC1) and oil pas-
ence compresses spring (3) and moves valve (4) sage (B) is increased and the oil is supplied to the
to the left to a large extent. accumulator on port (ACC1) side.
q Port (P) being connected to port (T) drains the q When the pressure in port (ACC1) is higher than
pump pressure and, thereby, regulates the maxi- that in port (ACC2), the oil is supplied to the accu-
mum pressure in the charge circuit in order to pro- mulator on port (ACC2) side.
tect the circuit. The oil from the pump is supplied first to the low-
pressure side of the 2 systems.
10-94 GD535-5
10 Structure and function Wheel brake
Wheel brake 1
1. Cage
2. Piston
3. Guide pin
4. Gear
5. Disc
6. Plate
GD535-5 10-95
Parking brake solenoid valve and lifter lock pin solenoid valve 10 Structure and function
Parking brake solenoid valve and lifter lock pin solenoid valve 1
P: From accumulator Outline

B1: To lifter lock pin cylinder q The parking brake solenoid valve and lifter lock
B2: To lifter lock pin cylinder pin solenoid valve have built-in solenoid valve for
PB: To parking brake parking brake and solenoid valve for lifter lock pin
T: To hydraulic tank respectively.
G2: To the accumulator pressure detection port q When the parking brake solenoid is energized, oil
is sent to the parking brake to release it.
1. Lifter lock pin solenoid q When the lifter lock pin solenoid is energized, oil is
2. Parking brake solenoid sent to the lifter lock pin cylinder to move it in the
3. Filter lock pin removal direction.
4. Check valve
10-96 GD535-5
10 Structure and function Parking brake
Parking brake 1
1. Piston 4. Caliper
2. Adjustment bolt 5. Disc
3. Pad
Outline
q The parking brake is the disc type and installed on
the differential.
q Structurally, the parking brake is mechanically
applied with the repulsive force of the spring in the
caliper and released with the force exerted by oil
pressure.
q The disc is installed on the coupling of the differ-
ential and rotates along with the coupling.
q When the accumulator pressure is sufficiently
high, if the gear shift lever is set to a position other
than P (PARK), the oil pressure acts on the cham-
ber to release the parking brake.
GD535-5 10-97
Frame 10 Structure and function
Undercarriage and frame 1
Frame 1
1. Front frame Outline

2. Rear frame q Front frame (1) and rear frame (2) are connected
3. Upper center hinge pin with center hinge pins (3) and (4).
4. Lower center hinge pin q Left and right articulate cylinders (6) connect to
5. Articulate lock pin both front frame (1) and rear frame (2) and the
6. Articulate cylinder frames can pivot 25 degrees to both sides on the
center hinge pin according to telescopic motion of
the cylinders.
q The articulate mechanism reduces turning radii
and assists with offset operations, escaping from
mud, and operations at corners.
10-98 GD535-5
10 Structure and function Tire
Tire 1
Bias tire
Structure
q Cords composing carcass (1) are arranged diago-
nally to the center line of tread (T) (radially).
q Sidewall (W) and tread (T) are structurally inte-
grated.
GD535-5 10-99
Hydraulic system 10 Structure and function
Hydraulic system 1
Hydraulic system 1
System outline
*1. For machines with scarifier

*2. For machines with ripper
Work equipment circuit

1. Hydraulic oil in the hydraulic tank is sent to the
control valve through the work equipment pump.
Steering circuit
1. The steering valve is an energy saving closed-
center type that allows hydraulic oil to flow only
when it is needed and does not allow it to flow
when the machine is not being steered.
At the same time, the LS pressure is transmitted to
the priority valve so that the priority valve spool will
wait at a position where the flow rate needed for
the steering circuit can be assured.
2. The steering valve is the Q/Amp type that provides
excellent controllability during high-speed travel
and allows steering operation even if the engine
stops or the main pump fails.
3. The maximum steering circuit pressure is set by
the relief valve built in the priority valve. So, it
differs from the work equipment circuit pressure.
10-100 GD535-5
10 Structure and function Hydraulic system
Brake circuit
1. The oil pressure from the brake pump is boosted to
the required pressure and accumulated in the
accumulators installed in the 2 brake circuits.
2. When the brake is used and the brake circuit pres-

sure drops below the set pressure of 9.36 MPa {95
kg/cm2}, the accumulator charge valve operates to
accumulate pressure until the pressure in the
accumulator reaches its set pressure of 13.8 MPa
{141 kg/cm2}.
3. Even when the engine stops, oil pressure in the

accumulator allows braking for a certain period.
4. When pressure in the accumulator drops, the

release pressure of the parking brake also lowers.
So, the parking brake is automatically applied by
the repulsive force of the spring. If the machine is
left parked for a certain period, the parking brake
can be applied naturally and it will not be released
until the engine is started again.
5. When the work equipment postures is changed to/

from the bank-cutting posture or shoulder reach
posture, the bank control lock pin needs to be
removed or inserted. For this purpose, the pres-
sure in the accumulator is also used as an oil pres-
sure source.
Control valve
1. The control valve is the open-center type and
hydraulic oil is sent to the control valve by the work
equipment pump.
The maximum pressure is set by the relief valve in
the control valve.
GD535-5 10-101
Hydraulic piping drawing of work equipment 10 Structure and function
Hydraulic piping drawing of work equipment 1
10-102 GD535-5
10 Structure and function Hydraulic piping drawing of work equipment
1. Lifter lock pin

2. Control valve
3. R.H. articulate cylinder
4. L.H. articulate cylinder
5. Power tilt cylinder
6. Blade side shift cylinder
7. Circle rotation motor
8. Leaning cylinder
9. Swivel joint
10. Scarifier cylinder (*1)
11. Drawbar shift cylinder
12. L.H. blade lift cylinder
13. R.H. blade lift cylinder
14. Brake circuit accumulator charge valve
15. Parking brake solenoid valve and lifter lock pin
solenoid valve
16. Brake pump
17. Work equipment and steering pump
18. Hydraulic tank
19. Hydraulic oil line filter
*1. For machines with scarifier
20. Ripper cylinder (*2)
*2. For machines with ripper
GD535-5 10-103
Work equipment control 10 Structure and function
Work equipment control 1
1. Control valve Outline

2. Machine monitor q Work equipment control levers are installed on the
3. Steering wheel shaft of the steering console and connected to the
4. Blade rotation control lever respective control valves through rods.
5. Blade side shift control lever q Steering wheel and machine monitor angle adjust-
6. L.H. blade lift cylinder control lever ment mechanism
7. Ripper and scarifier control lever (*1) When the steering wheel and machine monitor
8. Power tilt control lever angle adjustment knob (9) are loosened, the lock
9. Steering wheel and machine monitor angle adjust- is released allowing the angle of the steering
ment knob wheel and machine monitor to be adjusted. When
10. Drawbar side shift control lever knob (9) is tightened, the angle is fixed.
11. Articulate control lever q Steering console tilt mechanism
12. Leaning control lever When steering console tilt pedal (17) is pressed,
13. R.H. blade lift cylinder control lever the lock is released allowing the tilt angle of the
14. Accelerator pedal steering console to be adjusted. When the user's
15. Brake pedal foot is removed from pedal (17), the angle is fixed.
16. Inching pedal
17. Steering console tilt lever
18. Gas spring
*1. For machines with ripper or scarifier
10-104 GD535-5
10 Structure and function Hydraulic tank
Hydraulic tank 1
1. Breather Specifications
2. Oil filler cap Tank capacity (l) 72
3. Hydraulic tank
4. Sight gauge Oil quantity in hydraulic tank
51.5
5. Bypass valve (l)
6. Filter element Bypass valve set pressure
7. Suction strainer (kPa {kg/cm2}) 150 ± 30 {1.53 ± 0.31}
Cracking pressure of
pressure valve 38 ± 5.7 {0.39 ± 0.06}
(kPa {kg/cm2})
Cracking pressure of
vacuum valve 2 ± 0.3 {0.02 ± 0.003}
(kPa {kg/cm2})
GD535-5 10-105
Work equipment pump and steering pump 10 Structure and function
Work equipment pump and steering pump 1
1. Work equipment pump Outline

2. Steering pump q The work equipment pump and steering pump
installed on the PTO shaft of the transmission are
driven by the axial rotation and supply oil pressure
to the work equipment and steering circuits
respectively.
Specifications
Name Work equipment pump Steering pump
Model SAR (2) 40 SAR (2) 20
Type Gear type Gear type
Revolution speed (rpm) 3,000 3,000
Discharge pressure
20.6 {210} 20.6 {210}
(MPa{kg/cm2})
Theoretical discharge (cm3/rev) 40.2 20.4
10-106 GD535-5
10 Structure and function Power train pump
Power train pump 1
(Machines with non-differential type rear axle)
Outline
q The power train pump installed on the PTO shaft
of the transmission is driven by the axial rotation
and supply oil pressure to the power train circuit.
Specifications
Name Power train pump
Model SAR (2) 63
Type Gear type
Revolution speed (rpm) 2,300
Discharge pressure
4.4 {45}
(MPa {kg/cm2})
Theoretical discharge
63.5
(cm3/rev)
GD535-5 10-107
Power train pump and differential lock pump 10 Structure and function
1. Power train pump Outline

2. Differential lock pump q The power train pump and differential lock pump
installed on the PTO shaft of the transmission are
driven by the axial rotation and supply oil pressure
to the power train and differential lock circuits
respectively.
Specifications
Name Power train pump Differential lock pump
Model SAR (2) SBR (1) 10
Type Gear type Gear type
Revolution speed (rpm) 2,300 2,300
Discharge pressure (MPa {kg/cm2}) 4.4 {45} 4.4 {45}
Theoretical discharge (cm3/rev) 63.5 10.5
10-108 GD535-5
10 Structure and function Brake and cooling fan pump
Brake and cooling fan pump 1
Outline
q The brake and cooling fan pump installed in the
engine is driven by the axial rotation and supply oil
pressure to the brake and cooling circuit.
Specifications
Name Brake and cooling fan pump
Model SGP1A20
Type Gear type
Revolution speed range
400 to 3,000
(rpm)
Discharge pressure
20.6 {210}
(MPa {kg/cm2})
Theoretical discharge
29.9
(cm3/rev)
GD535-5 10-109
Control valve 10 Structure and function
Control valve 1
10-110 GD535-5
10 Structure and function Control valve
A1: To R.H. blade lift cylinder head

A2: To Leaning cylinder bottom
A3: To drawbar shift cylinder bottom
A4: To articulate cylinder
A5: To power tilt cylinder head
A6: To circle motor
A7: To blade lift cylinder head
A8: To L.H. blade lift cylinder head
A9: To ripper cylinder head or scarifier cylinder head (*1)
B1: To R.H. blade lift cylinder bottom
B2: To leaning cylinder head
B3: To drawbar shift cylinder head
B4: To articulate cylinder
B5: To power tilt cylinder bottom
B6: To circle motor
B7: To blade shift cylinder bottom
B8: To L.H. blade lift cylinder bottom
B9: To ripper cylinder bottom or scarifier cylinder bottom (*1)
P2: From work equipment pump
P3: From work equipment pump
T1: To tank
T2: To tank

*1. For machines with ripper or scarifier
GD535-5 10-111
Functions and valve operations 10 Structure and function
Functions and valve operations 1
Hydraulic circuit drawing and valve name
*1. Machines with ripper or scarifier

Set pressure: 19.1 MPa {195 kg/cm2}
10-112 GD535-5
10 Structure and function Hydraulic cylinder
Hydraulic cylinder 1
1. Piston rod
2. Cylinder
3. Piston
4. Bushing
5. Cylinder head
GD535-5 10-113
Swivel joint 10 Structure and function
Swivel joint 1
a: To power tilt cylinder head 1. Plug

b: To power tilt cylinder bottom 2. Plate
c: To blade lift cylinder head 3. Cover
d: To blade shift cylinder bottom 4. Shaft
5. Rotor
10-114 GD535-5
10 Structure and function Pilot check valve
Pilot check valve 1
Pilot check valve (with safety valve)

(For Blade lift L.H., scarifier (if equipped), ripper (if equipped))
1. Body 3. Check valve

2. Piston 4. Relief valve
The check valve with safety valve prevents hydraulic drift of the cylinder and also protects the cylinder from ab-
normal pressure caused by external force.
When the blade lift is raised to the maximum position and the drawbar is shifted to the side, the drawbar stopper
and lifter come into contact. The check valve with safety valve installed to the blade lift cylinder (left) acts to prevent
damage to the work equipment caused by this contact.
% %
$ $
$*
A1: From control valve

A2: From control valve
B1: To cylinder bottom side
B2: To cylinder head side
GD535-5 10-115
Pilot check valve 10 Structure and function
Operation
When the lever is operated to retract the cylinder, oil from the pump enters chamber (A2) and pushes check valve
(3). It then passes through chamber (B2) and flows to the chamber at the head of the cylinder to push the cylinder
piston. The oil at the cylinder bottom end flows back through chamber (B1) and chamber (A1) and returns to the
tank.
When the lever is operated to extend the cylinder, the oil from the pump enters chamber (A1) and flows through
chamber (B1) to the cylinder bottom end. As the pressure in chambers (A1) and (B1) rises, piston (2) is pushed,
This pushes open check valve (3), and the oil at the cylinder head flows from chamber (B2) through the throttle of
check valve (3). It then flows from chamber (A2) back to the tank.
If there is any shock to the work equipment during operations, and the pressure in chamber (B2) rises to an ab-
normal pressure, relief valve (4) is pushed open and the oil flows to chamber (B1). Ths raises the work equipment
and relieves the shock.
10-116 GD535-5
Pilot check valve

(For Blade lift R.H.)
1. Piston 2. Check valve
The check valve with safety valve prebents hydraulic drift of the cylinder and also protects the cylinder from ab-
normal pressure caused by external force.
When the blade lift is raised to maximum position and the drawbar is shifted to the side, the drawbar stopper and
lifter come into contact. The check valve with safety valve installed to the blade lift cylinder (left) acts to prevent
damage to the work equipment caused this contact.
% %
$ $
$*
A1: From control valve B1: To cylinder bottom side

A2: From control valve B2: To cylinder head side
GD535-5 10-117
Operation
When the control valve is operated to lower the blade, pressure is generated at the bottom end of the blade lift
cylinder. This pressure passes through a throttle valve and pushes piston (1). This opens pilot check valve (2),
and the oil in chamber (B2) at the cylinder head returns to the tank. The blade hold pressure is acting on the head
end of the blade lift cylinder.
When it pushes open check valve (2), the oil chamner (B2) suddenly escapes to chamber (A2), and the pressure
at the bottom drops.
When the happens, if there is no throttle at the pilot valve, the check valve will always open and close according
to the changes in the pressure at the bottom and head ends. This will cause blade chattering. To prevent this, a
throttle is insalled at (C) which acts as a damper, so even if the pressure at the bottom end drops, the check valve
will not close immediately.
10-118 GD535-5
Leaning cylinder (if equipped)
A1: From control valve 1. Check valve

A2: From control valve 2. Piston
B1: To cylinder head 3. Check valve
B2: To cylinder bottom 4. Piston
5. Relief valve
6. Body
Function
q The pilot check valve of the leaning cylinder has a safety valve.
q The check valve with safety valve protects the cylinder from abnormal pressure generated when an external
force is applied to the leaning cylinder.
GD535-5 10-119
Operation
q When the operator moves the control lever to extend the hydraulic cylinder, the oil from the pump flows in port
(A2) through the control valve.
q The oil in port (A2) pushes open check valve (1) and flows in port (B2).
q When the pressure is applied to port (A2), the oil pushes piston (2) to the right through orifice (a) and opens
check valve (3).
q If check valve (3) opens, ports (B1) and (A1) are connected and the oil in port (B1) is drained through port (A1).
q As check valve (1) opens and closes according to the pressure change on the bottom side and head side of
the cylinder, hunting occurs.
q When the pressure in port (A2) decreases, check valve (3) does not close immediately because of the damping
effect of orifice (a).
q If an impact is applied to the work equipment and the oil pressure in port (B2) exceeds 27.4 MPa {280 kg/cm2}
during operation, relief valve (4) opens.
q If relief valve (4) opens, the oil in port (B1) flows to port (B2) through the notch of collar (5).
q The work equipment is protected and impacts are relieved by making the oil in port (B1) flow to port (B2).
10-120 GD535-5
Articulation and drawbar shift cylinders
A1: From control valve 1. Body

A2: From control valve 2. Piston
B1: To cylinder head 3. Check valve
B2: To cylinder bottom 4. Piston
5. Check valve
Operation
q When the operator moves the control lever to retract the hydraulic cylinder, the oil from the pump flows in port
(A1) through the control valve.
q The oil in port (A1) pushes open check valve (1) and flows in port (B1).
q When the pressure is applied to port (A1), the oil pushes piston (2) to the right through orifice (a) to open check
valve (3).
q If check valve (3) opens, ports (B2) and (A2) are connected and the oil in port (B2) is drained through port (A2).
q As check valve (1) opens and closes according to the pressure change on the bottom side and head side of
the cylinder, hunting occurs.
q When the pressure in port (A1) decreases, check valve (3) does not close immediately because of the damping
effect of orifice (a).
GD535-5 10-121
Power tilt cylinder (if equipped)
A1: From control valve 1. Check valve

A2: From control valve 2. Plug
B1: To cylinder bottom side 3. Body
B2: To cylinder head side 4. Piston
5. Relief valve
Function
q The check valve with safety valve prevents hydraulic drift of the work equipment and protects the cylinder from
the abnormal pressure caused by external forces.
10-122 GD535-5
Operation
q When the operator operates the control valve to retract the cylinder, the oil from the pump flows in port (A2)
and pushes open tube valve (1), then flows through port (B2) to the cylinder head side.
q The oil in the cylinder bottom returns to the tank through ports (B1) and (A1).
q When the operator operates the control valve to extend the cylinder, the oil from the pump flows in port (A1)
and flows through port (B1) to the cylinder bottom side.
q When the oil pressures in ports (A1) and (B1) increase, piston (4) is pushed to open check valve (1).
q The oil in the cylinder head returns to the tank through port (B2) and check valve (1).
q If an impact is applied to the work equipment and the oil pressure in port (B2) exceeds 24.5 MPa {250 kg/cm2}
during operation, relief valve (5) opens and the oil in port (B2) flows into port (B1).
The work equipment is protected and impacts are relieved in this way.
GD535-5 10-123
Circle and drawbar 10 Structure and function
Work equipment system 1
Circle and drawbar 1
1. Drawbar
2. Drawbar shift cylinder
3. Blade lift cylinder
4. Circle (number of teeth: 64)
10-124 GD535-5
10 Structure and function Circle and drawbar
5. Ball stud Outline

6. Guide plate q Drawbar (1) is an vital component that supports
7. Adjustment bolt the circle and blade.
8. Guide q When ball stud (5) is worn and drawbar (1) has
excess play, the play can be adjusted by adjusting
shims in the ball joint.
q The clearance between circle (4) and drawbar (1)
can be adjusted by adjusting shims in the guide
mounting portion and adjustment bolt (7).
GD535-5 10-125
Blade 10 Structure and function
Blade 1
10-126 GD535-5
10 Structure and function Blade
1. Blade Function
2. Side edge q The side edges installed on the blade can be
3. Cutting edge reused structurally by turning them upside down
4. Power tilt cylinder or reversing them so that the right and left edges
5. Blade side shift cylinder switch positions.
6. Adjuster q The blade guide rail acts as a bushing for the slid-
7. Blade guide rail ing part when the blade is side-shifted. When the
required level of finishing accuracy cannot be
obtained due to excess clearance in the sliding
part, adjust the shim or replace the blade guide
rail (5).
a Machines with power tilt mechanisms can adjust
the cutting angle of blade (1) from 32 to 80
degrees freely via operation of the power tilt con-
trol lever.
GD535-5 10-127
Lifter 10 Structure and function
Lifter 1
1. Upper lifter bracket 6. lifter lock pin

2. Lower lifter bracket 7. Bushing
3. Cap 8. Case
4. Bushing 9. Cover
5. Yoke 10. Shaft
10-128 GD535-5
10 Structure and function Lifter
Outline
q Lifter brackets (1) and (2) are installed on the
guide that is welded to the front frame and allow
the work equipment system to be rotated.
q Liter lock pin (6) can be removed or inserted by
operating the lifter lock pin switch.
q When lifter lock pin (6) is removed, lifter brackets
(1) and (2) can rotate around the guide welded to
the front frame.
q Besides standard position (a), positions (b) and (c)
are available as insertion holes for the lifter lock
pin (6) to stop lifter rotation. These are used for
setting the work equipment to the bank cutting
posture and shoulder reach posture respectively.
q Bushing (7) is installed in each insertion hole of
lifter lock pin (6) to minimize the clearance
between lifter lock pin (6) and the hole.
q If the clearance between lifter lock pin (6) and the
insertion hole becomes large, vertical play of the
blade is magnified.
q The clearance between the guide welded to the
front frame and lifter brackets (1) or (2) can be
adjusted by adjusting shims inserted between lifter
brackets (1) and (2).
GD535-5 10-129
Circle rotation motor 10 Structure and function
Circle rotation motor 1
1. Output shaft
2. Flange
3. Shaft seal
4. Tapered roller bearing for heavy load
5. Main drive
6. O-ring
7. Gerotor
8. Valve drive
9. Wear compensation mechanism valve
10. PF1/2 O-ring port
11. Check valve
12. Valve plate
10-130 GD535-5
10 Structure and function Circle rotation motor
Outline
q The circle rotation motor is a low-speed, high-
torque motor. The gerotor that exhibits a sun-and-
planet motion allows this pump to output the same
torque as that obtained when the power from a
normal hydraulic motor is reduced to 1/6 with a
reduction gear.
q This motor will have fewer oil leaks because a
hydraulic balance type disc valve is used for the
valve mechanism and hi-accuracy gerotor is
employed.
q The valve parts are built in independent from the
power transmission mechanism. This ensures the
valve timing is always correct and that this motor
will demonstrate stable performance over the long
term.
q A tapered roller bearing for heavy loads is built
into the output shaft so that this motor can bear
high radial load and high thrust load.
Operation
q High pressure oil that has flown into the motor

enters gerotor (2) through disc valve (1), and the
star of gerotor (2) makes sun-and-planet motion.
Main drive (3) takes rotation only out of this sun-
and-planet motion and rotates output shaft (4).
q Disc valve (1) is driven by the valve drive and the
positional relationship between 12 ports in disc
valve (1) and 7 ports in valve plate (5) changes.
As a result, the position of oil that flows in the
gerotor (2) shifts successively.
GD535-5 10-131
Circle rotation gear 10 Structure and function
Slip clutch type
1. Circle rotation motor

2. Oil filler plug
3. Case
4. Pinion (number of teeth: 6)
5. Drain plug
10-132 GD535-5
10 Structure and function Circle rotation gear
6. Worm wheel (number of teeth: 36) Outline

7. Collar q The circle rotation gear is driven by circle rotation
8. Shim motor (1) that is connected to worm (15).
9. Spring q Shaft (13) has a clutch mechanism. If abnormal
10. Plate rotation is transmitted from the blade, disc (11)
11. Disc slips to prevent the blade from being damaged.
12. Shim q Clutch pressure of the clutch mechanism can be
13. Shaft adjusted by adjusting thickness of shim (8).
14. Floating seal
15. Worm
GD535-5 10-133
Ripper 10 Structure and function
Ripper 1
(Machines with ripper)
1. Ripper cylinder 5. Lower tank

2. Beam 6. Upper link
3. Shank 7. Mount bracket
4. Point
10-134 GD535-5
10 Structure and function ROPS cab
Cab and its attachments 1
ROPS cab 1
ROPS
Abbreviation for Roll-Over Protective Structure
1. Yellow revolving lamp (*1) Function

2. L.H. door wiper ROPS cab is to protect the operator wearing seat belt
3. Front windshield wiper from being crushed when the machine tips over.
4. Cab mount working lamp
5. KOMTRAX GPS antenna
6. KOMTRAX Communication antenna
7. Radio antenna
8. R.H. door wiper
9. Air conditioner fresh air filter
10. Rear windshield wiper
*1: Machines with yellow revolving lamp
GD535-5 10-135
Layout drawing of electrical system 10 Structure and function
Electrical system 1
Layout drawing of electrical system 1
1. Fusible link
2. Battery
3. Rear view camera (*1)
4. Battery disconnect switch
5. System operating lamp
6. Engine controller
*1: Machines with rearview monitor
10-136 GD535-5
10 Structure and function Layout drawing of electrical system
7. KOMTRAX GPS communication antenna

8. KOMTRAX communication antenna
9. Rearview monitor (*1)
10. Machine monitor
11. Accelerator pedal
12. Inching pedal potentiometer
13. Starting switch
15. Fuse box
16. KOMTRAX terminal
17. Rearview monitor reverse-interlock selector switch
(*1)
18. Rearview monitor brightness selector switch (*1)
19. Rearview monitor brightness adjustment switch
(*1)
*1: Machines with rearview monitor
GD535-5 10-137
System operating lamp system 10 Structure and function
System operating lamp system 1
1. Battery disconnect switch 6. Monitor controller

2. Battery 7. Engine controller
3. Fusible link 8. Transmission controller
4. Fuse box 9. KOMTRAX terminal
5. System operating lamp
Function ON and OFF of system operating lamp

The operating condition of each controller can be q Voltage of 24 V is constantly applied to one side of
checked with the system operating lamp to prevent system operating lamp (LED (Light Emitting
the abnormal end of the disconnection of the battery Diode)).
power supply circuit while the controllers are in opera- q When any controller is in operation, the controller
tion. side outputs Low (0 V), and a current flows
a Before shutting off the battery power supply cir- through the diode and the system operating lamp
cuit, turn the starting switch to “OFF” position, and lights up.
check that the system operating lamp goes off, q When all controllers are stopped, the controller
then turn the battery disconnect switch “OFF”. side outputs High (24 V), and no current flows
a If the battery disconnect switch is turned “OFF” through the diode and the system operating lamp
(the battery power supply circuit is OFF) while the goes off.
system operating lamp is lit, data loss error of con- The system operating lamp may look slightly lumi-
troller may occur. Never operate the battery dis- nous in the dark after it is turned off. It is due to the
connect switch while the system operating lamp is minute leakage of current and not an abnormal
lit. phenomenon.
a The system operating lamp goes off in 6 minutes q When the starting switch is in “OFF” position,
after the starting switch is turned to “OFF” posi- KOMTRAX terminal repeats the start and stop to
tion. maintain the periodic communication.
a The system operating lamp may sometimes light q The start and stop cycle (sleep cycle) of
up while the starting switch is in “OFF” position, KOMTRAX terminal varies depending on the fac-
because KOMTRAX terminal may maintain its tors including the communication state and
communication under this condition. machine stop time. So the lamp can be lit as long
as approximately 1 hour.
When you want to cut off the battery circuit for
maintenance but the system operating lamp is
kept lit, turn the starting switch to “ON” position
once and then turn it to “OFF” position. Lamp goes
off in max. 6 minutes. After system operating lamp
goes off, turn the battery disconnect switch imme-
diately to “OFF” position.
10-138 GD535-5
10 Structure and function Battery disconnect switch
Battery disconnect switch 1
(Machines with battery disconnect switch) q If battery disconnect switch (1) is turned to “OFF”
position while the alternator is generating power,
the generated current has nowhere to go. It leads
to over-voltage in the electrical system of the
machine, which may cause serious damage to the
electrical system including the electric devices and
controllers.
q If battery disconnect switch (1) has been “off” for a
long period, the machine monitor and the clock of
the radio may returned to the initial state. In this
case, re-setting is required.
(O): OFF position

(I): ON position
Function
q Battery disconnect switch (1) is usually used in the
following cases in the same purpose of discon-
necting the cable from the negative terminal of the
battery.
q When storing the machine for a long period (1
month or longer)
q When servicing or repairing the electrical sys-
tem
q When performing electric welding
q When battery disconnect switch (1) is turned to
OFF position (the contact is opened), all the con-
tinuous power supplies for the components,
including the starting switch B terminal and con-
trollers, are all cut out, and the condition is the
same as the time when the battery is not con-
nected. Accordingly, all of the electrical system of
the machine does not operate.
Notice
q If the system operating lamp lights up at this time,
do not turn “OFF” battery disconnect switch (1). It
indicates that the controller is in operation, or
AdBlue/DEF pump is in operation, or KOMTRAX
is performing communication even if the starting
switch is in “OFF” position.
q If battery disconnect switch (1) is turned to “OFF”
position while the system operating lamp is lit, the
data in the controller may be lost and the control-
ler may be damaged seriously.
q Do not turn battery disconnect switch (1) to “OFF”
position while the engine is running or immediately
after the engine is stopped.
GD535-5 10-139
Machine monitor 10 Structure and function
Machine monitor 1
1. Connector (AMP070-12P)
2. Connector (DT-TB-12P)
Function
q The machine monitor has the monitor display temporarily. However, this phenomenon does not
function, mode selection function, and switch func- indicate a failure.
tion of electrical equipment, and also has a built-in a For the machine monitor being used for the long
alarm buzzer. term, bright blue spots may be seen on the black
q A CPU (central processing unit) installed in it pro- background. However this phenomenon does not
cesses information, displays, and outputs a result. indicate a failure or defect. Bright blue spots do
q It consists of the display and switch section. LCD not matter because the normal screen of the dis-
(liquid crystal display) is used for the display and play has a blue or white background.
flat sheet switches are employed in the switch (To display white color on the LCD, red, green,
section. and blue spots light up simultaneously.)
a When there is any defect in the machine monitor a For the items below, see "Operation & Mainte-
itself, any controller, or wiring between the nance Manual".
machine monitor and any controller, the machine q Display (screen display)
monitor cannot correct information. q Switches section
a One of the features of the liquid crystal of the dis- q Guidance icon
play is that there may be black spots (spots that
do not light up) or bright spots (spots that stay lit)
on the screen.
LCD with black spots and bright spots not more
than 10 spots is not deemed to be a failed or
defective display.
a At engine start, the battery voltage can drop rap-
idly depending on ambient temperature or battery
condition. In this case, the display may black out
10-140 GD535-5
10 Structure and function Machine monitor
Input and output signals

AMP070-12P [FP1]
Input/
Pin No. Signal name Output
signal
1 Continuous power supply (24 V) Input
2 GND -
4 Starting switch (ACC) Input
3 Reserved Output
5 External buzzer output Output
6 Continuous power supply (24 V) Input
7 GND -
8 Reserved Input
9 External starting signal Input
10 System operating lamp Output
Input/
11 CANO_H
Output
Input/
12 CANO_L
Output
GD535-5 10-141
Gauges and meters

Gauge Display item Display range and display method Remarks
If a communication error occurs between
the monitor controller and the
Speedometer 0 to 99 km/h transmission controller, "0" is displayed.
q If engine speed increases above the

specified level, an engine overspeed
caution warning lamp lights up. (For
Engine speed
0 to 3,500 rpm details, see "Engine overspeed warn-
meter
ing lamp".)
q If a communication error occurs, the
meter reads "0".
Coolant q If the temperature exceeds 102°C,
Graduation
Range temperature the engine coolant temperature warn-
color
(°C) ing lamp lights up. (For details, see
"Engine coolant temperature warning
W1 135 Red lamp".)
Engine coolant W2 102 Red q If a communication error occurs, the
temperature gauge gauge reads "0".
W3 89 Green
W4 76 Green
W5 63 Green
W6 50 White
Oil q If the temperature exceeds 120°C,
Graduation
Range temperature the torque converter oil temperature
color
(°C) warning lamp lights up.
q If a communication error occurs, the
P1 135 Red gauge reads "0".
Torque converter oil
temperature gauge P2 120 Red
P3 93 Green
P4 66 Green
P5 20 White
Fuel level Graduation q If effective remaining fuel level drops
Range
(l) color below 100 l, a warning lamp lights up.
q If sensor error occurs, the gauge
F1 188 Green
reads "0".
F2 175 Green
Fuel level gauge
F3 122 Green
F4 62 Green
F5 54 Green
F6 51 Red
Articulated This gauge indicates the status of the
Graduation
Range angle articulated angle between the front and
color
(degree) rear frames.
A1 23 Green
Articulate gauge
A2 5 White
A3 5 White
A4 23 Green
10-142 GD535-5
Gauge Display item Display range and display method Remarks

q This meter integrates engine running
hours.
Service meter (*1) 0 to 999999.9 h q When the integrated value exceeds
999999.9 h, the meter reading stops
at 999999.9 h.
q This meter integrates travel distances.
q When the integrated value exceeds
Odometer (*1) 0 to 3999999.9 km
3999999.9 km, the meter reading stops
at 3999999.9 km.
This meter displays average fuel
Fuel consumption q Daily fuel consumption display consumption.
meter (*1) q Split fuel consumption display
q This clock displays time.

q 12-hour clock display (AM/PM) (12-hour and 24-hour settings can be
Clock (*1)
q 24-hour clock display switched by using Monitor setting →
Clock adjustment in User Menu.) )
*1 Each time switch "F2" is pressed, display item changes in the order shown below each time.
q Service meter → Odometer → Fuel consumption gauge → Clock
GD535-5 10-143
Warning lamps
Display range and display method

Warning
Symbol Display item Action Remarks
lamp display
Range level
(backgroun
display
d color)
When a defect of q When any machine defect is detected,
Lighting up
action level L04 is L04 a centralized warning lamp lights up.
(red)
detected q When a warning lamp lights up with
red background color, a warning buzz-
When a defect of er sounds continuously for a defect re-
Lighting up
action level L03 is L03 lated to L04 and sounds intermittently
(red)
detected
Action level for a defect related of L02 or L03.
When a defect of
Lighting up
action level L02 is L02
(red)
detected
When a defect of
Lighting up
action level L01 is L01 (*2)
(yellow)
detected
When any defect of action level L02 and
When a defect of above is defected or it is requested to give
Centralized Lighting up
action level L02 and - a warning to the operator, a centralized
warning lamp (red)
above is detected warning lamp lights up and a warning
buzzer sounds intermittently.
When a defect is If brake oil pressure drops excessively
detected while the while the engine is running, a centralized
engine is running L03 warning lamp lights up and a warning
(below specified buzzer sounds intermittently.
value)
When a defect is After the engine has been started, if brake
detected at the time oil pressure has not risen sufficiently, a
Brake oil Lighting up
of starting engine - centralized warning lamp lights up and a
pressure (red)
(below specified warning buzzer sounds intermittently.
value)
When a defect is If brake oil pressure drops excessively
detected while the while the engine is stopped, a warning
engine is stopped - lamp lights up.
(below specified
value)
If engine coolant temperature rises above
105 °C, a centralized warning lamp
Min. 105 °C L02
Engine coolant Lighting up lights up and a warning buzzer sounds
temperature (red) intermittently.
If engine coolant temperature rises above
Min. 102 °C -
102 °C, a warning lamp lights up.
If torque converter oil temperature rises
Torque
Lighting up above 120 °C, a centralized warning
converter oil Min. 120 °C L02
(red) lamp lights up and a warning buzzer
temperature
sounds intermittently.
This lamp lights up when effective
Remaining fuel Lighting up remaining fuel level is 51 l or below.
76 l or below -
level (red)
10-144 GD535-5
Display range and display method

Warning
Symbol Display item Action Remarks
lamp display
Range level
(backgroun
display
d color)
If hydraulic oil temperature rises above
Hydraulic oil Lighting up 100 °C, a centralized warning lamp
100 °C and above L02
temperature (red) lights up and a warning buzzer sounds
intermittently.
A centralized warning lamp lights up and
Differential oil Lighting up a warning buzzer sounds intermittently.
120 °C and above L02
temperature (red)
When maintenance Lighting up q This lamp lights up for 30 seconds af-

-
time is over (red) ter starting switch is turned to the "ON"
position if maintenance time of any
item is over.
Maintenance
When maintenance q Maintenance reminder time can be
time Lighting up
reminder time is - changed by using "Maintenance mode
(yellow) setting" → "Maintenance mode
over
change" → "Maintenance mode re-
minder time setting" in Service menu.
When a defect of q When any defect is detected in the en-
Lighting up L04 and
action level L03 is gine system, a warning lamp lights up.
(red) L03
detected q When any defect of action level L03 is
Engine system detected, a centralized warning lamp
(*1) When a defect of lights up with a red background color,
Lighting up a centralized warning lamp lights up,
(yellow) and a warning buzzer sounds intermit-
detected
tently.
Centralized warning lamp lights up, and
Engine overrun Engine speed Lighting up alarm buzzer sounds intermittently.
L02
(*1) exceeds 2550 rpm (red)
If any defect is detected while the engine

When a defect is
Engine oil Lighting up is running, a centralized warning lamp
detected (below L03
pressure (*1) (red) lights up and a warning buzzer sounds
specified value)
intermittently.
When a defect of q If any defect is detected in transmis-
action level L04 or Lighting up L04, L03 sion system, a caution lamp lights up.
L03 or L02 is (red) and L02 q When a caution lamp lights up with a red
Transmission detected background color, a centralized warning
system (*1) lamp lights up and a warning buzzer
When a defect of sounds continuously for a defect related
Lighting up
action level L01 is L01 (*2) to L04 or sounds intermittently for a de-
(yellow)
detected fect related to L03 and L02.
When a defect of q If any defect is detected in fan control
Lighting up
action level L03 is L03 system, a warning lamp lights up.
(red)
Fan control detected q A centralized warning lamp lights up
system with a red background color, and a
When a defect of
Lighting up warning buzzer sounds intermittently.
(yellow)
detected
When a defect is A caution lamp lights up with a red
detected in the background color, a centralized warning
Battery charge Lighting up
battery charge L03 lamp lights up, and a warning buzzer
level (*1) (red)
system while the sounds intermittently.
engine is running
GD535-5 10-145
*1: If 3 or more warning lamps become active at the same time, symbols to be displayed switch every 2 seconds
in units of 2 symbols.
*2: After lighting up for 2 seconds, it goes off.
10-146 GD535-5
Pilot lamp
Symbol Display item Display range and display method Remarks
This lamp indicates the state of
Lighting up: LOCK parking brake lever.
Parking brake
Going off: FREE
Flashing: When the L.H. turn signal is indicated

Turn signal (L.H.) or the hazard lamp switch is set to the "ON"
position
Headlamp (high Lighting up: When the headlamp is set to high

beam) beam
Flashing: When the R.H. turn signal is indicated

Turn signal (R.H.) on or the hazard lamp switch is set to the "ON"
position
Lighting up: When the clearance lamp is turned

Clearance lamp
on
Indication: Gear speed (F1, F2, F3, F4, F5, F6,

Shift indicator
F7, F8, N, R1, R2, R3, and R4)
q If the engine starting switch is

turned to the "ON" position
with gear shift lever set to a
position other than "P" and
"N", character indicating cur-
rent travel direction (F or R)
Position of gear shift Highlighting: Position of gear shift lever (1, 2, 3, flashes and a centralized
lever 4, 5, 6, 7, 8, R, N, and F) warning lamp and warning
buzzer are activated. (Neutral
safety warning)
q If all signals from gear shift le-
ver turn to "OFF", normal po-
sition that were input shortly
before is indicated.
This lamp indicates read/unread
Lighting up: There is an unread message. state of messages.
Message (unread)
Going off: There are no unread messages.
This lamp indicates read/unread

Lighting up: There is a message that is read but
Message state of messages.
unanswered.
(Read or unanswered)
Going off: There are no unread messages.
P mode Lighting up: When P mode is selected
E mode Lighting up: When E mode is selected
GD535-5 10-147
Symbol Display item Display range and display method Remarks

Lighting up: When torque converter lock up is
activated
Lock up
Going off: When torque converter lock up is not
activated
Displays the operation state of
Light is lit: Fan is rotating in reverse
fan.
Flashing: Fan rotation direction is being selected
Not lit: Fan is rotating forward
Fan rotating in reverse
Light is lit: Waiting for fan rotation switching

conditions to be satisfied
Lighting up: When transmission mode selector

switch is set to T/C auto mode ON
Transmission mode
Going off: When transmission mode selector switch

is set to MANUAL mode ON
Lighting up: When the working lamp is turned on

Working lamp
Going off: When the working lamp is turned off
Lighting up: When the differential lock switch is

set to ON
Differential lock (*1)
Going off: When the differential lock switch is set to
OFF
Lighting up: When the lifter lock pin is in the
FREE position
Lifter lock pin
Going off: When the lifter lock pin is in the LOCK
position
Lighting up: When the accelerator pedal
opening is set
RPM set
Going off: When the accelerator pedal opening
is not set
Lighting up: When the engine preheat electrical
intake airheater is operated
Preheating
Going off: When the engine preheat electrical
intake airheater is not operated
The lamp indicates economic
Lighting up or off in accordance with accelerator operation.
Economy operation
pedal
10-148 GD535-5
Operator mode functions

q These functions are displayed normally. An opera-
tor can dis play and set them by operating
switches.
Some functions require special switch operations
to display and set them.
q The following items can be selected in the opera-
tor mode.
Display sequence
Group (*1) Item pattern (*2)
W X Y Z
Display of KOMATSU logo 1 1 1 1
Display of password input request 2 - - -
Display of results of check before starting 3 2 2 2
A Display of warning after check before starting - - 3 -
Display of maintenance due time over - - - 3
Display of standard screen 4 3 4 4
Display of end screen
Setting and display in user menu
q ECO Guidance
q Machine Setting and Information
B
q Maintenance
q Monitor Setting
q User Message (including KOMTRAX message for users)
Display of caution monitor
C
Display of maintenance due time over
Checking function of LCD display
D Confirmation function of service meter and odometer
Function of usage limitation setting/ changing password
*1. Operator mode items are classified as follows. *2: Display sequence from the time when the starting
A: Display from the time when the starting switch switch is turned to the "ON" position to the time
is turned to the "ON" position to the time when when the s ta ndar d sc r een appe ars v ar ie s
the display changes to the standard screen, depending on the settings and conditions of the
and display after the starting switch is turned to machine as follows:
the "OFF" position W: When the engine start lock is enabled
B: Display when machine monitor switch is oper- X: When the engine start lock is disabled
ated Y: When any abnormality is detected by the check
C: Display when condition is satisfied before starting
D: Display that requires special operations of Z: When any maintenance item that is near the
switches maintenance due time or maintenance due time
is over is detected
q For the operation method of each operator mode

function, see Operation and Maintenance Manual.
q For the operation method of the engine start lock
function, see "Password setting and canceling
manual".
GD535-5 10-149
Service mode functions

q These functions are not displayed normally. A
technician can display and set them with special
operation of switches. They are used for special
settings, inspection, adjustment, and troubleshoot-
ing.
q The following items can be selected in the service
mode.
Monitoring /defined
Monitoring / Custom
Mechanical Systems
Abnormality Record
Electrical Systems
Maintenance Time Reset
Maintenance Record
Maintenance Mode Setting
Phone Number Entry
Machine Model Select
Default Option Selection
Unit Selection
Diagnostic Tests Cylinder Cut-out
ECMV Automatic Compensation
T/M Initial Learning
T/M Initial Learning Reset
T/C Stall
Adjustment
Inching Pedal 0% Adjustment
Inching Pedal 100% Adjustment
Zero Point Adjustment For Art Angle
Fan 100% Speed Adjustment
No Injection
Terminal Status
KOMTRAX Settings GPS & Communication Status
Modem Status
Service Message
a For the operation method of each service mode

function, see "Service Mode" in the Testing and
Adjusting section.
10-150 GD535-5
10 Structure and function Automatic gear shift control system
Automatic gear shift control system 1
Outline
q In the automatic gear shift control system, the
transmission controller receives lever position sig-
nals from the gear shift lever, electrical potential
signals from the accelerator pedal and inching
pedal, speed signals from the transmission, and
signals from other switches and sensors, and
automatically sets the transmission at an optimum
gear speed.
q The transmission controller performs torque con-
verter lockup control as well as transmission gear
speed control.
GD535-5 10-151
Automatic gear shift control system 10 Structure and function
Gear shift lever position
Gear shift lever position and automatic gear shift range

q The table below shows the relationship between gear shift lever position and gear speed.
q Gear shift and lockup patterns switches according to operation of the transmission mode selector switch.
q When the transmission mode selector switch is set to "MANU" (manual mode), the transmission is manually
shifted according to the gear shift lever position. Note, however, that the transmission is automatically shifted
according to the machine travel speed when the gear shift lever is positioned in R3 or R4.
q When the transmission mode selector switch is set to "T/C AUTO" (automatic mode), the transmission is
manually shifted when the gear shift lever is positioned in F1 to F4 or R1 to R2. It is automatically shifted
according to the machine travel speed when the gear shift lever is positioned in F5 to F8 or R3 and R4.
q When the transmission is in manual gear shift condition, to prevent engine overrun, the transmission may not
switch to the selected gear speed regardless of operations of the transmission mode selector switch.
MANU mode
Gear shift lever Gear speed
position N F1 F2 F3 F4 F5 F6 F7 F8 R1 R2 R3 R4
N A
F1 B
F2 B
F3 B
F4 B
F5 B
F6 B
F7 B
F8 B
R1 A
R2 A
R3 A C
R4 A C C
T/C AUTO mode

Gear shift lever Gear speed
position N F1 F2 F3 F4 F5 F6 F7 F8 R1 R2 R3 R4
N A
F1 A
F2 A
F3 A
F4 A
F5 A C
F6 A C C
F7 A C C C
F8 A C C C C
R1 A
R2 A
R3 A C
R4 A C C
A: Lockup clutch is not engaged. C: Lockup clutch is automatically engaged.

B: Lockup clutch is engaged.
10-152 GD535-5
Overrun prevention function q With gear shift lever at "F1", transmission mode
q When the machine travels downhill or rapid gear selector switch at "T/C AUTO", and accelerator
shifting is carried out, to prevent engine overrun, pedal not pressed, if the travel speed lowers to
the transmission may shift to a gear speed that is 1.97 km/h or below, inching pedal is not pressed,
different from that indicated by the gear shift lever and engine speed lowers below 1,000 rpm, the
position. machine enters into the ultra-low speed travel
Ultra-low speed travel control mode and the travel speed is kept at 0.8 km/h.
q When engine overrun is detected, this function
emits a brief warning sound to warn the operator.
q When the machine decelerates, the engine over-
run prevention function is canceled and the trans-
mission automatically shifts to the gear speed
corresponding to the gear shift lever position.
VHPC control
q The transmission controller and engine controller q Any change of engine power mode is made after
exchange signals through CAN communication. gear shifting is completed.
Transmission controller ← CAN communication → Engine controller

(VHPC signal →)
High ← Priority of judgment → Low

Torque converter stall mode Normal gear shift mode (VHPC control)
Gear speed ALL
See the table shown below.
Engine power mode MID
Table 1: Direct drive mode Table 2: Torque converter AUTO mode

Engine power mode switch Engine power mode switch
○: E Mode ○: E Mode
●: P Mode ●: P Mode
Engine power mode Engine power mode
E mode P mode F8 mode E mode P mode F8 mode
F1 ○ ● F1 ○ ●
F2 ○ ● F2 ○ ●
F3 ○ ● F3 ○ ●
F4 ○ ● F4 ○ ●
F5 ○ ● F5 ○ ●
Gear speed
Gear speed
F6 ○● F6 ○●
F7 ○● F7 ○●
F8 ○● F8 ○●
P, N ○● P, N ○●
R1 ○ ● R1 ○ ●
R2 ○ ● R2 ○ ●
R3 ○ ● R3 ○ ●
R4 ○ ● R4 ○ ●
Engine output value (NET value) at each engine power mode is shown below.
E mode: 101 kW {135 HP}
P mode: 108 kW {145 HP}
F8 mode: 108 kW {145 HP}
GD535-5 10-153
Automatic gear shift control system 10 Structure and function
System circuit diagram
10-154 GD535-5
*1: For machines with rearview monitor

*2: For machines with battery disconnect switch
GD535-5 10-155
Transmission controller 10 Structure and function
Transmission controller 1
Function
Real time monitoring function
q Input and output signals of the controller can be
checked by using the monitoring function of the
machine monitor.
q For the points of the monitoring function, see Test-
ing and Adjusting, "Special functions of machine
monitor".
Self-diagnosis function
q The transmission controller always monitor state
of input and output signals to self-diagnose the
system.
q If the transmission defects any defect, it send the
defect occurrence information to the machine
monitor through the network.
q If any defect occurs, it can be checked by using
machine monitor.
10-156 GD535-5
10 Structure and function Transmission controller

DEUTSCH-24P [TM39]
Input and Input and
Pin No. Signal name output Pin No. Signal name output
signals signals
1 (*1) - 14 Differential oil temperature sensor Input
2 Transmission L/U pressure sensor Input 15 Alternator terminal R Input
3 Transmission oil temperature sensor Input 16 Sensor power supply Output
4 GND (SIG) - 17 Gear shift mode switch Input
5 Engine preheat signal Input 18 RPMset MODE-MANU Input
Brake accumulator F oil pressure
6 Input 19 Fuel gauge sensor Input
switch
7 Inching potentiometer Input 20 Hydraulic oil temperature sensor Input
8 Articulated sensor Input 21 GND (analog GND) -
Torque converter outlet oil temperature
9 Input 22 Power supply (5 V) Output
sensor:
10 GND (SIG) - 23 Clearance lamp relay signal Input
11 Stop lamp signal Input 24 RPMset MODE-AUTO Input
*1: Be sure not to connect anything to this pin. Doing so
12 Engine power mode selector switch Input
can cause a malfunction or failure.
13 (*1)
DEUTSCH-40P (1) [TM40]

Input and Input and
signals signals
1 Power supply (5 V) Output 22 CAN0_L -
2 T/M FILL 3 Input 23 (*1) -
3 T/M FILL 2 Input 24 Service connector input Input
4 (*1) - 25 F (forward) signal (shifter) Input
5 1st signal (shifter) Input 26 3rd signal (shifter) Input
6 5th signal (shifter) Input 27 T/M FILL R Input
7 T/M FILL FH Input 28 BR DRIVE Output
8 Differential control relay Output 29 GND (pulse GND) Input
9 (*1) - 30 Transmission output shaft speed sensor Input
10 Fan rotation sensor Input 31 (*1) -
11 (*1) - 32 CAN0_H -
12 Differential lock switch Input 33 (*1) -
13 T/M FILL Input 34 (*1) -
14 (*1) - 35 Neutral signal (shifter) Input
15 R (reverse) signal (shifter) Input 36 2nd signal (shifter) Input
16 4th signal (shifter) Input 37 Brake accumulator R oil pressure switch Input
17 T/M FILL FL Input 38 T/M FILL 4 Input
18 Backup lamp relay Output 39 GND (pulse GND) Input
19 Centralized warning lamp Output 40 Transmission input shaft speed sensor Input
Transmission intermediate shaft speed *1: Be sure not to connect anything to this pin. Doing so
20 Input
sensor can cause a malfunction or failure.
21 (*1) -
GD535-5 10-157
Transmission controller 10 Structure and function
DEUTSCH-40P (2) [TM41]

Input and Input and
signals signals
1 VB (controller PWR) Input 21 GND (controller GND) Input
2 VIS (solenoid PWR) Input 22 VIS (solenoid PWR) Input
3 SOL_COM (solenoid common GND) Input 23 SOL_COM (solenoid common GND) Input
4 T/M self-holding relay Output 24 KEY_SIG Input
5 T/M 1 Output 25 T/M 3 Output
6 (*1) - 26 T/M FL Output
7 Parking brake solenoid Output 27 (*1) -
8 ENG START RELAY Output 28 Hydraulic-drive fan reverse Output
9 6th signal (shifter) Input 29 8th signal (shifter) Input
10 Starting motor C terminal signal Input 30 RPMset-DECEL/RESUME Input
11 VB (controller PWR) Input 31 GND (controller GND) Input
12 VIS (solenoid PWR) Input 32 GND (controller GND) Input
13 SOL_COM (solenoid common GND) Input 33 GND (controller GND) Input
14 KEY_SIG Input 34 (*1) -
15 T/M 2 Output 35 T/M 4 Output
16 T/M R Output 36 T/M FH Output
17 (*1) - 37 Hydraulic-drive fan variable Output
18 (*1) - 38 T/M torque converter L/U Output
19 7th signal (shifter) Input 39 Parking signal (shifter) Input
20 RPMset-ACCEL/SET Input 40 Not (EXC.) P signal (shifter) Input
*1: Be sure not to connect anything to this pin. Doing so can cause a malfunction or failure.
10-158 GD535-5
10 Structure and function Engine controller
Engine controller 1

q The symbols in the signal classification column in
the Input/output signal table are as follows.
A: Power supply
B: Input
C: Ground/Shield/Return
D: Output
E: Communication
DTP06-4P [EC3]
Signal
Pin No. Signal name classifica
tion
1 GND C
2 GND C
3 Continuous power supply (+24 V) A
4 Continuous power supply (+24 V) A
GD535-5 10-159
Engine controller 10 Structure and function
DRC26-60P [EC1]
Input Input
and and
Pin No. Signal name Pin No. Signal name
output output
signals signals
1 (*1) - 31 NC -
2 IMA power supply D 32 IMA return C
3 Ambient pressure sensor B 33 Sensor power supply (+5 V) A
4 (*1) - 34 (*1) -
5 (*1) - 35 (*1) -
6 CAN (-) E 36 (*1) -
7 (*1) - 37 Sensor power supply (+5 V) A
8 CAN (+) E 38 GND C
9 (*1) - 39 (*1) -
10 (*1) - 40 (*1) -
11 (*1) - 41 (*1) -
12 (*1) - 42 (*1) -
13 (*1) - 43 (*1) -
14 Water-in-fuel sensor B 44 Boost pressure sensor B
15 Coolant temperature sensor B 45 Injector #1 (+) D
Crankshaft speed sensor power
16 A 46 Injector #5 (+) D
supply (+5 V)
17 (*1) - 47 G sensor GND C
18 (*1) - 48 Ne sensor GND C
19 (*1) - 49 (*1) -
20 (*1) - 50 (*1) -
21 (*1) - 51 Injector #2 (-) C
22 (*1) - 52 Injector #3 (-) C
23 Boost temperature sensor B 53 Injector #1 (-) C
24 (*1) - 54 Injector #2 (+) D
25 Common rail pressure sensor B 55 Injector #3 (+) D
26 G sensor (+) B 56 Injector #4 (+) D
27 Ne sensor (+) B 57 Injector #6 (+) D
28 (*1) - 58 Injector #4 (-) C
29 (*1) - 59 Injector #6 (-) C
30 (*1) - 60 Injector #5 (-) C
10-160 GD535-5
10 Structure and function Engine controller
DRC26-50P [EC2]
Input Input
and and
Pin No. Signal name Pin No. Signal name
output output
signals signals
1 Idle validation signal 2 B 26 (*1) -
2 (*1) - 27 (*1) -
3 (*1) - 28 (*1) -
4 (*1) - 29 (*1) -
5 (*1) - 30 (*1) -
6 (*1) - 31 (*1) -
7 (*1) - 32 Idle validation (-) C
8 (*1) - 33 GND C
Accelerator pedal potentiometer
9 B 34 (*1) -
signal
10 (*1) - 35 (*1) -
11 Idle validation signal 1 B 36 (*1) -
12 (*1) - 37 (*1) -
13 (*1) - 38 (*1) -
14 (*1) - 39 Starting switch ACC signal B
15 (*1) - 40 Grid heater relay drive signal D
16 (*1) - 41 (*1) -
17 (*1) - 42 (*1) -
18 (*1) - 43 (*1) -
19 (*1) - 44 (*1) -
20 (*1) - 45 (*1) -
21 (*1) - 46 CAN_H E
Accelerator pedal potentiometer
22 A 47 CAN_L E
power supply (+5 V)
23 Accelerator pedal potentiometer C 48 (*1) -
24 (*1) - 49 PWM OUTPUT D
25 (*1) - 50 (*1) -
GD535-5 10-161
KOMTRAX system 10 Structure and function
KOMTRAX system 1
Function
q The KOMTRAX system transmits various machine
information by using the radio communication.
KOMTRAX operators can refer to this information
in their offices and provide various services to cus-
tomers.
q The KOMTRAX system can transmit the following
information.
q Position information
q Operation information (service meter, odome-
ter, etc.)
q Alarm and failure information
q Fuel consumption information
q Maintenance information
q Machine working condition information
a To start this service, the radio communication
establishment for KOMTRAX system must be per-
formed separately.
10-162 GD535-5
10 Structure and function KOMTRAX terminal
KOMTRAX terminal 1
Model: TC630
1. GPS antenna connection

2. Machine wiring harness connection port (070-18P)
3. Machine wiring harness connection port (070-12P)
4. Communication antenna connection
5. LED lamp display
Function
q This terminal uses mobile communication technol-
ogy.
q This is wireless communication equipment that
transmits various machine information obtained
from the network signals and input signals, as well
as the GPS position information. This terminal can
send information through the communication
antenna.
q Conditions of the KOMTRAX terminal can be
checked by using "KOMTRAX setting display" in
the service mode menu of the machine monitor.
q Use of this terminal is not allowed in the countries
or regions where legal authorization is not
obtained.
q The terminal has LED lamps and 7-segment pilot
lamp used for testing and troubleshooting on its
display section.
GD535-5 10-163
KOMTRAX terminal 10 Structure and function

070-18P [L08A] 070-18P [L08B]
Input and Input and
signals signals
1 (*1) - 1 GND (continuous power supply) -
2 (*1) - 2 GND (continuous power supply) -
3 (*1) - 3 Starting switch ACC signal Input
4 (*1) - 4 Alternator R signal Input
5 (*1) - 5 (*1) -
6 (*1) - 6 Continuous power supply (24 V) Input
7 (*1) - 7 Continuous power supply (24 V) Input
8 (*1) - 8 (*1) -
9 (*1) - 9 (*1) -
Input/ 10 (*1) -
10 CAN2_H
Output
11 Starting switch C signal Input
Input/
11 CAN2_L 12 (*1) -
Output
12 (*1) - *1: Be sure not to covnnect anything to this pin. Doing
so can cause a malfunction or failure.
13 (*1) -
Input/
14 External starting signal
Output
15 System operating lamp Output
16 (*1) -
17 (*1) -
18 (*1) -
*1: Be sure not to connect anything to this pin. Doing

so can cause a malfunction or failure.
10-164 GD535-5
10 Structure and function Rearview monitor system
Rearview monitor system 1
Function
Rearview monitor system mainly consists of the
rearview monitor and rearview camera.
This system displays the rear view camera image to
the operator according to the setting of the rear view
monitor controller (reference lines, display of reverse-
interlock, luminance, etc.)
a The reference lines must be adjusted again in the
following cases.
q When the machine dimensions are changed
because of replacement of tires, installation of
optional attachment, etc.
q When the rear view camera is removed or its
direction is changed because of damage etc.
GD535-5 10-165
Rearview monitor 10 Structure and function
Rearview monitor 1
Input/output signals of rearview monitor

AMP-12P [RVM1] AMP-8P [RVM2]
Pin Input and Pin Input and

Signal name Signal name
No. output signals No. output signals
1 Continuous power supply (24 V) Input Rear view camera power supply
1 Output
output
2 Power supply return GND -
2 Rear view camera NTSC signal Input
Service connector external start
3 Input
signal 3 (*1) -
4 (*1) - 4 (*1) -
Brightness adjustment switch of rear GND (rear view camera power
5 Input 5 -
view monitor + supply)
Brightness adjustment switch of rear 6 (*1) -
6 Input
view monitor -
7 (*1) -
7 Gear shift lever R signal Input
8 GND (rear view camera shield) -
Monitor brightness selector switch
8 Input
(night mode signal) *1: Never connect these pins. It may cause malfunc-
Input and tion or failure.
9 LIN
output
10 (*1) -
11 (*1) -
12 Key switch ACC signal Input
*1: Never connect these pins. It may cause malfunc-

tion or failure.
10-166 GD535-5
10 Structure and function Rearview camera
Rearview camera 1
Input/output signals of rearview camera

DT-T-4P [RL11]
Pin Input and

Signal name
No. output signals
1 Rear view camera power supply Input
2 Rear view camera NTSC signal Output
3 (*1) -
GND (rear view camera power
4 -
supply)
*1: Never connect these pins. It may cause malfunc-

tion or failure.
GD535-5 10-167
Engine starting circuit 10 Structure and function
Engine starting circuit 1
Function
1. This circuit employs a parking safety circuit to
assure safety when the engine is started.
q The engine cannot start with the gear shift
lever set to a position other than "P (PARK)".
2. The KOMTRAX engine cut-off circuit is employed to

prevent the engine from starting when the
KOMTRAX terminal receives an engine cut-off
command issued via external operation.
10-168 GD535-5
10 Structure and function Engine starting circuit
Operation
1. When starting switch is in "ON" position
q When the starting switch is turned to the "ON"
position, starting switch terminals B and BR
are connected and a current flows from the
battery to the ground through the starting
switch and battery relay coil, and the battery
relay contacts are closed.
This allows electric power to be supplied to
each circuit of the machine. At this time, the
ACC signal is sent from the starting switch
ACC terminal to the engine controller to com-
plete engine start preparations.
2. Parking safety circuit

q When the gear shift lever is in "P (PARK)", a
current flows from the gear shift lever terminal
6 to safety relay coil to activate safety relay.
q When the starting switch is turned to the
"START" position while the safety relay is acti-
vated, the self hold relay is activated. So, the
safety relay can be held even if the P signal
from the gear shift lever is interrupted due to a
drop in voltage.
q When the gear shift lever is in a position other
than "P (PARK)", the current from the gear shift
lever terminal 6 to safety relay is cut off. As a
result, the starting circuit is cut off because no
current flows through the safety relay coil.
3. When starting switch is in "START" position

q When the starting switch is turned to the
"START" position, a current flows from the
starting switch C terminal to the starting motor
safety relay through the KOMTRAX engine
cut-off relay, and safety relay float ENG cancel
relay, allowing the engine to start.
q When the gear shift lever is set to a position
other than "P (PARK)", the parking relay is not
activated and the engine cannot be started.
q When the KOMTRAX terminal receives an
engine cut-off command issued via external
operation, the KOMTRAX engine cut-off relay
is activated. This breaks the circuit from the
starting switch C terminal to the parking relay
and the engine cannot be started.
4. After starting the engine

q When the starting switch is returned to the
"ON" position, the current from the starting
switch C terminal is cut off and no current flows
from the safety relay to the starting motor.
GD535-5 10-169
Engine stop circuit 10 Structure and function
Engine stop circuit 1
Operation
q When the starting switch is turned to the "OFF"
position, the ACC signal from the starting switch
terminal ACC to the engine controller is cut off and
fuel supply to the engine is stopped.
q When fuel supply to the engine is stopped, engine
speed drops and then stops.
q When the engine stops, power generation by the
alternator is stopped and voltage feed from the
alternator R terminal is cut off.
q When the current from the starting switch BR ter-
minal is cut off, battery relay contacts open. So,
power supply to each circuit of the machine is
stopped.
10-170 GD535-5
10 Structure and function Preheating circuit
Preheating circuit 1
Outline Operation
q This machine is equipped with an automatic pre- q When the starting switch is turned to the "ON"
heating system to improve engine startability in position, the engine controller starts. At this time, if
cold districts. the engine coolant temperature is below the set
q With the automatic preheating system, preheating value, the engine controller activates the heater
time is automatically set according to the intake air relay just after the starting switch is turned to the
temperature when the starting switch is turned to "ON" position, and then the intake air heater starts
the "ON" position. preheating.
q When the starting switch is turned to the "ON" q The figure below shows the operating time of
position, the preheating pilot lamp on the machine automatic preheating.
monitor lights up and the intake air heater pre-
heats the intake air.
q The engine controller detects the engine coolant
temperature and sets the preheating time.
q While the pilot lamp lights up, the preheating is in
progress. So, be sure to keep the starting switch
set at "ON" position during the period. If the start-
ing switch is turned to the "START" position during
the period, the preheating is canceled.
q The automatic preheating system judges the
necessity of preheating depending on the engine
coolant temperature. Therefore, the engine may
not start easily under such special conditions that
the engine is warmed with an external heater.
q In this case, turn the starting switch to the "R (pre-
heat)" position to enable manual preheating.
q When the starting switch is turned to the "R (pre-

heat)" position, the heater relay is activated and
preheating by the intake air heater starts regard-
less of outside air temperature.
The operating time of manual preheating needs to
be within 5 to 30 seconds.
GD535-5 10-171
Sensors 10 Structure and function
Sensors 1
Engine oil pressure switch
1. Connector
2. Sensor
3. O-ring
Coolant temperature sensor

Fuel temperature sensor
1. Connector
2. Sensor
3. O-ring
10-172 GD535-5
10 Structure and function Sensors
Engine speed sensor
1. Connector
2. Sensor
3. O-ring
Ambient pressure sensor
1. Connector
2. Pressure introduction hole
GD535-5 10-173
Charge (Boost) pressure and temperature sensor
1. Connector
2. Sensor
3. O-ring
WIF (water-in-fuel) sensor
1. Connector
2. Tube
3. Sensor
4. O-ring
10-174 GD535-5
Accelerator pedal sensor
1. Pedal Output characteristics

2. Connector
3. Sensor
Function
q This sensor installed on the top surface of the floor
outputs accelerator pedal potentiometer signals
and idle validation signals according to the press-
ing angle of the accelerator pedal.
Accelerator pedal potentiometer signal

q The sensor detects the amount of accelerator
pedal displacement with the potentiometer in it
and outputs variable voltages from its No. 2 pin.
Idle validation signal

q To detect a failure of the potentiometer, the sensor
outputs ON and OFF signals from the No. 5 and
No. 6 pins according to the accelerator pedal
manipulation.
GD535-5 10-175
Inching pedal potentiometer
1. Pedal
2. Return spring
3. Potentiometer
4. Arm assembly
5. Lever assembly
6. Spring
Function
q This sensor installed on the top surface of the floor
detects the pressing angle of the inching pedal,
converts it into an electric signal corresponding to
the angle, and outputs the signal
Relationship between pedal operation angle and Relationship between pedal operation angle and
lever stroke (point (a)) output voltage
10-176 GD535-5
Potentiometer
1. Shaft Output characteristics

2. Housing
3. Bearing
4. Brush
5. Variable resistor
6. Connector
Function
q This sensor is installed on the front frame side of
the joint between the front and rear frames.
q This sensor detects the articulation angle between
the front and rear frames, converts it into an elec-
tric signal corresponding to the angle, and outputs
the signal.
GD535-5 10-177
Torque converter oil temperature sensor

Transmission oil temperature sensor
Hydraulic oil temperature sensor
Differential lock oil temperature sensor (*1)
1. Connector 3. Thermistor
2. Plug
Function
q The torque converter oil temperature sensor is installed on the torque converter outlet port at the top of the
transmission front case, and the transmission oil temperature sensor and differential lock oil temperature sen-
sor are installed on the lubrication line at the front face of the transmission rear case and the rear face of the
rear axle respectively.
q These sensors detect respective hydraulic oil temperatures, converts them into electric signals corresponding
to the temperature, and outputs these signals.
Brake oil pressure switch
1. Pressure switch 3. Connector

2. cable
Function
q This switch is installed on the brake accumulator piping.
q This switch detects the brake oil pressure (accumulator pressure) and comes ON when the pressure drops
below the set pressure.
10-178 GD535-5
Transmission input shaft speed sensor

Transmission intermediate shaft speed sensor
Transmission output shaft speed sensor
1. Wire 4. Housing
2. Magnet 5. Connector
3. Terminal
Function
q These sensors are installed on the input shaft section, shaft section, and output shaft section of the transmis-
sion case respectively.
q These sensors detect gear speeds, converts them into pulse signals corresponding to the speed, and outputs
the signals.
GD535-5 10-179
Fuel level sensor
1. Connector 5. Spring
2. Float 6. Contact
3. Arm 7. Spacer
4. Body
Function
q This sensor is installed on the side face of the fuel tank.
q This sensor detects the level of remaining fuel, converts it into an electric signal corresponding to the level of
remaining fuel, and outputs the signal.
q The float rises and falls according to the level of remaining fuel.
q The movement of the float activates the variable resistor through the arm.
10-180 GD535-5
10 Structure and function Engine power mode selector circuit
Engine power mode selector circuit 1
a: Engine power mode selector signal

b: Power supply
c. CAN signal
1. Battery
2. Battery relay
3. Fuse box 1
4. Power mode selector switch
6. Machine monitor
7. Engine controller
Function
q Pressing the power mode selector switch switches
the power mode between "P mode", in which the
engine output is maximized and "E mode", in
which the fuel consumption in work is reduced.
q The switch signal is input to the transmission con-
troller and an engine output curve that matches
the selected engine power mode is selected.
Operation
q When the power mode selector switch, that is a
momentary switch, is pressed, the switch signal is
input to the transmission controller, and the mode
switches to the P mode or E mode.
q The transmission controller transmits a CAN sig-
nal that corresponds to each mode to the engine
controller to switch engine torque performance
curves.
q The engine power mode pilot lamp is displayed on
the machine monitor.
GD535-5 10-181
Cooling fan control system 10 Structure and function
Cooling fan control system 1
a: Accelerator throttle position signal 1. Radiator

b: Coolant temperature signal 2. Cooling fan motor
c: Engine speed signal 2a. Cooling fan reverse solenoid valve
d: CAN signal 2b. Cooling fan motor control EPC valve
e: Cooling fan speed signal 3. Brake and cooling fan pump
f: Hydraulic oil temperature signal 4. Cooling fan speed sensor
g: Torque converter oil temperature signal 5. Accelerator pedal
h: Cooling fan reverse rotation signal 6. Engine
j: Cooling fan reverse pilot lamp signal 7. Coolant temperature sensor
k: Front brake accumulator pressure drop signal 8. Engine speed sensor
l: Rear brake accumulator pressure drop signal 9. Engine controller
m: Cooling fan motor control signal 10. Transmission controller
11. Hydraulic oil temperature sensor
12. Hydraulic tank
13. Torque converter oil temperature sensor
14. Torque converter
15. Monitor controller
16. Front brake accumulator pressure drop sensor
switch
17. Rear brake accumulator pressure drop sensor
switch
18. Transmission
10-182 GD535-5
10 Structure and function Cooling fan control system
Function of cooling fan control system

q This system reduces the horsepower loss and noise and shortens the warm-up time at low temperature by
employing the hydraulic cooling fan and controlling the discharge of the hydraulic motor.
q The transmission controller receives information of the engine speed, coolant temperature, boost tempera-
ture, torque converter oil temperature, and hydraulic oil temperature that the engine controller receives via the
network.
q Transmission controller sends the signal current to the cooling fan motor control EPC valve on the basis of the
received information, and controls the swash plate angle to obtain the fan speed which corresponds to each
temperature and engine speed.
Cooling fan speed determined by temperature
*1: The target fan speed is determined by the information of the highest temperature among the coolant temper-
ature, torque converter oil temperature, hydraulic oil temperature, and boost temperature.
*2: In this range, the fan speed corresponds to the coolant temperature, torque converter oil temperature, hydraulic
oil temperature, and boost temperature.
*3: When the boost air temperature is at the lower limit or when the torque converter oil temperature is low, the fan
speed is decreased to increase the oil and coolant temperature (heater blow out temperature) and shorten the
warm-up operation time.
Cooling fan speed control function at engine start
Point A: Starting switch is turned to “ON” position Range C: Restriction of minimum fan speed
while engine is stopped Range D: Basic control
Point B: Conditions for starting fan speed control are
satisfied
GD535-5 10-183
Cooling fan control system 10 Structure and function
*1: When minimum boost temperature is 20 °C or higher while it is not included in conditions for fan speed control
at low speed.
*2: Actual speed of the fan remains in approximately 600 rpm because it corresponds to the discharged volume
from the brake and cooling fan pump.
Cooling fan reverse rotation function
q When “Manual Fan Reverse Mode” is operated on the user menu of the machine monitor to clean the radiator
core, the fan reverse solenoid valve of the cooling fan motor operates to reverse the fan rotation.
1. Fan manual reverse rotation function
q Operator can change the fan rotation direction freely by setting “Manual Fan Reverse Mode” to “Reverse” or
“Normal”.
q Pilot lamp is displayed on the standard screen to notify the operator of the operating condition while the fan
rotation direction is being changed.
If the changing condition is not satisfied because of high temperature of the coolant or oil, the pilot lamp is lit
while waiting for conditions to be satisfied.
q On the standard screen, there is a cooling fan reverse pilot lamp which indicates the fan reverse rotation con-
dition.
The fan rotation is switched from “Normal” to “Reverse” when all of the following conditions are satisfied.
Condition 1 Manual Fan Reverse Mode is set.
Engine speed is in range of 500 rpm or higher and lower than 900 rpm.
Condition 2
In order to prevent the peak pressure from being generated when rotation direction is changed
Coolant temperature is lower than 102 °C.
Condition 3
In order to prevent overheat.
The hydraulic oil temperature is lower than 100 °C.
Condition 4
The boost temperature is lower than 80 °C.
Condition 5
It has been 30 seconds after the engine was started (after the engine speed reached 500 rpm or higher).
Condition 6
In order to ensure that enough oil is fed to the brake accumulator.
Condition 7 Gear shift lever is in “P (PARK)” position.
The fan rotation is switched from “Reverse” to “Normal” when all of the following conditions are satisfied.
Manual Fan Reverse Mode is set to Normal while the fan is rotating in reverse.
Condition 1
Or, fan has been rotating in reverse for 10 minutes.
Condition 2 Engine speed is in range of 500 rpm or higher and lower than 900 rpm.
2. Overheat prevention function during fan reverse rotation

q When the coolant temperature, hydraulic oil temperature, or boost air temperature becomes higher than the
specific temperature while the fan is rotating in reverse, the reverse rotation is stopped and the forward rota-
tion is forcibly started to increase the air flow to the radiator.
3. Fan speed control function during fan reverse rotation
q While the fan is rotating in reverse, command current (0 mA) to fan motor flow control EPC valve is blocked
and the fan speed is set to the maximum.
The air flow to the radiator core is increased to the maximum by increasing the fan speed to the maximum for
easy cleaning.
10-184 GD535-5
20 Standard value table
GD535-5 20-1
(01)
Contents 20 Standard value table
Contents 1
Acronyms - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20-3
Standard value table- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20-8
Standard value table for engine- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20-8
Standard value table for machine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20-10
20-2 GD535-5
(01)
20 Standard value table Acronyms
Acronyms 1
System
Advanced Joystick
ARAC
braking force.
Automatic Retarder
Automatic Spin
Brake Cooling oil
Regulator
used independently.
Closed-center Load
Sensing System
injection timing.
ECU)
GD535-5 20-3
(01)
Acronyms 20 Standard value table
Electronic Control
Modulation Valve

ECM)
Exhaust Gas
Recirculation
Equipment
Monitoring System
Electromagnetic
Forward-Neutral-
Reverse
Global Positioning
System
Plus) earth

Global Navigation
Satellite System

HSS
Hydro Static
control
Unit
motions.
20-4 GD535-5
(01)
KOMATSU Closed
KCSF Engine
KOMATSU Diesel
Oxidation Catalyst
muffler.
Particulate Filter
KOMATSU Traction
LIN
load.
LVDS
sensor.
Service
NC Normally Closed
NO Normally Open
PC Hydraulic system
GD535-5 20-5
(01)
Acronyms 20 Standard value table
PCCS
Pre-stroke Control
Valve
Control
hydraulic pressure.
Hydraulic system
PTP

Structure
Selective Catalytic
Reduction
VGT Engine

D: Bulldozer
HD: Dump truck
WA: Wheel loader
20-6 GD535-5
(01)

A/C Air Conditioner
A/M Air Mix damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
ENG Engine
F.G. Frame Ground
GND Ground
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/M Transmission
GD535-5 20-7
(01)
Standard value table for engine 20 Standard value table
Standard value table 1
Standard value table for engine 1
Machine model GD535-5

Engine SAA6D107E-1
Classification
Standard value for

Item Measurement condition Unit Repair limit
new machine
E mode rpm 1875 ± 50 1875 ± 50

q Coolant tempera- At High idle
P mode rpm 2150 ± 50 2150 ± 50
ture: 80 to 90°C
q Hydraulic oil tem- Low idle rpm 800 ± 50 800 ± 50
perature:
Engine speed In E mode / In P
45 to 55°C In P mode with
mode with a gear
q Torque converter gear speed F7 or
Rated speed rpm speed other than
oil temperature: F8
F7 and F8
60 to 80°C
2000 2100
q Coolant temperature: 60 to 100°C
q Torque converter oil temperature: 60 to 80°C
kPa Min. 127 Min. 100
Boost Pressure q Hydraulic oil temperature: 45 to 55°C
{mmHg} {Min. 950} {Min. 750}
q At rated horsepower
q At aftercooler outlet
Exhaust
temperature
q Hydraulic oil temperature: 45 to 55°C
(Temperature at °C Max. 650 Max. 700
q Whole speed range
turbocharger
q Ambient temperature: 20°C
inlet)
q At turbocharger inlet
Engine
At sudden acceleration %
q Engine coolant Max. 25 35
Exhaust gas (LooHi) (Opacity)
temperature:
color %
60 to 100°C At high idle - -
(Opacity)
Intake valve mm 0.25 ± 0.05 0.152 to 0.381
Valve clearance q Normal temperature
Exhaust valve mm 0.51 ± 0.05 0.381 to 0.762
q Engine oil temperature: 40 to 60°C
Compression MPa Min. 2.41 Min. 1.69
q At cranking (engine speed: 250 to 280 rpm
pressure {kg/cm2} {Min. 24.6} {Min. 17.2}
(reference))
q Torque converter oil temperature: 60 to 80°C kPa Max. 1.17 Max. 1.96
Blowby pressure
q Hydraulic oil temperature: 45 to 55°C {mmH2O} {Max. 120} {Max. 200}
q Coolant tempera- MPa Min. 0.29 Min. 0.25
At high idle
ture:60 to 100°C {kg/cm2} {Min. 3.0} {Min. 2.5}
q Engine Oil (*1)
Engine oil
EO10W30-LA
pressure MPa Min. 0.10 Min. 0.07
EO15W40-LA At low idle
EOS5W30-LA {kg/cm2} {Min. 1.0} {Min. 0.7}
EOS5W40-LA
Oil temperature q Whole speed range (inside oil pan) °C 80 to 110 Max. 120
*1: KES diesel engine oil
20-8 GD535-5
(01)
20 Standard value table Standard value table for engine
a When using the standard value table for checking, adjusting, and troubleshooting, the following cautions are
required.
1. The standard values for new machine in the table are based on the values at factory shipment. Use them for
estimating wear and tear after operation and as targets of repair.
2. The repair limits in the table are estimated based on the results of various tests at factory shipment. Use them
for reference for troubleshooting according to the situations such as degree of repair and operation history.
3. This standard value table is not used as criteria for claims.
GD535-5 20-9
(01)
Standard value table for machine 20 Standard value table
Standard value table for machine 1

Classification
Standard value
Item Measurement condition Unit for new Repair limit
machine
NEUTRAL a For details, see Fig. A

in "Machine posture 45 ± 2 45 ± 2
(α1)
Depressing and procedure for mea-
Accelerator pedal deg.
angle Travel suring performance".
q With engine started 17 ± 2 17 ± 2
(α)
q α = α1 - α2
Traveling mm 84 ± 4.2 84 ± 4.2

q With engine stopped
q Tip of pedal
q Traveling: Between released Play mm Max. 5 Max. 5
and fully depressed positions
Inching pedal Height
q Play: At released position mm
(Released) 175 ± 5 175 ± 5
q Height: Released position and
fully depressed position from Height
floor top surface (Fully mm 90 ± 5 90 ± 5
depressed)
Travel of levers, pedals, and steering wheel
PoN mm 28.5 ± 5 28.5 ± 5
NoF1 mm 28.5 ± 5 28.5 ± 5
F1oF2 mm 28.5 ± 5 28.5 ± 5
F2oF3 mm 28.5 ± 5 28.5 ± 5
F3oF4 mm 28.5 ± 5 28.5 ± 5
F4oF5 mm 28.5 ± 5 28.5 ± 5

Gear shift lever F5oF6 mm 28.5 ± 5 28.5 ± 5
q At 24 mm below top of lever
F6oF7 mm 28.5 ± 5 28.5 ± 5
F7oF8 mm 28.5 ± 5 28.5 ± 5
NoR1 mm 28.5 ± 5 28.5 ± 5
R1oR2 mm 28.5 ± 5 28.5 ± 5
R2oR3 mm 28.5 ± 5 28.5 ± 5
R3oMAX mm 28.5 ± 5 28.5 ± 5
20-10 GD535-5
(01)
20 Standard value table Standard value table for machine

Classification
Standard value
machine
q With engine running at Low

idle No. of rotations Rotation 6.0 to 7.0 6.0 to 7.0
q Front wheels raised off the
ground
q No. of rotations: Between
Steering wheel
steering stroke ends
q Play: Between rotation start- Play mm 0 to 25 0 to 25
ing point of steering wheel and
point where machine starts
steering
Travel mm 39 ± 3.9 39 ± 3.9
q Tip of pedal
q Travel: Between released po-
Brake pedal
sition and position where brake
starts to work Play mm Max. 5 Max. 5
q Play: At released position
Travel of levers, pedals, and steering wheel
L.H. blade lift N o FORWARD

cylinder control No mm 26 ± 5 26 ± 5
lever REARWARD
N o FORWARD
Attachment
No mm 29 ± 5 29 ± 5
control lever
REARWARD
N o FORWARD
Blade rotation
No mm 26 ± 5 26 ± 5
control lever
REARWARD
N o FORWARD
Articulate control
No mm 29 ± 5 29 ± 5
lever
REARWARD
N o FORWARD
Drawbar side shift q With engine stopped
No mm 26 ± 5 26 ± 5
control lever q Center of lever knob
REARWARD
N o FORWARD
Power tilt control
No mm 29 ± 5 29 ± 5
lever
REARWARD
N o FORWARD
Leaning control
No mm 26 ± 5 26 ± 5
lever
REARWARD
N o FORWARD
Blade side shift
No mm 26 ± 5 26 ± 5
control lever
REARWARD
R.H. blade lift N o FORWARD
cylinder control No mm 26 ± 5 26 ± 5
lever REARWARD
GD535-5 20-11
(01)

Classification
Standard value
machine
At start of 24.5 to 37.8 24.5 to 37.8

depressing q With engine started {2.5 to 3.9} {2.5 to 3.9}
Depressing q Measure at 150 mm
Accelerator pedal At fully N {kg}
effort away from pedal ful- 45.1 to 58.8 45.1 to 58.8
depressed crum {4.6 to 6.0} {4.6 to 6.0}
position
Max. 142 Max. 142
Inching pedal q Measure at 150 mm away from pedal fulcrum N {kg}
{Max. 14.5} {Max. 14.5}
q Read values through travel end
Max. 29.4 Max. 29.4
PoN N {kg}
{Max. 3.0} {Max. 3.0}
Max. 29.4 Max. 29.4
NoF1 N {kg}
{Max. 3.0} {Max. 3.0}
Control effort of levers, pedals, and steering wheel
Max. 29.4 Max. 29.4

F1oF2 N {kg}
{Max. 3.0} {Max. 3.0}
Max. 29.4 Max. 29.4
F2oF3 N {kg}
{Max. 3.0} {Max. 3.0}
Max. 29.4 Max. 29.4
F3oF4 N {kg}
{Max. 3.0} {Max. 3.0}
Max. 29.4 Max. 29.4
F4oF5 N {kg}
q With engine stopped {Max. 3.0} {Max. 3.0}
q Measure at 24 mm below tip of
Max. 29.4 Max. 29.4
Gear shift lever lever knob F5oF6 N {kg}
{Max. 3.0} {Max. 3.0}
q Max. value to just before finish
of gear shifting Max. 29.4 Max. 29.4
F6oF7 N {kg}
{Max. 3.0} {Max. 3.0}
Max. 29.4 Max. 29.4
F7oF8 N {kg}
{Max. 3.0} {Max. 3.0}
Max. 29.4 Max. 29.4
NoR1 N {kg}
{Max. 3.0} {Max. 3.0}
Max. 29.4 Max. 29.4
R1oR2 N {kg}
{Max. 3.0} {Max. 3.0}
Max. 29.4 Max. 29.4
R2oR3 N {kg}
{Max. 3.0} {Max. 3.0}
Max. 29.4 Max. 29.4
R3oMAX N {kg}
{Max. 3.0} {Max. 3.0}
q With engine running at low idle Max. 29.0 Max. 49.0
Steering wheel N {kg}
q During travel in F1 {Max. 3} {Max. 5}
q With engine running at high idle
Brake pedal q At position 150 mm from center of rotation N {kg} 276 ± 28 276 ± 28
q Max. value read until machine stops completely {28.1 ± 2.8} {28.1 ± 2.8}
20-12 GD535-5
(01)

Classification
Standard value
machine
L.H. blade lift N o FORWARD

20 to 35 20 to 35
cylinder control No N {kg}
{2.04 to 3.57} {2.04 to 3.57}
lever REARWARD
N o FORWARD
Attachment 20 to 35 20 to 35
No N {kg}
control lever {2.04 to 3.57} {2.04 to 3.57}
REARWARD
Control effort of levers, pedals, and steering wheel
N o FORWARD
Blade rotation 20 to 45 20 to 45
No N {kg}
REARWARD
N o FORWARD
Articulate control 20 to 35 20 to 35
No N {kg}
lever {2.04 to 3.57} {2.04 to 3.57}
REARWARD
q With engine stopped N o FORWARD
Drawbar side shift 20 to 35 20 to 35
q Read values through travel N o N {kg}
end REARWARD
N o FORWARD
Power tilt control 20 to 35 20 to 35
No N {kg}
lever {2.04 to 3.57} {2.04 to 3.57}
REARWARD
N o FORWARD
Leaning control 20 to 35 20 to 35
No N {kg}
lever {2.04 to 3.57} {2.04 to 3.57}
REARWARD
N o FORWARD
Blade side shift 20 to 35 20 to 35
No N {kg}
REARWARD
R.H. blade lift N o FORWARD
20 to 35 20 to 35
cylinder control No N {kg}
{2.04 to 3.57} {2.04 to 3.57}
lever REARWARD
Rotation speed
q Torque converter stall function

Torque converter
q Torque converter oil temperature: 60 to 80 °C rpm 1890 ± 100 1890 ± 100
stall speed
GD535-5 20-13
(01)

Classification
Standard value
machine
Low idle 2.55 ± 0.2 2.55 ± 0.2

Transmission {26.0 ± 2.0} {26.0 ± 2.0}
main relief
pressure Rated speed 2.73 ± 0.2 2.73 ± 0.2
(2,000 rpm) {27.9 ± 2.0} {27.9 ± 2.0}
Torque converter Rated speed Max. 0.9 Max. 0.9
inlet pressure (2,000 rpm) {Max. 9.2} {Max. 9.2}
Torque converter Rated speed 0.58 ± 0.1 0.58 ± 0.1
Power train oil pressure and pump performance
outlet pressure (2,000 rpm) {5.9 ± 1.0} {5.9 ± 1.0}

Torque converter q Torque converter oil tempera- Rated speed 1.76 ± 0.2 1.76 ± 0.2
lockup clutch ture: 60 to 80 °C (2,000 rpm) {18.0 ± 2.0} {18.0 ± 2.0}
pressure q Transmission oil temperature:
Transmission FL 60 to 80 °C Rated speed 2.21 ± 0.25 2.21 ± 0.25
clutch pressure q With engine running at Low (2,000 rpm) MPa {22.5 ± 2.5} {22.5 ± 2.5}
idle, or at rated speed (2,000 {kg/cm2}
Transmission R rpm) Rated speed 2.21 ± 0.25 2.21 ± 0.25
clutch pressure q During running wheels idle off (2,000 rpm) {22.5 ± 2.5} {22.5 ± 2.5}
Transmission FH ground with gear shift lever in Rated speed 2.21 ± 0.25 2.21 ± 0.25
clutch pressure P position or each speed range (2,000 rpm) {22.5 ± 2.5} {22.5 ± 2.5}
Transmission 1st Rated speed 2.21 ± 0.25 2.21 ± 0.25
clutch pressure (2,000 rpm) {22.5 ± 2.5} {22.5 ± 2.5}
Transmission 2nd Rated speed 2.21 ± 0.25 2.21 ± 0.25
Transmission 3rd Rated speed 2.21 ± 0.25 2.21 ± 0.25
Transmission 4th Rated speed 2.21 ± 0.25 2.21 ± 0.25
Power train pump
q Torque converter oil temperature: 60 to 80 °C
discharged l/min 210 -
q With engine running at High idle
volume
F1 km/h 4.3 ± 0.2 4.3 ± 0.2
F2 km/h 6.1 ± 0.3 6.1 ± 0.3
F3 km/h 8.2 ± 0.4 8.2 ± 0.4
Power train performance
F4 km/h 11.6 ± 0.6 11.6 ± 0.6

q In manual mode
q In P-mode F5 km/h 16.2 ± 0.8 16.2 ± 0.8
q Torque converter oil tempera- F6 km/h 22.7 ± 1.1 22.7 ± 1.1
Travel speed ture: 60 to 80 °C
q While machine is traveling with F7 km/h 31.1 ± 1.6 31.1 ± 1.6
engine at rated speed (2,000 F8 km/h 43.4 ± 2.2 43.4 ± 2.2
rpm)
R1 km/h 4.8 ± 0.2 4.8 ± 0.2
R2 km/h 9.4 ± 0.5 9.4 ± 0.5
R3 km/h 18.4 ± 0.9 18.4 ± 0.9
R4 km/h 35.2 ± 1.8 35.2 ± 1.8
Differential lock
Differential
q Final drive oil temperature: 60 to 80 °C 3.05 (+0.1 /

pressure MPa 3.05 (+0.2 / 0)
q With engine running at high idle -0.294)
[Differential lock {kg/cm2} {31.2 (+1 / 0)}
q When differential lock is operated {31.2 (+1 / -3)}
specification]
20-14 GD535-5
(01)

Classification
Standard value
machine
q Hydraulic oil temperature: 45 to 55 °C

Steering oil MPa 17.6 ± 1.0 17.6 ± 1.0
pressure {kg/cm2} {180 ± 9.8} {180 ± 9.8}
q With steering cylinder relieved
Oil leak from
q With engine running at high idle cc/min Max. 10 Max. 10
steering cylinder
Steering system and tires
q With steering cylinder relieved

q On flat paved surface
Camber deg. 0 0
q Camber: Kingpin inclination angle
q On flat paved surface
Toe-in q Toe-in: Difference between front center distance mm -5 ± 5 -5 ± 5
and rear center distance of tires
q Measure the face runout by putting a dial gauge
Face runout of tire mm Max. 7 Max. 7
at tire side walls (both front and rear tires)
kPa 260 ± 20 260 ± 20
13.00-24-12PR
Tire inflation {kg/cm2} {2.6 ± 0.2} {2.6 ± 0.2}
pressure kPa 260 ± 20 260 ± 20
14.00-24-12PR
{kg/cm2} {2.6 ± 0.2} {2.6 ± 0.2}
GD535-5 20-15
(01)

Classification
Standard value
machine
q Hydraulic oil temperature: kPa 9.36 (0 / -0.5) 9.36 (0 / -0.5)

Brake Cut-in pressure
45 to 55 °C {kg/cm2} {95.5 (0 / -5)} {95.5 (0 / -5)}
accumulator
q With engine running at high Cut-out kPa 13.8 (0 / -0.5) 13.8 (0 / -0.5)
charge pressure
idle pressure {kg/cm2} {140 (0 / -5)} {140 (0 / -5)}
Wheel brake
q With engine stopped (after accumulator is MPa 4.4 ± 0.4 4.4 ± 0.4
operating
charged) {kg/cm2} {45 ± 4.1} {45 ± 4.1}
pressure
q When brake pedal is depressed
Pressure drop of
q With engine stopped (after accumulator is
wheel brake kPa Max. 98 Max. 98
charged)
operating {kg/cm2} {Max. 1.0} {Max. 1.0}
q Pressure drop in 5 minutes after wating 1 minite
pressure
with brake pedal depressed
Parking brake q With engine stopped (after accumulator is
MPa Min. 8.2 Min. 8.2
releasing charged)
{kg/cm2} {Min. 83.6} {Min. 83.6}
pressure q Starting switch at ON position and gear shift lever
in N position
Brake

Wheel brake
q Braking distance when machine is traveling at 35 m Max. 15.8 Max. 15.8
braking distance
km/h
q Brake pedal: Depress to the stroke end.
Disc wear of
q Protrusion of shaft mm 1.5 (0/-0.2) 0
wheel brake
q Check with shaft of disc wear gauge
q Engine: Stopped
q Thickness (a) and (b) of pad Thickness (a) 12.5 ± 0.5 Min. 9.5
Thickness of (1)
mm
parking brake pad q For details, see Fig. B in "Ma-
chine posture and procedure Thickness (b) 6.5 ± 0.5 Min. 3.5
for measuring performance".
q Engine: Stopped
q Sum of clearances (c) and (d) between pad (1)
and disc (2)
Clearance at
q Use manual hand hydraulic pump to apply park- mm 1.5 to 1.8 Min. 2.5
parking brake pad
ing brake. (Specified pressure: 8.2 MPa)
q For details, see Fig. B in "Machine posture and
procedure for measuring performance".
Travel and operating effort of control valve
Blade rotation
mm 5 ± 0.5 5 ± 0.5
q With engine stopped only
Travel of control
q N o RAISE side, N o LOWER
valve spool
side Other than
mm 5.5 ± 0.5 5.5 ± 0.5
blade rotation
Blade rotation N Max. 110 Max. 110

only {kg} {Max. 11.2} {Max. 11.2}
Control valve q N o RAISE side, N o LOWER
spool operating side
effort q Read values through travel Other than N Max. 102.5 Max. 102.5
end blade rotation {kg} {Max. 10.5} {Max. 10.5}
20-16 GD535-5
(01)

Work equipment oil pressure and performance of hydraulic pump Classification
Standard value
machine
q Hydraulic oil temperature:

45 to 55 °C
Work
q With engine running at high
Work equipment equipment relief MPa 19.1 (+0.5/0) 19.1 ± 0.5
idle
oil pressure pressure {kg/cm2} {195 (+5/0)} {195 ± 5}
q Work equipment relief pres-
sure: With leaning cylinder re-
lieved
Steering pump q Hydraulic oil temperature: 45 to 55 °C
l/min 13.5 ± 2.5 13.5 ± 2.5
discharge q With engine running at Low idle
Discharge of work q With engine running at Low idle
l/min 29 ± 4.5 29 ± 4.5
equipment pump q Blade rotation control (measure during opera-
tion)
Cooling fan and

brake pump l/min 21.5 ± 3.5 21.5 ± 3.5
q With engine running at Low idle
discharge
q Hydraulic oil temperature: RAISE 2.0 ± 0.3 Max. 4.0

Blade lift speed 45 to 55 °C
LOWER 3.0 ± 0.4 Max. 5.0
q With engine running at High
Blade side shift idle Left shifting 8.2 ± 1.3 Max. 10.0
speed q Blade lift: Move cylinder full Right shifting Max. 7.0
5.3 ± 0.8
stroke over full travel and oper-
Drawbar side shift ate both cylinders indepen- Left shifting 2.3 ± 0.4 Max. 4.0
speed dently. Right shifting 3.3 ± 0.5 Max. 5.0
q Blade side shift: Move cylinder
Blade rotation between stroke ends. Left rotation 8.1 ± 1.3 Max. 10.0
speed q Drawbar side shift: Set blade Right rotation Max. 10.0
Work equipment speed
8.1 ± 1.3
with its bottom at a height of
100 mm and move cylinder be- With large
2.0 ± 0.3 Max. 3.0
tween stroke ends. cutting angle
Power tilt speed
q Blade rotation Measure time With small Sec.
1.7 ± 0.3 Max. 3.0
required for blade to rotate cutting angle
from start to 90-degree rota-
Left turn 4.2 ± 0.6 Max. 6.0
Articulate speed tion.
q Power tilt: Move cylinder be- Right turn 4.2 ± 0.7 Max. 6.0
tween stroke ends.
Leaning to left 0.7 ± 0.1 Max. 2.0
Leaning speed q Articulate: Move cylinder be-
tween stroke ends. Leaning to right 1.0 ± 0.1 Max. 2.0
(During traveling) RAISE Max. 3.0
1.6 ± 0.5
Ripper lift speed q Leaning: Move cylinder be-
tween stroke ends. LOWER 2.4 ± 0.4 Max. 4.0
q Ripper lift: Move cylinder be- RAISE 1.0 ± 0.2 Max. 2.0
tween stroke ends
Scarifier lift speed q Scarifier lift: Move cylinder be- LOWER 1.4 ± 0.3 Max. 3.0
tween stroke ends.
GD535-5 20-17
(01)

Hydraulic drift and oil leak of work equipment Classification
Standard value
machine
q R.H. and L.H. blade lift cylinders: RAISE stroke

Blade hydraulic
end
drift
q Hydraulic oil temperature: 45 to 55 °C mm Max. 10 Max. 20
(No load on
cylinder)
q Cylinder extension in 10 minutes after setting
q R.H. and L.H. blade lift cylinders: LOWER stroke
Blade hydraulic end (to raise machine off ground)
drift q Hydraulic oil temperature: 45 to 55 °C mm Max. 20 Max. 35
(machine lifted) q With engine stopped
q Cylinder retraction in 10 minutes after setting
Oil leak from work q Hydraulic oil temperature: 45 to 55 °C

equipment q With engine running at High idle cc/min Max. 3 Max. 3
cylinder q With cylinder relieved
q Power mode: P mode

Maximum fan
q Fan 100% speed adjustment mode
speed of cooling 1,300 ± 50 1,300 ± 50
q Accelerator pedal: Depress to stroke end (High
fan
idle)
rpm
Cooling fan
q Engine coolant temperature: Max. 80 °C

Minimum fan
q Hydraulic oil temperature: Max. 70 °C
speed of cooling 700 ± 50 700 ± 50
q Torque converter oil temperature: Max. 85 °C
fan
q Accelerator pedal: Not depressed (Low idle)
q Fan 100% speed adjustment mode
Cooling fan drive MPa 14.5 ± 1.0 14.5 ± 1.0
q Accelerator pedal: Depress to stroke end (High
pressure { kg/cm2} {147.9 ± 10.2} {147.9 ± 10.2}
idle)
a When using the standard value table for checking, adjusting, and troubleshooting, the following cautions are
required.
1. The standard values for new machine in the table are based on the values at factory shipment. Use them for
estimating wear and tear after operation and as targets of repair.
2. The repair limits in the table are estimated based on the results of various tests at factory shipment. Use them
for reference for troubleshooting according to the situations such as degree of repair and operation history.
3. This standard value table is not used as criteria for claims.
20-18 GD535-5
(01)
Machine posture and procedure for mea-

suring performance
a Fig. A
a Fig. B
GD535-5 20-19
(01)
20-20 GD535-5
(01)
30 Testing and adjusting
GD535-5 30-1
(01)
Contents 30 Testing and adjusting
Contents 1
Acronyms - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-4
Tools for testing, adjusting, and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-9
Tools for testing, adjusting, and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-9
Testing engine speed - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-16
Testing boost pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-18
Testing exhaust gas temperature - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-20
Testing exhaust gas color - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-22
Adjusting valve clearance- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-24
Testing compression pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-26
Testing blowby pressure- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-29
Testing engine oil pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-30
Handling fuel system devices - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-31
Releasing remaining pressure from fuel system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-32
Testing fuel pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-33
Bleeding air from fuel circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-34
Testing fuel circuit for leakage- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-35
Handling cylinder cutout mode operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-36
Handling no-injection cranking operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-37
Handling voltage circuit of engine controller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-38
Testing muffler (main body) and stacked muffler for looseness and damage - - - - - - - - - - - - - - - - - - - - 30-39
Testing muffler function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-40
Testing installed condition of cylinder heads and manifolds - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-41
Testing of engine piping for damage and looseness - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-42
Testing fuel discharge, return rate, and leakage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-43
Testing and adjusting air conditioner compressor belt tension - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-47
Checking and replacing alternator belt- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-49
Checking and replacing auto-tensioner - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-51
Power train - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-54
Testing power train oil pressure- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-54
Adjusting transmission speed sensor- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-68
Retrieval of disabled machine due to transmission valve failure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-71
Flushing procedure for torque converter and transmission circuits - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-74
Testing and adjusting toe-in - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-76
Testing and adjusting differential lock oil pressure (differential lock specification)- - - - - - - - - - - - - - - - - 30-78
Steering system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-80
Testing and adjusting steering oil pressure- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-80
Testing oil leakage of steering cylinder- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-81
Bleeding air from steering circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-82
Brake system- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-83
Releasing remaining pressure from brake circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-83
Testing and adjusting brake oil pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-84
Bleeding air from brake circuit- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-87
Testing wear of wheel brake disc- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-88
Testing and adjusting parking brake pad - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-89
Releasing parking brake manually- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-92
Charging brake accumulator with gas - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-93
Testing work equipment oil pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-95
Testing lifter lock pin circuit pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-97
Testing cooling fan speed - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-99
Testing cooling fan circuit oil pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-100
Testing oil leakage of work equipment cylinder - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-102
30-2 GD535-5
(01)
30 Testing and adjusting Contents
Bleeding air from work equipment circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-105

Work equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-106
Adjusting drawbar ball joint clearance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-106
Testing and adjusting circle guide clearance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-107
Testing and adjusting slip clutch type circle drive - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-109
Procedure for testing diodes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-111
Special functions of machine monitor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-113
Handling high-voltage circuit of engine controller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-162
KOMTRAX terminal start-up procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-163
Adjusting rearview camera angle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-167
Handle battery disconnect switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-169
Preparatory work for troubleshooting of electrical system failure - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-170
Pm Clinic - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-172
Pm Clinic - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-172
GD535-5 30-3
(01)
Acronyms 30 Testing and adjusting
Acronyms 1
System
Advanced Joystick
ARAC
braking force.
Automatic Retarder
Automatic Spin
Brake Cooling oil
Regulator
used independently.
Closed-center Load
Sensing System
injection timing.
ECU)
30-4 GD535-5
(01)
30 Testing and adjusting Acronyms
Electronic Control
Modulation Valve

ECM)
Exhaust Gas
Recirculation
Equipment
Monitoring System
Electromagnetic
Forward-Neutral-
Reverse
Global Positioning
System
Plus) earth

Global Navigation
Satellite System

HSS
Hydro Static
control
Unit
motions.
GD535-5 30-5
(01)
KOMATSU Closed
KCSF Engine
KOMATSU Diesel
Oxidation Catalyst
muffler.
Particulate Filter
KOMATSU Traction
LIN
load.
LVDS
sensor.
Service
NC Normally Closed
NO Normally Open
PC Hydraulic system
30-6 GD535-5
(01)
30 Testing and adjusting Acronyms
PCCS
Pre-stroke Control
Valve
Control
hydraulic pressure.
Hydraulic system
PTP

Structure
Selective Catalytic
Reduction
VGT Engine

D: Bulldozer
HD: Dump truck
WA: Wheel loader
GD535-5 30-7
(01)

A/C Air Conditioner
A/M Air Mix damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
ENG Engine
F.G. Frame Ground
GND Ground
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/M Transmission
30-8 GD535-5
(01)
30 Testing and adjusting Tools for testing, adjusting, and troubleshooting
Tools for testing, adjusting, and troubleshooting 1
Tools for testing, adjusting, and troubleshooting 1
Sym-
Testing/Adjusting item Part No. Part name Q'ty Remarks
bol
-101 to 200 kPa
1 799-201-2202 Boost gauge kit 1
Testing boost pressure B {-760 to 1500 mmHg}
2 790-301-1530 Elbow 1 R1/8×R1/8, 90°
Testing exhaust gas
C 799-101-1502 Digital thermometer 1 -99.9 to 1299 °C
temperature
1 799-201-9002 Handy smoke checker 1
Testing exhaust gas color D Commercially Bosch index: 0 to 9
2 Smoke meter 1
available
1 795-799-1131 Gear 1
Adjusting valve clearance E Commercially
2 Feeler gauge 1 Intake: 0.33 mm, exhaust: 0.71 mm
available
1 795-799-6700 Puller 1
Testing compression 2 795-502-1590 Gauge assembly 1 0 to 7 MPa {0 to 70 kg/cm2}

F
pressure 3 795-790-4411 Adapter 1 For 107E-1 engine
4 6754-11-3130 Gasket 1 For 107E-1 engine
Testing blowby pressure G 799-201-1506 Blowby checker 1 0 to 5 kPa {0 to 500 mmH2O}
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
1
Pressure gauge: 70 MPa {700 kg/
Testing engine oil pressure H 790-261-1205 Digital hydraulic tester 1
cm2}
2 799-401-2320 Gauge 1 Pressure gauge: 1 MPa {10 kg/cm2}
3 790-301-1220 Nipple 1 PT1/8
{25, 60, 400, 600 kg/cm2}
1
790-261-1205 Digital hydraulic tester 1
cm2}
Testing fuel pressure J
2 799-401-2320 Gauge 1 Pressure gauge: 1 MPa {10 kg/cm2}
799-101-5220 Nipple 1
3 Size: 10 x 1.25 mm
07002-11023 O-ring 1
Checking and replacing Commercially
AA Wrench 1
alternator belt available
Checking and replacing Commercially
AB Wrench 1
auto-tensioner available
GD535-5 30-9
(01)
Tools for testing, adjusting, and troubleshooting 30 Testing and adjusting
Sym-
bol
{25, 60, 400, 600 kg/cm2}
1
cm2}
Testing power train oil
K 2 799-401-2320 Gauge 1 Pressure gauge: 1 MPa {10 kg/cm2}
pressure
799-101-5220 Nipple 1
3 Size: 10 x 1.25 mm
07002-11023 O-ring 1
Commercially
4 Block 2
available
Retrieval of disabled 794-423-1190 Plug 3
machine due to L
transmission valve failure 07002-22034 O-ring 3

{25, 60, 400, 600 kg/cm2}
1
cm2}
Testing differential lock 2 799-401-2320 Gauge 1 Pressure gauge: 1 MPa {10 kg/cm2}
pressure [differential lock
M
specification] 790-301-1271 Joint 1
3 Size: 10 x 1.25 mm
07002-11023 O-ring 1
4 799-401-3200 Adapter 1 Size: 03
791T-601-
5 Elbow 1
2220
{25, 60, 400, 600 kg/cm2}
1
Testing steering oil pressure N 790-261-1205 Digital hydraulic tester 1
cm2}
790-301-1271 Joint 1
2 Size: 10 x 1.25 mm
07002-11023 O-ring 1
Testing oil leakage of Commercially
P Measuring cylinder 1
steering cylinder available
{25, 60, 400, 600 kg/cm2}
1
cm2}
Testing and adjusting brake 2 793-520-1805 Brake test kit 1 0 to 20 MPa {0 to 200 kg/cm2}
Q
oil pressure
3 799-401-3100 Adapter 1 Size: 02
790-301-1271 Joint 1
4 Size: 10 x 1.25 mm
07002-11023 O-ring 1
5 791T-601-2220 Elbow 1
Testing wear of wheel brake Commercially
R Vernier calipers 1
disc available
30-10 GD535-5
(01)
Sym-
bol
1 792-454-1100 Pump assembly 1
2 792-454-1120 Valve 1
3 792-454-1110 Pump 1
4 790-425-1240 Nipple 1 Size: 7/16-20UNF-2A-Rc1/8
5 416-62-11480 O-ring 1
Testing and adjusting
S
parking brake pad 6 790-612-5110 Adapter 1 Size: R1/8-Rc1/4
7 790-190-2310 Hose 1 Size: R1/4-Rc1/4
Commercially
8 Hose 1
available
Commercially
9 Oil container 1
available
Charging brake accumulator
T 792-610-1702 Charging tool 1
with gas
1 Pressure gauge: 70 MPa {700 kg/
cm2}
Testing and adjusting work
U
equipment oil pressure 2 790-301-1530 Elbow 1 R1/8×R1/8, 90°
790-301-1271 Joint 1
3 Size: 10 x 1.25 mm
07002-11023 O-ring 1
{25, 60, 400, 600 kg/cm2}
Testing lifter lock pin circuit 1
V Pressure gauge: 70 MPa {700 kg/
pressure 790-261-1205 Digital hydraulic tester 1
cm2}
2 799-401-3100 Adapter 2 Size: 02
- 799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
1 799-101-5120 Gauge 1
cm2}
Cooling fan circuit oil Pressure gauge: 70 MPa {700 kg/
W 2 790-261-1205 Digital hydraulic tester 1
pressure cm2}
3 799-401-3400 Adapter 1 Size: 05
4 799-101-5220 Nipple 1 Size: M10×1.25 mm
5 07002-11023 O-ring 1
Testing oil leakage of work Commercially
Y Measuring cylinder 1
equipment cylinder available
GD535-5 30-11
(01)
Sym-
bol
1 795-790-4700 Tester kit 1
6754-71-5340 Connector 1
3
6754-71-5350 Washer 1
Commercially
4 Measuring cylinder 1
available
Testing fuel discharge,
Z
return rate, and leakage Commercially
5 Stopwatch 1
available
Commercially Hose (inside diameter: 14
6 1
available mm)
Commercially Hose (inside diameter: 8
7 1
available mm)
Testing operating effort and 79A-264-0021 Push-pull scale 1 0 to 294 N {0 to 30 kg}

-
depressing effort 79A-264-0091 Push-pull scale 1 0 to 490 N {0 to 50 kg}
Testing travel and hydraulic Commercially
- Ruler 1
drift available
Testing work equipment Commercially
- Stopwatch 1
speed available
Testing voltage and Commercially
resistance - available
Multimeter 1
799-601-4130 T-adapter - For NE sensor

799-601-4130 T-adapter - For oil pressure sensor
799-601-4240 Socket - For ambient pressure sensor
799-601-4250 Socket - For boost pressure sensor
799-601-4330 Socket - For G sensor
799-601-9020 T-adapter - For injector
Diagnosing controllers, 799-601-9030 T-adapter - For CAN
sensors, and actuators -
799-601-9040 T-adapter - For EGR valve position sensor
799-601-9430 Socket - For supply pump
For coolant temperature sensor and
795-799-5530 Socket - fuel temperature sensor
795-799-5540 Socket - For boost temperature sensor
799-601-4211 T-adapter - For controller (50 poles)
799-601-4220 T-adapter - For controller (60 poles)
30-12 GD535-5
(01)
Sym-
bol
799-601-4101,
or 799-601-
4201, or 799- T-adapter assembly 1 Adapter for DT
601-9000, or
799-601-9200
799-601-9020 q Adapter for DT 1 For DT2P
For DT3P (parts 799-601-4100 and
799-601-9030 q Adapter for DT 1
799-601-4200 are not contained.)
799-601-9040 q Adapter for DT 1 For DT4P
For DT6 (parts 799-601-4100 and
For DT12GR (parts 799-601-4100
799-601-9110 q Adapter for DT 1 and 799-601-4200 are not
contained.)
For DT12B (parts 799-601-4100 and
For DT12G (parts 799-601-4100
contained.)
For DT12BR (parts 799-601-4100
contained.)
799-601-7000,
or 799-601-
Diagnosing sensors and 7100, or 799- T-adapter assembly 1 Adapter for X, SWP, and M
wiring harnesses for - 601-7400, or
machine 799-601-8000
For X1P (parts 799-601-7000 and
799-601-7010 q Adapter for X 1
799-601-7020 q Adapter for X 1 For X2P
For SW6P (part 799-601-8000 is not
799-601-7050 q Adapter for SWP 1
contained.)
For SW14P (parts 799-601-7000
799-601-7070 q Adapter for SWP 1 and 799-601-7100 are not
contained.)
For M1P (parts 799-601-7000 and
799-601-7080 q Adapter for M 1
799-601-7090 q Adapter for M 1 1 For M2P
799-601-7310 q Adapter for SWP 1 For SW12P
799-601-7500 T-adapter assembly 1 Adapter for 070
799-601-7520 q Adapter for 070 1 For 070-12P
799-601-7550 q Adapter for 070 1 For 070-20P
799-601-9300 T-adapter assembly 1 Adapter for DRC
799-601-9350 q Adapter for DRC 1 For DRC-40P
GD535-5 30-13
(01)
Sym-
bol
Diagnosing sensors and
wiring harnesses for - 799-601-9360 q Adapter for DRC 1 For DRC-24P
machine
Removing and installing 795T-981-
coolant temperature sensor - 1010
Socket 1
a For types and part numbers for T-adapters and boxes for troubleshooting for machine monitor, controller, sen-
sor, actuator, and wiring harness, see Troubleshooting, "T-box and T-adapter list".
30-14 GD535-5
(01)
Note) Komatsu does not take any responsibility for special tools manufactured according to these sketches.
Elbow
Socket
GD535-5 30-15
(01)
Testing engine speed 30 Testing and adjusting

a For standard values, see the Standard
value table, "Standard value table for
Testing engine speed 1 engine".
4. Testing torque converter stall speed
k Park
1) Start the engine, and hold the gear shift lever at
the machine on flat ground, place the
P position.
work equipment on the ground surely, set the
2) Switch the machine monitor to "T/C Stall"
gear shift lever to P (PARK) position, and then
display to prepare for stalling the torque
stop the engine.
k Chock the tires to prevent the machine from
converter.
a For the operating method, see "Special
moving.
functions of machine monitor".
a Perform the testing of the engine speed under the
following conditions.
1. Preparation
(For the testing of low and high idle speeds)
Turn the starting switch to ON position, and switch
the machine monitor to "Monitoring" display to
prepare for testing the engine speed.
a For the operating method, see "Special func-
tions of machine monitor".
q Monitoring code: 01002 "Engine Speed"
q Monitoring code: 04107 "Coolant Temperature"
q Monitoring code: 30100 "T/C Oil Temperature" 3) While depressing the brake pedal completely,
q Monitoring code: 04401 "Hydraulic Oil Temper- operate the gear shift lever to F8 position.
ature" k Keep the brake pedal firmly depressed.
4) Depress the accelerator pedal gradually to stall
the torque converter with the engine at high
idle.
5) When the torque converter oil temperature
reaches 90°C, release the accelerator pedal
to the low idle position immediately, and return
the gear shift lever to P position.
k Do not operate the gear shift lever while
the accelerator pedal is depressed. Oth-
erwise internal damage may be induced
in the transmission.
6) While holding the gear shift lever at P position,
run the engine at medium speeds. When the
torque converter oil temperature decreases to
2. Testing low idle speed approximately 80°C, release the accelerator
1) Start the engine, and hold the gear shift lever at pedal to the low idle position.
P position. 7) Repeat steps 3) to 6) to equalize the oil temper-
2) Check the engine speed when the accelerator ature of the torque converter and transmission.
pedal is not depressed. 8) While repeating steps 3) to 6), check the torque
a For standard values, see the Standard converter stall speed when the torque
value table, "Standard value table for converter oil temperature is 80°C.
engine". a Check the torque converter stall speed 2 to
3 times in the same procedure.
3. Testing high idle speed a For standard values, see the Standard
1) Start the engine, and hold the gear shift lever at value table, "Standard value table for
P position. engine".
2) Check the engine speed when the accelerator
pedal is depressed to the stroke end.
30-16 GD535-5
(01)
30 Testing and adjusting Testing engine speed
<Reference>
Be sure to check the torque converter stall speed
before delivery since the variation in speed is gener-
ated under the following conditions.
q Variation unique to each engine
q Variation due to differences in ambient pressure
and temperature
q Variation due to differences in consumption of
torque by auxiliaries
q Variation due to differences in characteristics
among torque converters
q Variation due to differences in testing methods
GD535-5 30-17
(01)
Testing boost pressure 30 Testing and adjusting
Testing boost pressure 1
a Tools for testing boost pressure
Sym-
Part No. Part name
bol
1 799-201-2202 Boost gauge kit
B
2 790-301-1530 Elbow (R1/8 x R1/8, 90°)
k Park the machine on flat ground, place the

stop the engine.
k Chock the tires to prevent the machine from 3. Run the engine at middle or higher speed and drain
moving. oil from the hose.
k When installing and removing testing tools, a Repeat opening the self-sealing portion on the
take care not to touch a hot part of the engine. hose to drain oil with the gauge and hose
a Perform the testing of the boost pressure under being connected approximately half at their
the following conditions. connection part.
q Coolant temperature: 60 to 100°C a When the Pm kit is available, you can use air
q Hydraulic oil temperature: 45 to 55°C bleeding coupling (790-261-1130) in the kit.
q Torque converter oil temperature: 60 to 80°C a If oil is left in the hose, the gauge does not
work. Accordingly, be sure to drain the oil.
1. Open the R.H. engine side cover, and remove
boost pressure pickup plug (1) from the air intake 4. Set the gear shift lever to P position and keep the
connector. engine running at low idle.
5. Switch the machine monitor to "T/C Stall" display to

prepare for stalling the torque converter.
2. Install elbow B2 and nipple [1] in boost gauge kit

B1, and then connect gauge [2].
30-18 GD535-5
(01)
30 Testing and adjusting Testing boost pressure
6. While depressing the brake pedal completely,

operate the gear shift lever to F8 position.
k Keep the brake pedal firmly depressed.
7. Depress the accelerator pedal gradually, then
measure the boost pressure when the torque
converter stalls with the engine at high idle.
a For standard values, see the Standard value
table, "Standard value table for engine".
8. After the test is finished, release and return the
accelerator pedal to the low idle position immedi-
ately, and return the gear shift lever to P position.
k Do not operate the gear shift lever while the
accelerator pedal is depressed. Otherwise
internal damage may be induced in the
transmission.
9. After finishing the test, remove the testing tools,
and restore the machine.
GD535-5 30-19
(01)
Testing exhaust gas temperature 30 Testing and adjusting
Testing exhaust gas temperature 1 a Clamp the wiring harness of the digital ther-
mometer so that it does not touch a hot part
during measurement.
a Tools for testing exhaust gas temperature
Sym-
Part No. Part name
bol
C 799-101-1502 Digital thermometer

stop the engine.
moving.
k Install or remove the testing tools after the
exhaust manifold temperature has lowered.
a Perform the testing of the exhaust gas tempera-
ture under the following conditions.
1. Open the L.H. engine side cover and remove

bracket (1) of the turbocharger.
4. Procedure for testing periodically in Pm clinic

a In order to prevent overheating of the torque
converter, stabilize exhaust gas temperature
with full stall (torque converter stall + hydraulic
relief) once. Then stall the torque converter
only for the measurement.
1) Start the engine, and hold the gear shift lever at
P position.
2. Remove exhaust gas temperature pickup port plug
2) Hold the accelerator pedal at the low idle posi-
(2) from the exhaust manifold.
tion.
3) Operate the right and left blade lift control
levers to move the right and left blade lift cylin-
ders to the RAISE stroke ends.
4) Switch the machine monitor to "T/C Stall"
display to prepare for stalling the torque
converter.
a For the operating method, see "Special
functions of machine monitor".
3. Install sensor [1] of digital thermometer C and

connect it to meter [2].
30-20 GD535-5
(01)
30 Testing and adjusting Testing exhaust gas temperature

5) While depressing the brake pedal completely,

operate the gear shift lever to F8 position.
6) Depress the accelerator pedal gradually to stall
the torque converter at engine high idle. At the
same time, operate the right and left blade lift
control levers to RAISE position to relieve oil
pressure in the work equipment circuit (full stall
state).
a Continue the above operations until the
exhaust gas temperature reaches near
670°C, which is the standard value.
7) After the exhaust gas temperature is stabilized
at around the targeted temperature, return the
right and left blade lift control levers to
NEUTRAL position, and check the exhaust gas
temperature when the torque converter alone is
stalled.
engine".
8) After the check is finished, release the acceler-
ator pedal immediately, and return the gear
shift lever to P position.
k Do not operate the gear shift lever while
the accelerator pedal is depressed. Oth-
erwise internal damage may be induced
in the transmission.
5. Procedure for measuring maximum value in

troubleshooting
Measure the maximum exhaust gas temperature
when the actual operations are performed.
a Use the digital temperature gauge in the PEAK
mode (the maximum temperature is automati-
cally recorded when it is set to the PEAK
mode).
a As the exhaust gas temperature differs greatly
depending on the ambient temperature (intake
air temperature of the engine), correct the
value by using the following formula if an
abnormal value is recorded.
q Compensation value [°C] = Measured value +
2 x (20 - Ambient temperature)
GD535-5 30-21
(01)
Testing exhaust gas color 30 Testing and adjusting
Testing exhaust gas color 1 a For standard values, see the Standard
engine".
a Tools for testing exhaust gas color
6) After finishing the test, remove the testing tools,
Sym- and restore the machine.
Part No. Part name
bol
2. Testing by using smoke meter D2
1 799-201-9002 Handy smoke checker
1) Insert probe [1] of smoke meter D2 into the
D Commercially outlet of exhaust pipe (1), and fix it to the
2 Smoke meter
available exhaust pipe with clip.

stop the engine.
moving.
k Be careful not to touch any hot part when
installing or removing the testing tools.
a Perform the testing of the exhaust gas color under
the following conditions.
a If an air source and an electric power source are
not available in the field, use handy smoke
checker D1. When recording official data, etc., use
smoke meter D2. 2) Connect the probe hose, accelerator switch
outlet, and air hose to smoke meter D2.
1. Measuring by using handy smoke checker D1 a The supplied air pressure must be 1.5 MPa
1) Place a sheet of filter paper to smoke checker {15 kg/cm2} or below.
D1. 3) Connect the power cable to an 100 VAC recep-
2) Insert the exhaust gas intake pipe into exhaust tacle.
pipe (1). a Check that the smoke meter power switch
3) Start the engine, and hold the gear shift lever at is in OFF position before connecting the
P position. power cable to the receptacle.
4) Accelerate the engine suddenly or run it at high 4) Loosen the cap nut of the suction pump, and
idle and operate the handle of smoke checker place the filter paper.
D1 to collect exhaust gas on the filter paper. a Fit the filter paper securely so that the
a Suction time: 1.4 ± 0.2 seconds exhaust gas does not leak.
5) Turn on the power switch of D2.
5) Remove the filter paper and compare it with the

attached scale for judgment.
30-22 GD535-5
(01)
30 Testing and adjusting Testing exhaust gas color
6) Start the engine and leave the gear shift lever

set in P position.
7) Accelerate the engine quickly or run it at high
idle, and depress the accelerator pedal of
smoke meter D2 to collect exhaust gas on the
filter paper.
8) Place the contaminated filter paper on the
clean filter paper (at least 10 sheets) in the filter
paper holder and read the indicated value.
engine".
GD535-5 30-23
(01)
Adjusting valve clearance 30 Testing and adjusting
Adjusting valve clearance 1
a Tools for adjusting valve clearance
Sym-
Part No. Part name
bol
1 795-799-1131 Gear
E Commercially
2 Feeler gauge
available
1. Remove hood assembly and air cleaner assembly

(1).
For removal and installation procedure, see
"Removal and installation of engine hood assem-
5. Rotate the crankshaft forward by using gear E1 to
bly" in disassembly and assembly.
align the wide slit (b) (1 place) of the disc for
detecting rotation at the rear of the crankshaft
2. Remove muffler assembly (2).
pulley to the top surface (a) of protruding part of
front cover.
3. Remove cylinder head cover (3).
a Positioning is accepted if the top surface (a) of
the protruding part is within the range of wide
slit (b) when viewed from intake manifold side.
4. Remove plug (4) at the top of the starting motor,

and install gear E1.
k Note that this positioning does not set No. 1

and No. 6 cylinders at their top dead cen-
ters. (They are positioned 76 to 88 degrees
before their top dead centers.)
30-24 GD535-5
(01)
30 Testing and adjusting Adjusting valve clearance
6. Adjust the valve clearance according to the 7. Similarly to step 5, rotate the crankshaft forward
following procedure. one turn by using gear E1 to align the wide slit (b)
a If the rocker arm of exhaust valve (EX side) of to the top surface (a) of the protruding part.
No. 1 cylinder cannot be moved by hand,
adjust the valves marked with Q in the valve 8. Adjust the clearances of the other valves according
arrangement drawing. to steps 6.
q If the rocker arm of exhaust valve (EX side) of a If the valves marked with Q in the valve
No. 1 cylinder can be moved by hand by the arrangement drawing are adjusted in step 4,
distance of the valve clearance, adjust the adjust the rest of the valves marked with q. (If
valves marked with q in the valve arrange- the valves marked with q have been already
ment drawing. adjusted, adjust those marked with Q.)
9. After finishing the adjustment, remove the

adjusting tools, and restore the machine.
k Be sure to remove gear E1.
3 Cylinder head cover mounting bolt:
20 to 28 Nm {2.04 to 2.86 kgm}
1) Insert feeler gauge E2 into the clearance

between rocker arm (5) and crosshead (6).
2) Loosen lock nut (7) and adjust valve clearance
by using adjustment screw (8).
a With feeler gauge inserted, turn the adjust-
ment screw so that the feeler gauge can
move lightly.
engine".
3) Fix adjustment screw (8) and tighten lock nut
(7).
3 Lock nut:
20 to 28 Nm {2.04 to 2.86 kgm}
a After tightening the lock nut, check the
valve clearance again.
GD535-5 30-25
(01)
Testing compression pressure 30 Testing and adjusting
Testing compression pressure 1
a Tools for testing compression pressure
Sym-
Part No. Part name
bol
1 795-799-6700 Puller
2 795-502-1590 Gauge assembly
F
3 795-790-4411 Adapter
4 6754-11-3130 Gasket
k When testing the compression pressure, take

care not to get yourself burned by touching
the exhaust manifold or muffler, or get caught 7. Remove retainer (6), and remove fuel inlet
in a rotating part. connector (7).
a Test the compression pressure with the engine
being warmed up. 8. Remove injector holder (8).
a Perform the testing of the compression pressure
under the following conditions. 9. Remove injector (9).
q Engine oil temperature: 40 to 60°C a Use puller F1 to remove the injector with the
q At cranking (engine speed): impacts of the slide hammer.
250 to 280 rpm (for reference) a Do not pry the top of the injector to remove.
1. Remove cylinder head cover (1).
2. Disconnect clamp (2) of the injector wiring harness

connector and move the wiring harness out of the
way.
3. Disconnect fuel high-pressure tube (3).
4. Loosen injector terminal nuts (4) and remove the

terminals from the injector.
5. Set the cylinder to be checked to the compression

top dead center.
a See "Adjusting valve clearance".
10. Install adapter F3 with gasket F4 fitted at its tip into
6. Remove rocker arm assembly (5). the injector mounting bore.
30-26 GD535-5
(01)
30 Testing and adjusting Testing compression pressure
11. Fix adapter F3 with injector holder (8).

a Tighten mounting bolts of the injector holder
alternately.
3 Injector holder mounting bolt:
8±0.8 Nm {0.8 ± 0.08 kgm}
12. Connect gauge assembly F2 to adapter F3.

a Apply a small amount of engine oil to the con-
tact faces of the adapter and gauge to prevent
air leakage.
13. Install rocker arm assembly (5).

3 Rocker arm assembly mounting bolt:
36 ± 5 Nm {3.67 ± 0.51 kgm}
14. Adjust the valve clearance. 2) Tighten injector holder mounting bolt (10) by
a See "Adjusting valve clearance". approximately 3 to 4 threads.
3) Set fuel inlet connector (7).
a Press it in until you feel the O-ring clicks in.
4) Tighten fuel inlet connector (7) lightly with
retainer (6).
3 Retainer: 15 ± 5.0 Nm {1.5 ± 0.5 kgm}
5) Tighten injector holder mounting bolts (10)
alternately.
3 Holder mounting bolt:
8 ± 0.8 Nm {0.8 ± 0.08 kgm}
6) Tighten retainer (6) of the fuel inlet connector
lightly.
3 Retainer: 50 ± 5 Nm {5.1 ± 0.5 kgm}
15. Select the no-injection cranking mode by operating

the machine monitor.
k Be sure to select the no-injection cranking
mode, otherwise the engine may start dur-
ing measurement creating a dangerous sit-
uation.
16. Measure the compression pressure when the

engine is cranked by the starting motor.
a Read the pressure gauge pointer when it is
stabilized. 7) Tighten the sleeve nuts of fuel high-pressure
a For standard values, see the Standard value pipe (3) in the order of nuts on the head side
table, "Standard value table for engine". and those on the common rail side.
3 Sleeve nut: 35 ± 3.5 Nm {3.6 ± 0.4 kgm}
a Install the injector and fuel high-pressure tube
according to the following procedure.
1) Align protrusion (a) of the injector with notch (b)
of the injector holder, and set the injector to the
cylinder head.
a Set the injector with the mating position fac-
ing the fuel inlet connector insertion side.
GD535-5 30-27
(01)
Testing compression pressure 30 Testing and adjusting
18. After installing the rocker arm assembly, adjust the

valve clearance. For details of the procedure, see
"Adjusting valve clearance".
3 Rocker arm assembly mounting bolt:
36 ± 5 Nm {3.67 ± 0.51 kgm}
19. Install the injector wiring harness.

3 Terminal nut:
1.5 ± 0.25 Nm {0.15 ± 0.025 kgm}
a Check that the injector wiring harness does not
interfere with the rocker arm.
20. Install the cylinder head cover.

3 Head cover mounting nut:
24 ± 4 Nm {2.45 ± 0.41 kgm}
30-28 GD535-5
(01)
30 Testing and adjusting Testing blowby pressure
Testing blowby pressure 1
a Tools for testing blowby pressure
Sym-
Part No. Part name
bol
G 799-201-1506 Blowby checker

stop the engine.
moving. 4. While depressing the brake pedal completely,
a Perform the testing of the boost pressure under operate the gear shift lever to F8 position.
the following conditions.
5. Depress the accelerator pedal gradually, then
measure the boost pressure when the torque
converter stalls with the engine at high idle.
1. Install nozzle [1] of blowby checker G to the tip of a For standard values, see the Standard value
blowby hose (1), and connect it to gauge [2]. table, "Standard value table for engine".
a Normally, the blowby pressure should be mea-
sured while the engine is operated at the rated
horsepower. In the field, however, an approxi-
mate value can be obtained by stalling the
torque converter.
a If rated horsepower operation or torque con-
verter stalling is not possible, measure the
blowby pressure while the engine is running at
high idle. In this case, the measured value of
blowby pressure comes to approximately 80 %
of that obtained at rated horsepower operation.
a Blowby pressure varies greatly with the condi-
tion of the engine. Therefore, if the measured
value obtained by the test is considered
unusual, check for excessive oil consumption,
bad color of exhaust gas, early oil deteriora-
tion, early oil contamination, etc., which are
related to improper blowby pressure.
6. After the test is finished, release the accelerator

pedal to the low idle position immediately, and
return the gear shift lever to P position.
k Do not operate the gear shift lever while the
accelerator pedal is depressed. Otherwise
internal damage may be induced in the
transmission.

2. Start the engine, set the gear shift lever to P posi-
tion, and keep the engine running at low idle.
3. Switch the machine monitor to "T/C Stall" display to

prepare for stalling the torque converter.
GD535-5 30-29
(01)
Testing engine oil pressure 30 Testing and adjusting
Testing engine oil pressure 1
a Tools for testing engine oil pressure
Sym-
Part No. Part name
bol
799-101-5002 Hydraulic tester
1
790-261-1205 Digital hydraulic tester
H
2 799-401-2320 Gauge
3 790-301-1220 Nipple

4. Start the engine and measure the engine oil pres-
sure when the engine is running at low idle and at
high idle.
stop the engine.
table, "Standard value table for engine".
moving.
a Perform the testing of the engine oil pressure
under the following conditions.
1. Open R.H. engine side cover (1).

2. Remove oil pressure pickup plug (2) of the cylinder

block.
3. Install nipple H3 and connect it to gauge H2.
30-30 GD535-5
(01)
30 Testing and adjusting Handling fuel system devices
Handling fuel system devices 1
a Precautions when testing and servicing fuel sys-

tem
The common rail fuel injection system (CRI) con-
sists of more precise parts than the parts used in
the conventional fuel injection pump and nozzle. If
foreign material enters this system, it may cause a
failure.
Use extreme care more strictly than ever to pre-
vent entry of foreign material when servicing the
fuel system. If any dust or other material sticks to
any part, wash the part thoroughly with clean fuel.
a Precautions for replacing fuel filter cartridge
Be sure to use the Komatsu genuine fuel filter car-
tridge.
The common rail fuel injection system (CRI) con-
sists of more precise parts than the parts used in
the conventional fuel injection pump and nozzle.
To prevent the entry of foreign material, this sys-
tem uses a special filter with high-efficiency filter-
ing performance.
Therefore, use of filters other than Komatsu genu-
ine filters can cause a failure in the fuel system.
Be sure not to use filters other than Komatsu gen-
uine ones.
GD535-5 30-31
(01)
Releasing remaining pressure from fuel system 30 Testing and adjusting
Releasing remaining pressure from

fuel system 1
a While the engine is running, pressure is generated

in the low-pressure and high-pressure circuits of
the fuel circuit.
Low-pressure circuit: Between feed pump and fuel
filter, between fuel filter and fuel supply pump
High-pressure circuit: Between fuel supply pump
and common rail, between common rail and fuel
injector
a The pressure in both low-pressure circuit and
high-pressure circuit lowers to a safety level auto-
matically 30 seconds after the engine is stopped.
a Before the fuel circuit is tested and its parts are
removed or installed, the remaining pressure in
the fuel circuit must be released completely.
Accordingly, observe the following.
k Before testing the fuel system or removing/
installing the tools, wait at least 30 seconds
after stopping the engine until the remaining
pressure in the fuel circuit is released. (Do not
start the work immediately after the engine is
stopped since remaining pressure is still in the
circuit.)
30-32 GD535-5
(01)
30 Testing and adjusting Testing fuel pressure
Testing fuel pressure 1
a Tools for testing fuel pressure
Sym-
Part No. Part name
bol
1
J 2 799-401-2320 Gauge
799-101-5220 Nipple
3
07002-11023 O-ring
3. Start the engine, run it at low idle, and measure the
k Park the machine on flat ground, place the fuel pressure.
work equipment on the ground surely, set the a The fuel pressure is normal when it is within
gear shift lever to P (PARK) position, and then the following range.
stop the engine. 0.5 to 1.3 MPa {5.1 to 13.3 kg/cm2}
moving. 4. After finishing the test, remove the testing tools,
a Measure the fuel pressure only in the low-pres- and restore the machine.
sure circuit from the feed pump through the fuel fil- 3 Fuel pressure pickup plug:
ter to the supply pump. 10 ± 2 Nm {1 ± 0.2 kgm}
k Check of the high-pressure circuit from the
supply pump through the common rail to the
injector cannot be performed because
extremely high pressure is generated there.
1. Open the R.H. engine side cover, and remove fuel

pressure pickup plug (1) from the fuel filter.
2. Install nipple J3 and connect it to gauge J2.
GD535-5 30-33
(01)
Bleeding air from fuel circuit 30 Testing and adjusting
Bleeding air from fuel circuit 1
a If fuel is used up or if a fuel circuit component is

removed and installed, bleed air from the fuel cir-
cuit according to the following procedure.
1. Loosen knob (1) of the priming pump and move it

back and forth.
a Move the knob until its motion becomes heavy.

(If the main filter is empty, moving the knob 60
to 70 times bleeds air from the circuit. )
2. Start the engine by cranking it with the starting

motor.
a The air in the high-pressure circuit is bled auto-
matically by cranking the engine.
a If the engine does not start, there still may be
air in the low-pressure circuit. In this case,
repeat from step 2.
30-34 GD535-5
(01)
30 Testing and adjusting Testing fuel circuit for leakage
Testing fuel circuit for leakage 1

stop the engine.
moving.
k Very high pressure is generated in the high-
pressure circuit of the fuel system. If fuel leaks
while the engine is running, it presents a seri-
ous danger such as fire, etc.
a Clean the engine and the parts around it, and
degrease them in advance so that you can check
it easily for fuel leakage.
1. Spray color checker (developer) to the fuel supply

pump, common rail, fuel injectors, and joints of the
high-pressure piping.
2. Start the engine, keep its speed at 1000 rpm or

below, and stop it when the speed is stabilized.
3. Check the fuel piping and devices for fuel leakage.

a Check the high-pressure circuit for fuel leak-
age focusing on the area where the color
checker is sprayed.
a If any fuel leakage is detected, repair it and
perform the checks from step 1 again.
4. Start the engine, and keep it running at low idle.

checker is sprayed.
6. Start the engine, and keep it running at high idle.

checker is sprayed.
8. Start the engine and keep it running at high idle,

and apply a load to the engine.
a Perform blade RAISE relief for right and left.

checker is sprayed.
a If no fuel leakage is detected, this check is
completed.
GD535-5 30-35
(01)
Handling cylinder cutout mode operation 30 Testing and adjusting
Handling cylinder cutout mode

operation 1
a The cylinder cutout mode operation means to run

the engine with the fuel injectors of one or more
cylinders disabled electrically to reduce the num-
ber of active cylinders. The purposes and effects
of this operation are as follows.
1. This operation is used to find out a cylinder which

does not output power normally (or, combustion in
it is abnormal).
2. When a cylinder is selected for the cylinder cutout

mode operation, if the engine speed and output do
not change from the normal operation (all-cylinder
operation), that cylinder has a failure.
q The possible failures are as follows.
q Compression gas leakage from cylinder
head gasket area
q Defective injection
q Defective piston, piston ring or cylinder
liner
q Defective valve mechanism (valve operat-
ing system)
q Defective electrical system
3. The injector of each cylinder is separately

controlled electronically in the common rail fuel
injection system, so the cylinder cutout test can be
performed more easily by the simple operations of
the switches compared with the mechanical fuel
injection system. So, the defective cylinder can be
found out easily.
a Cylinder cutout mode operation is set in the
service mode of the machine monitor.
For details, see "Diagnostic Tests (Cylinder
Cut-out)" of "Special functions of machine
monitor".
30-36 GD535-5
(01)
30 Testing and adjusting Handling no-injection cranking operation
Handling no-injection cranking

operation 1
a No-injection cranking operation means to crank

the engine by using the starting motor while dis-
abling injection in every cylinder electrically. The
purpose and effect of this operation are as follows.
a No-injection cranking is performed to lubricate the
engine parts and to protect them from seizure. It is
performed before the engine is started after the
machine or engine has been stored for a long
period.
a No-injection cranking operation is set in the ser-
vice mode of the machine monitor.
For details, see "No Injection" of "Special functions
of machine monitor".
GD535-5 30-37
(01)
Handling voltage circuit of engine controller 30 Testing and adjusting
Handling voltage circuit of engine

controller 1
1. Be sure to turn the starting switch to OFF position

before disconnecting or connecting the connectors
between the engine controller and engine.
2. When you perform troubleshooting, do not start the

engine while a T-adapter is inserted into or
connected to the connector between the engine
controller and engine.
a You may turn the starting switch to OFF or ON
position but must not turn it to START position.
30-38 GD535-5
(01)
30 Testing and adjusting Testing muffler (main body) and stacked muffler for looseness and damage
Testing muffler (main body) and

stacked muffler for looseness and
damage 1
1. Visually check the muffler and stacked muffler for

cracks and damage. If damage is found on them,
replace it with new one.
2. Check the mounting bolts and nuts of the muffler

and stacked muffler for looseness. If any part is
loosened, retighten it.
GD535-5 30-39
(01)
Testing muffler function 30 Testing and adjusting
Testing muffler function 1
q Check for an unusual noise or abnormal noise

compared to that when the machine was new. If
an unusual noise is heard, make repairs.
30-40 GD535-5
(01)
30 Testing and adjusting Testing installed condition of cylinder heads and manifolds
Testing installed condition of

cylinder heads and manifolds 1
Check the mounting state of the cylinder head and

intake and exhaust manifolds. If any part is loosened,
retighten it.
a For the tightening torques, see the "Disassembly
and assembly".
GD535-5 30-41
(01)
Testing of engine piping for damage and looseness 30 Testing and adjusting
Testing of engine piping for

damage and looseness 1
Intake and exhaust system: Check the piping for dam-

age, mounting bolts and nuts for looseness, and the
joints for air suction and exhaust gas leakage. If any
part is loosened or damaged, retighten or repair it.
Cooling system: Check the piping for damage, mount-

ing bolts and nuts for looseness, and the joints for
water leakage. If any part is loosened or damaged,
retighten or repair it.
Fuel system: Check the piping for damage, mounting

bolts and nuts for looseness, and the joints for fuel
leakage. If any part is loosened or damaged, retighten
or repair it.
30-42 GD535-5
(01)
30 Testing and adjusting Testing fuel discharge, return rate, and leakage
Testing fuel discharge, return rate,

and leakage 1
a Tools for testing fuel discharge, return and leak-

age
Sym-
Part No. Part name
bol
1 795-790-4700 Tester kit
6754-71-5340 Connector
3
6754-71-5350 Washer
Commercially
4 Measuring cylinder
available
Z 3) Crank the engine for 30 seconds and measure
Commercially
5 Stopwatch the discharge by using measuring cylinder Z4.
available
a Arrange the route of the test hose so that it
Commercially does not sag, and put its end in a container.
6 Hose (inside diameter: 14 mm)
available a To protect the starting motor, do not con-
Commercially tinue cranking for more than 30 seconds
7 Hose (inside diameter: 8 mm) except for this test.
available
a When the supply pump discharge is in the
following standard range, it is normal.
a Prepare a container of approximately 20 l to
receive fuel that leaks out during the testing. At cranking (125 rpm) Min. 75 cc
At cranking (150 rpm) Min. 90 cc
1. Testing supply pump discharge
1) Loosen clamp (2) of tube (1) on the discharge
side of the supply pump and disconnect tube
(1) .

3 Sleeve nut of tube:
2) Connect test hose Z6 to the nipple on the 35 ± 4 Nm {3.6 ± 0.4 kgm}
discharge side of the supply pump. 3 Clamp mounting bolt:
a Clamp the hose with a wire, etc. so that the 10 ± 2 Nm {1.0 ± 0.2 kgm}
hose is not disconnected.
does not sag, and put its end in a container.
GD535-5 30-43
(01)
Testing fuel discharge, return rate, and leakage 30 Testing and adjusting
2. Testing supply pump return rate 4) Start the engine, run it at low idle, and measure
1) Disconnect return hose (3) of the supply pump. the fuel return rate of the supply pump for 25
seconds by using measuring cylinder Z4.
a When the return rate from the supply pump is
in the following standard range, it is normal.
At low idle 400 cc
2) Install connector Z3 and cap nut [1] of tester kit

Z1 to the return hose to prevent the fuel from
flowing out.
3) Connect test hose [2] of tester kit Z1 to the
supply pump.
does not sag, and put its end in a container. 5) After finishing the test, remove the testing tools,
3. Testing leakage from pressure limiter

1) Disconnect return hose (4) from the pressure
limiter.
a Leave the seal washer fitted to the connec-
tor bolt.
2) Install the removed connector bolt and cap nut

[1] of tester kit Z1 to the return hose side to
prevent the fuel from flowing out.
3) Install connector Z3 to the common rail side
and connect test hose [2] of tester kit Z1 to the
connector.
does not sag, and put its end in a container.
30-44 GD535-5
(01)
30 Testing and adjusting Testing fuel discharge, return rate, and leakage
4. Testing fuel return rate from injector

1) Disconnect return hose (6) from the cylinder
head.
a Leave the seal washer fitted to the connec-
tor bolt side.
4) Start the engine, run it at low idle, and measure

the fuel leakage rate for 1 minute by using
measuring cylinder Z4.
a When the leakage from the pressure limiter
is in the following standard range, it is nor-
mal. 2) Install connector Z3 to the cylinder head rail,
0 cc connect test hose [2] of tester kit Z1 to the
At low idle connector, and put its end in a container.
(No leakage)
3) Install removed connector bolt (7) and cap nut
[1] of tester kit Z1 to block the return hose so
that fuel does not flow out.
4) Start the engine, run it at low idle, and measure
the return rate from the injector for 1 minute by
using measuring cylinder Z4.
a When the return rate from the injector is in
the following standard range, it is normal.
At low idle Max. 180 cc/min
At cranking Max. 90 cc/min

3 Joint bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm}
k If the engine cannot be started, you may

perform the measurement while rotating
the engine by using the starting motor.
However, to protect the starting motor,
do not rotate the engine for more than 20
seconds continuously.
GD535-5 30-45
(01)
Testing fuel discharge, return rate, and leakage 30 Testing and adjusting

3 Joint bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm}
30-46 GD535-5
(01)
30 Testing and adjusting Testing and adjusting air conditioner compressor belt tension
Testing and adjusting air

conditioner compressor belt
tension 1
k Stop the machine on a level ground, lower the

work equipment to the ground, set the gear
shift lever to PARKING (P) position, and then
stop the engine.
k Chock the tires up to prevent the machine
from moving.
For testing and adjusting of the tension of air condi-
tioner compressor belt to perform troubleshooting,
Pm Clinic, or periodic maintenance, refer to this sec-
tion.
Testing
a If the driving belt slackens, air is not cooled well.
1. Press the middle point between drive pulley (A)
and compressor pulley (B) with a finger (approxi-
mately 98.1 Nm {10.0 kgm}). Adjust the belt so that
the slack (C) is 11 to 14.5 mm (8 to 11 mm if it is a
new belt).
a When it is a new belt, elongation is expected in
the initial period of use. Be sure to make an
adjustment in a few days after the replace- 3. Loosen nut (5), then tighten bolt (6).
ment. a Compressor (3) moves in direction (A), and the
2. Check each pulley for breakage and wear of the V- compressor belt is tensed.
groove and check the V-belts for wear. 4. Adjust the compressor belt tension properly.
a In particular, check carefully that the V-belt is 5. Tighten nut (5) until it hits boss (7).
not in contact with the V-groove bottom. a Tighten nut (5) further in direction (B) so that it
is not loosened.
3 Nut (5): 245 to 309 Nm {25.0 to 31.5 kgm}
6. Tighten bolts (1) and (2), and fix bracket (4).
3 Bolts (1) and (2):
98.1 to 123 Nm {10 to 12.5 kgm}
Adjusting
1. Open the engine side cover on the right side of the
machine.
2. Loosen bolts (1) and (2).
a When the bolts (1) and (2) are loosened,
bracket (4) to which compressor (3) is installed
can move, using the mounting position of bolt
(2) as a fulcrum.
GD535-5 30-47
(01)
Testing and adjusting air conditioner compressor belt tension 30 Testing and adjusting
a Check each pulley for damage, wear of the V-

groove, and the wear of the V-belt. In particular, be
sure to check that the V-belt is not touching the
bottom of the V-groove.
a Replace the belt with a new one if the belt is
stretched and has no allowance for adjustment, or
has slipping sound or squeak because of cuts or
cracks of the belt.
a When the new V-belt is installed, readjust it after
operating for 1 hour.
a When adjusting the V-belt, do not push the com-
pressor directly with the bar. Use the wrench.
30-48 GD535-5
(01)
30 Testing and adjusting Checking and replacing alternator belt
Checking and replacing alternator 5. Check the alternator belt (3).

belt 1
a Replace the alternator belt (3) in the following
cases.
a Testing tools q The alternator belt has a vertical scratch
(b) which crosses the horizontal scratch
Sym-
Part No. Part name (a).
bol
q The alternator belt has tears (c).
Commercially Need not to be replaced if it has only a horizon-
AA Wrench
available tal scratch (d).
a Possible causes of the damage on the belt
k Park the machine on flat ground, set the gear Improper tension has been applied.
shift lever to the P position, and lower the work Part whose size or length is wrong has been
equipment to the ground. used.
k Stop the engine and chock the wheels. q Pulley is out of the position.
k Disconnect the cable from the negative (-) ter- q Pulley is damaged.
minal of the battery. q Auto-tensioner is damaged.
a When replacing the alternator belt, remove the air q Installation state is improper.
conditioner compressor belt beforehand. q Severe operating environment
a The auto-tensioner is provided for the alternator q Oil and grease are attached to the side of
belt. Thus, checking and adjusting the belt is usu- the belt.
ally not necessary. a If the belt is obviously worn, there is a possibil-
ity that the auto-tensioner is also worn and the
Testing surface of the pulley is rough.
1. Open cover (1a). In that case, the newly replaced belt may be
2. Remove cover (1b). worn early if the pulley is continuously used.
Therefore, replacement of the belt and auto-
tensioner as a set is recommended.
3. Remove cover (2a).

4. Remove cover (2b).
GD535-5 30-49
(01)
Checking and replacing alternator belt 30 Testing and adjusting
Replacing
1. Install the wrench (AA) to the (g) part (width
across flats: 12.7 mm) of the auto-tensioner (4).
a Check that the wrench (AA) is securely
installed. If the wrench (AA) is loosely installed
and rotated, it can accidentally come off and
this is extremely dangerous because the
spring force of the auto-tensioner (4) is strong.
2. Turn the wrench (AA) in the direction of the
arrow, and loosen the tension of the alternator
belt (3).
7. After installing the alternator belt (3), return the

auto-tensioner (4) slowly and carefully.
3. Remove the alternator belt (3).

a Be careful not to get your fingers caught
between the pulley and alternator belt (3)
during work.
4. After removing the alternator belt (3), return the
auto-tensioner (4) slowly and carefully. 8. Check that the groove of the alternator belt (3)
fits in the each pulley groove (5) without any dis-
placement.
5. Install the wrench (AA) to the (g) part (width

a Check that the wrench (AA) is securely
installed. If the wrench (AA) is loosely
installed and rotated, it can accidentally
come off and this is extremely dangerous
because the spring force of the auto-ten-
sioner (4) is strong.
6. Turn the wrench (AA) in the direction of the
arrow, and install the alternator belt (3).
during work.
30-50 GD535-5
(01)
30 Testing and adjusting Checking and replacing auto-tensioner
Checking and replacing auto-tensioner 1
a Testing tools 5. Check that there is no crack on the arm (a), pul-
ley (b), arm stop part (c), and spring case stop
Sym- parts (d) and (e) of the auto-tensioner (4).
Part No. Part name
bol
a Replace the auto-tensioner (3) if there is any
Commercially crack or damage.
AB Wrench
available 6. Check with the alternator belt installed that the
arm stop part (c) of the auto-tensioner does not
k Park the machine on flat ground, set the gear contact with the spring case stop parts (d) or (e).
shift lever to the P position, and lower the work a Replace the alternator belt if the arm stop
equipment to the ground. part (c) contacts with the spring case stop
k Stop the engine and chock the wheels. parts (d) or (e).
k Disconnect the cable from the negative (-) ter-
minal of the battery.
a When replacing the alternator belt, remove the air
conditioner compressor belt beforehand.
a The auto-tensioner is provided for the alternator
belt. Thus, checking and adjusting the belt is usu-
ally not necessary.
Testing
1. Open cover (1a).
3. Remove cover (2a).

7. Install the wrench (AB) to the (g) part (width

a Check that the wrench (AB) is securely
installed. If the wrench (AB) is loosely
installed and rotated, it can accidentally
come off and this is extremely dangerous
because the spring force of the auto-ten-
sioner (4) is strong.
GD535-5 30-51
(01)
Checking and replacing auto-tensioner 30 Testing and adjusting
8. Turn the wrench (AB) in the direction of the arrow,

and loosen the tension of the alternator belt (3).
9. Remove the alternator belt (3).

during work.
10. After removing the alternator belt (3), return the
auto-tensioner (4) slowly and carefully.
11. Check that the arm stop part (c) of the auto-ten-
sioner (4) does contact with the spring case stop
part (e).
a Replace the auto-tensioner (4) if it does not.
12. Check that the arm (a) of the auto-tensioner (4) is
not moved by hand.
a Replace the auto-tensioner (4) if the arm (a)
is moved by hand.
13. Check that the arm stop part (c) contacts with the
spring case stop part (d) by using the wrench
(AB).
a If the arm stop part (c) does not contact with
the spring case stop part (d), replace the
auto-tensioner (4).
a The auto-tensioner (4) is not needed to be
replaced if there is no abnormality in steps
11, 12, and 13.
30-52 GD535-5
(01)
30 Testing and adjusting Checking and replacing auto-tensioner
Replacing
1. Remove the bolt (5), and remove the auto-ten-
sioner (4).
2. Set the dowel pin (6) of the new auto-tensioner

(4) to be aligned with the groove (7) of the cylin-
der block.
3. Install the bolt (5).

3 Bolt (5) :43 ± 6 Nm {4.4 ± 0.6 kgm}
GD535-5 30-53
(01)
Testing power train oil pressure 30 Testing and adjusting
Power train 1
Testing power train oil pressure 1
a Tools for testing power train oil pressure

Sym-
Part No. Part name
bol
1
2 799-401-2320 Gauge
K 799-101-5220 Nipple
3
07002-11023 O-ring
Commercially
4 Block
available

stop the engine.
moving.
a Check this testing under the following conditions.
q Transmission oil temperature: 60 to 80°C
a The following figure shows the measuring positions of each oil pressure on the transmission.
30-54 GD535-5
(01)
30 Testing and adjusting Testing power train oil pressure
a Oil pressure to be measured and measuring range a Combination of gear speed and clutch used
of oil pressure gauge
Operating clutch pack No.
Oil pressure
No FL FH R 1st 2nd 3rd 4th
Oil pressure to be measured gauge
.
(MPa {kg/cm2}) F1 q q
1 Main relief pressure of power train 6.0 {60} F2 q q
2 Torque converter inlet pressure 2.5 {25} F3 q q
3 Torque converter outlet pressure 1.0 {10} F4 q q
Torque converter lockup clutch F5 q q
4 6.0 {60}
pressure
q q
Gear speed
F6
5 Transmission FL clutch pressure 6.0 {60}
F7 q q
6 Transmission FH clutch pressure 6.0 {60}
F8 q q
7 Transmission R clutch pressure 6.0 {60}
N
8 Transmission 1st clutch pressure 6.0 {60}
R1 q q
9 Transmission 2nd clutch pressure 6.0 {60}
R2 q q
10 Transmission 3rd clutch pressure 6.0 {60}
R3 q q
11 Transmission 4th clutch pressure 6.0 {60}
R4 q q
<Reference> Gear shift lever and transmission gear

speed
q To protect the transmission, for gear shifting
among forward gears, the machine has a function
to prevent transmission gear shift from skipping 2
gear speeds even when the gear shift lever is
operated by skipping 2 gear speeds.
For gear shifting among reverse gears, there is a
function to prevent transmission gear shift from
skipping one gear speed even when the gear shift
lever is operated by skipping one gear speed.
a) Example of gear shift lever operation: F1 - > F4
b) Operation of transmission: F1 -> F3 -> F4
q The transmission shifts directly to the target gear
speed only when the gear shift lever is operated
from N position to the target gear speed (F1 to
F4).
a) Example of gear shift lever operation: N - > F4
b) Operation of transmission: N -> F4
GD535-5 30-55
(01)
Preparatory work (preparation for running wheel Testing method

idle off ground) Testing main relief pressure of power train
k Install or remove testing tools while the engine
a Among measurement items of oil pressure, when is stopped.
measuring the lockup clutch pressure of the 1. Remove cover (1) on the right side of the machine.
torque converter and each clutch pressure of the
transmission, raise the rear wheels off the ground
according to the following procedure to prepare for
running the wheels idle off ground.
a When operating the gear shift lever with wheels
running idle off ground, restrict the engine speed
to 1,300 rpm or below. When the gear shift lever is
positioned in F5 to F8, R3, and R4 in "T/C AUTO"
mode or R3 and R4 in "MANUAL" mode, the
transmission shifts automatically. So, be sure not
to increase the engine speed to 1,300 rpm and
above when running wheel idle off ground.
1. Chock the right and left front wheels backward and

2. Connect gauge K2 to pickup nipple (2) for the
forward to prevent the machine from moving.
power train main relief pressure.
q For the position of the pickup plug, see "mea-
2. Start the engine, and operate the right and left
suring positions of each oil pressure" above.
blade lift cylinder control levers to lower the blade
a Use a 6-MPa {60-kg/cm2} gauge for gauge K2.
horizontally to the ground.
3. Operate the left blade lift cylinder control lever in

LOWER direction to raise the left rear wheel off the
ground, and install a block or stand under the left
tandem case.
4. Operate the right blade lift cylinder control lever in

LOWER direction to raise the right rear wheel off
the ground, and install a block or stand under the
right tandem case.
5. Raise the blade off the ground to check that the

rear wheels are completely off the ground, and
lower the blade to the ground again and stop the
engine.
k After raising the rear wheels off the ground,
install safety poles to keep people away
from the tires.
3. Start the engine and hold the gear shift lever at P

position to increase the torque converter oil
temperature to 60 to 80°C.
30-56 GD535-5
(01)
4. While holding the gear shift lever, measure the Testing torque converter inlet pressure
power train main relief pressure when the acceler- k Install or remove testing tools while the engine
ator pedal is not depressed (at low idle) and when is stopped.
the engine is running at the rated speed (2000 1. Remove cover (1) on the right side of the machine.
rpm).
a Use "RPM set switch" to set the engine rated
speed. For "RPM set switch", see the Opera-
tion and Maintenance Manual.
table, "Standard value table for machine".
5. After finishing the measurement, remove the

testing tools, and restore the machine.
2. Connect gauge K2 to oil pressure pickup nipple (3)

for the torque converter inlet pressure.
a Use a 2.5-MPa {25-kg/cm2} gauge for gauge K2.

4. While holding the gear shift lever, measure the

torque converter inlet pressure with the engine
running at the rated speed (2,000 rpm).
GD535-5 30-57
(01)
a For standard values, see the Standard value Torque converter outlet pressure
table, "Standard value table for machine". k Install or remove testing tools while the engine
is stopped.
5. After finishing the measurement, remove the 1. Remove cover (4) on the left side of the machine.
2. Remove pickup plug (5) for the torque converter

outlet pressure.
3. Install nipple K3 and connect gauge K2 to it.

a Use a 1-MPa {10 kg/cm2} gauge for gauge K2.

5. While holding the gear shift lever, measure the

torque converter outlet pressure with the engine
running at the rated speed (2,000 rpm).
30-58 GD535-5
(01)
a For standard values, see the Standard value Testing torque converter lockup clutch pressure
table, "Standard value table for machine". (L/C)
6. After finishing the measurement, remove the is stopped.
testing tools, and restore the machine. 1. Remove covers (6) above the transmission valve.
2. Remove pickup plug (7) of the lockup clutch valve

(ECMV).
3. Install nipple K3 and connect gauge K2 to it.

a Use a 6-MPa {60 kg/cm2} gauge for gauge K2.

5. Set the transmission mode selector switch to

MANUAL mode.
GD535-5 30-59
(01)
Testing transmission FL clutch pressure

is stopped.
1. Remove covers (8) above the transmission valve.
6. Operate the gear shift lever to run the rear wheels

idle.
k Before starting the engine, check that the
rear wheels are completely off ground.
k Check that the engine side cover is closed 2. Remove pickup plug (9) of FL clutch valve (ECMV).
before running the rear wheels idle off
ground. 3. Install nipple K3 and connect gauge K2 to it.
k If the brake pedal is depressed with the rear a Use a 6-MPa {60 kg/cm2} gauge for gauge K2.
wheels running, the tandem may turn due to
the reaction force of the brake. So, do not
depress the brake pedal strongly.
a Be sure to operate the gear shift lever while
the engine is running at 1,300 rpm or below.
a In MANUAL mode, because the drive mode
changes to the torque converter drive mode
just before the engine stops, do not depress
the brake pedal.
a The gear shift lever may be in any position
other than N or R1 through R4.
7. Run the rear wheels idle with the engine running at

the rated speed (2,000 rpm), and measure the
lockup clutch pressure.



MANUAL mode.
30-60 GD535-5
(01)
Testing transmission FH clutch pressure

is stopped.
6. Operate the gear shift lever to F1 position to run

the rear wheels idle.
rear wheels are completely raised off
ground. 2. Remove pickup plug (10) of FH clutch valve
k Check that the engine side cover is closed (ECMV).
k If the brake pedal is depressed with the rear a Use a 6-MPa {60 kg/cm2} gauge for gauge K2.
the brake pedal.
7. Run the rear wheels idle off ground with the engine
running at the rated speed (2,000 rpm), and
measure the FL clutch pressure.



MANUAL mode.
GD535-5 30-61
(01)
Testing transmission R clutch pressure (R)

is stopped.

rear wheels are completely off the ground.
k Check that the engine side cover is closed 2. Remove pickup plug (11) of R clutch valve
before running the rear wheels idle off (ECMV).
ground.
k If the brake pedal is depressed with the rear 3. Install nipple K3 and connect gauge K2 to it.
wheels running, the tandem may turn due to q Use a 6-MPa {60 kg/cm2} gauge for gauge K2.
the brake pedal.
7. Run the rear wheels idle off ground with the engine
running at the rated speed (2,000 rpm), and
measure the FH clutch pressure.



MANUAL mode.
30-62 GD535-5
(01)
Testing transmission 1st clutch pressure

is stopped.
6. Operate the gear shift lever to R1 position to run

k Check that the engine side cover is closed 2. Remove pickup plug (12) of the 1st clutch valve
ground.
the brake pedal.

the rated speed (2,000 rpm), and measure the R
clutch pressure.



MANUAL mode.
GD535-5 30-63
(01)
Testing transmission 2nd clutch pressure

is stopped.

rear wheels are completely raised off
ground. 2. Remove pickup plug (13) of 2nd clutch valve
k Check that the engine side cover is closed (ECMV).
k If the brake pedal is depressed with the rear q Use a 6-MPa {60 kg/cm2} gauge for gauge K2.
the brake pedal.

the rated speed (2,000 rpm), and measure the 1st
clutch pressure.



MANUAL mode.
30-64 GD535-5
(01)
Testing transmission 3rd clutch pressure

is stopped.

k Check that the engine side cover is closed 2. Remove pickup plug (14) of 3rd clutch valve
ground.
the brake pedal.

the rated speed (2,000 rpm), and measure the 2nd
clutch pressure.



MANUAL mode.
GD535-5 30-65
(01)
Testing transmission 4th clutch pressure

is stopped.

k Check that the engine side cover is closed 2. Remove pickup plug (15) of 4th clutch valve
ground.
the brake pedal.

the rated speed (2000 rpm), and measure the 3rd
clutch pressure.



MANUAL mode.
30-66 GD535-5
(01)

k Check that the engine side cover is closed
ground.
k If the brake pedal is depressed with the rear
the brake pedal.

the rated speed (2000 rpm), and measure the 4th
clutch pressure.

GD535-5 30-67
(01)
Adjusting transmission speed sensor 30 Testing and adjusting
Adjusting transmission speed

sensor 1

stop the engine.
moving.
a If a transmission speed sensor is removed and
installed or the transmission is disassembled and
assembled, adjust each of the speed sensors
a The following figure shows the installed position of each speed sensor on the transmission.
1. Transmission input shaft speed sensor (connector: 3. Transmission output shaft speed sensor
TM20) (connector: TM22)
2. Intermediate shaft speed sensor (connector: TM21)
30-68 GD535-5
(01)
30 Testing and adjusting Adjusting transmission speed sensor
Adjustment method Adjusting intermediate shaft speed sensor

Adjusting transmission input shaft speed sensor 1. Remove intermediate shaft speed sensor (2) to
1. Remove transmission input shaft speed sensor (1) check there is no adherence of iron particles or the
to check there is no adherence of iron particles or scratches on its tip. Then reinstall the sensor
scratches on its tip. Then reinstall the sensor temporarily to its original position.
temporarily to its original position. 2 Sensor threaded part:
2 Sensor threaded part: Liquid gasket (LG-5)
Liquid gasket (LG-5) 2. Tighten it until the end of sensor (2) lightly touches
2. Tighten it until the end of sensor (1) lightly touches tooth tip of gear (6).
tooth tip of gear (4). 3. Loosen sensor (2) from the current position by a
3. Loosen sensor (1) from the current position by a half to 1 turn.
half to 1 turn. a Clearance (b) of 0.75 to 1.5 mm is made
a Clearance (a) of 0.75 to 1.5 mm is made between the sensor end and gear tooth tip.
between the sensor end and gear tooth tip. a Adjust the installation angle of sensor (2) so
a Adjust the installation angle of sensor (1) so that the harness is in installation angle adjust-
that the harness is in installation angle adjustment range (e).
ment range (d). Installation angle adjustment range (e): 180
Installation angle adjustment range (d): 180 deg.
deg. a Adjust lead wire (10) so that it will not be
a Adjust lead wire (10) so that it will not be stretched too tight.
stretched too tight. 4. With sensor (2) fixed, tighten nut (7).
4. With sensor (1) fixed, tighten nut (5). 3 Nut (7): 49.0 to 68.6 Nm {5 to 7 kgm}
3 Nut (5): 49.0 to 68.6 Nm {5 to 7 kgm}
GD535-5 30-69
(01)
Adjusting transmission speed sensor 30 Testing and adjusting
Adjusting transmission output shaft speed sensor Checking sensor input signal
1. Remove transmission output shaft speed sensor Check that the signal from each speed sensor is
(3) to check there is no adherence of iron particles inputted normally by using the "Monitoring" function of
or scratches on its tip. Then reinstall the sensor the machine monitor.
temporarily to its original position. a For the operating method, see "Special functions
2 Sensor threaded part: of machine monitor".
Liquid gasket (LG-5) q Monitoring code: 31200 "T/M input shaft speed"
2. Tighten it until the end of sensor (3) lightly touches q Monitoring code: 31300 "T/M intermediate shaft
tooth tip of gear (8). speed"
3. Loosen sensor (3) from the current position by a q Monitoring code: 31400 "T/M output shaft speed"
half to 1 turn. k You cannot check the speed of other shafts
a Clearance (c) of 0.75 to 1.5 mm is made than the input shaft unless actually driving the
between the sensor end and gear tooth tip. machine or running wheels idle off ground.
a Adjust the installation angle of sensor (3) so a For the method for running wheel idle off ground,
that the harness is in installation angle adjust- see "Testing power train oil pressure".
ment range (f).
Installation angle adjustment range (f): 180
deg.
a Adjust lead wire (10) so that it will not be
stretched too tight.
4. With sensor (3) fixed, tighten nut (9).
3 Nut (9): 49.0 to 68.6 Nm {5 to 7 kgm}
30-70 GD535-5
(01)
30 Testing and adjusting Retrieval of disabled machine due to transmission valve failure
Retrieval of disabled machine due

to transmission valve failure 1
a Testing tools
Sym-
Part No. Part name
bol
1 794-423-1190 Plug
L
2 07002-22034 O-ring

stop the engine.
moving.
k Use this clutch engaging method only when
the machine is disabled due to a failure of
transmission valve (ECMV). Be sure to restore
the machine immediately after the machine is
moved.
a If the machine does not move because of failure of
the clutch valve (ECMV) of the transmission,
move the machine by engaging the transmission
clutch according to the following procedure.
a The following figure shows the installed positions of the clutch valves (ECMV) on the transmission.
GD535-5 30-71
(01)
Retrieval of disabled machine due to transmission valve failure 30 Testing and adjusting
Retrieving method a Travel direction and clutch to be engaged

1. Remove covers (6) and (8) above the transmission
valve, and clean the periphery of the clutch valve. Directional Gear speed
Gear speed
clutch clutch
a Remove mud and dirt completely so that for-
eign materials do not enter the clutch valve When traveling
FL 2nd F3
during operation. forward
When traveling
R 2nd R2
reverse
a Because the lockup clutch of the torque con-

verter is not engaged, the torque converter is
in the torque converter drive mode regardless
of the selection of the transmission mode
selector switch.
4. Install plug L1 to the mounting bore of the solenoid.

a Clean the plug and check that the O-ring is fit-
ted so that no foreign material enters before
installation.
2. Disconnect 8 connectors on the solenoid side of a Tighten the plug until the stepped portion of the
the torque converter and transmission clutch valve. plug touches the valve body even though it
k All the connectors need to be disconnected may become slightly heavy because the plug
so that the clutch does not engage unex- pushes the internal spool spring.
pectedly during traveling. 3 Plug L1: 49.0 ± 5.0 Nm {5.0 ± 0.5 kgm}
a Solenoid connector No.

q TM4: FL clutch
q TM2: FH clutch
q TM13: R clutch
q TM11: 1st clutch
q TM6: 2nd clutch
q TM8: 3rd clutch
q TM15: 4th clutch
q TM16: Lockup clutch
3. Remove 2 solenoids (1) of the clutch valve to be

engaged.
a Remove the solenoid by turning the solenoid
main body at the hexagonal part (width across
5. Remove the chocks and start the engine.
k When the engine is started, the transmis-
flats: 33 mm).
sion is left engaged at F3 or R2. If the gear
shift lever is moved from P position unnec-
essarily, the parking brake is released and
the machine moves off.
30-72 GD535-5
(01)
30 Testing and adjusting Retrieval of disabled machine due to transmission valve failure
6. Operate the gear shift lever to N position while

depressing the brake pedal, and release the brake
pedal gradually to move the machine to a safe
place.
a If you cannot release the parking brake, see
"Parking brake manual releasing procedure".
k After moving the machine, return the gear
shift lever to P position, stop the engine,
and chock the tires.
7. After the operation is finished, restore the clutch

valve immediately.
GD535-5 30-73
(01)
Flushing procedure for torque converter and transmission circuits 30 Testing and adjusting
Flushing procedure for torque 2. Replacing transmission oil filter

converter and transmission circuits 1 1) Open cover (4) on the left side of the machine.

stop the engine.
moving.
a Dust such as metal powder, etc. in the hydraulic
circuits of the torque converter and transmission
shortens the life of the torque converter and trans-
mission and causes internal breakage.
To remove dust in the hydraulic circuit, perform
flushing according to the following procedure.
a Perform flushing in the following cases. 2) Loosen center bolt (5), and remove filter case
q When metal powder flows into the circuit (6).
because of damage to the torque converter, 3) Install a new filter case (6) again for flushing.
transmission and hydraulic components. a Filter case (6) is integrated with an ele-
q When the torque converter and transmission ment.
are overhauled or modified.
Flushing procedures
1. Draining oil from transmission case
Drain the oil from the transmission case if any oil
is remaining.
1) Loosen drain plug (1) and then loosen drain
plug (2) to drain the oil.
6 Transmission case:
45 l (refill capacity)
a After draining is complete, tighten the drain
plug.
3 Drain plug (1):
58.8 to 78.4 Nm {6.0 to 8.0 kgm}
3 Drain plug (2): 3. Refilling transmission case with oil
49.0 to 78.4 Nm {5.0 to 8.0 kgm} 1) Refill the transmission case with new oil to the
specified level from oil filler port (7).
2) Loosen drain plug (3) to drain the remaining oil. 6 Transmission case: 45 l
a After draining is complete, tighten the drain 2) Start the engine to circulate the oil through the
plug. system. Then, check the oil level again.
3 Drain plug (3):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
30-74 GD535-5
(01)
30 Testing and adjusting Flushing procedure for torque converter and transmission circuits
4. Flushing
1) Start the engine, and run it for approximately 20
minutes for warm-up without depressing the
accelerator pedal (at low idle).
a Increase the engine speed to approxi-
mately 1,500 rpm occasionally.
a If the engine coolant temperature gauge
does not rise to the operating range (green
range) because of low ambient tempera-
ture, continue the operation further.
2) Drive the machine or run the drive wheels idle
off ground for approximately 20 minutes.
a For the method for running the wheels idle
off ground, see "Testing power train oil
7. Checking oil level of transmission case
pressure".
Start the engine to circulate the oil through the
a Use all the gear speeds of F1 through F8
system. Then, check the oil level again.
and R1 through R4.
3) Repeat the same operation as step 1 for
approximately 20 minutes.
5. Replacing transmission oil filter

Replace the filter case of the transmission oil filter
with a new one in the same procedure as step 2.
a The filter case is integrated with an element.
6. Replacing transmission last chance filter

1) Turn and remove filter case (8), and remove
element (9).
2) Replace element (9) with a new one, and install

filter case (8).
a Clean the filter case if there is any dust or
the like inside.
a Apply a small amount of grease on the out-
side perimeter of the O-ring.
3 Filter case (8):
34.3 to 44.1 Nm {3.5 to 4.5 kgm}
GD535-5 30-75
(01)
Testing and adjusting toe-in 30 Testing and adjusting
Testing and adjusting toe-in 1 6. Stop the machine when the mark is positioned at a
height equal to that between road surface and the
center of the axle.
If the front axle is disassembled and assembled, or Be sure to perform this operation while moving the
straight-travel stability is low, test and adjust toe-in machine forward.
Testing
Adjust toe-in so that a sideslip tester reads 0.
If the sideslip tester is unavailable, adjust it according
to the following procedure.
1. Park the machine on a flat road surface with the
steering and leaning controls set at their center
positions.
When parking the machine, be sure to move it
forward several meters and then stop it.
2. Measure height (h) from the road surface to the

center of the front axle.
7. Measure the distance between the two marks put
on both tires.
Let this dimension be (B).
When the value of (B) - (A) is -5 ± 1 mm, the toe-
in meets the standard. The sideslip tester reads 0
in this case.
If the value is out of this range, perform the
following adjustment
3. Put a mark on the tire at the nearly center of the tire

width and at a height equal to the dimension
obtained in step 2.
Put the mark on both tires in a similar manner.
4. Measure the distance between the two marks put

on both tires.
Let this dimension be (A).
5. Move the machine forward slowly so that the mark

put on the tire is positioned at the back.
30-76 GD535-5
(01)
30 Testing and adjusting Testing and adjusting toe-in
Adjusting
a When adjusting it, keep the front axle horizontal
and set leaning angle to 0.
1. Loosen clamp nuts (1), apply a wrench to square
part (2) of the tie rod, and then turn tie rods on both
sides to adjust toe-in.
Turning th em in the dir ection of the arr ow
increases toe-in and turning in the opposite direc-
tion reduces toe-in.
For the extension amount, turning both tie rods 1/3
turn in the extension direction extends them by 6
mm.
2. After the adjustment, tighten clamp nuts (1).
GD535-5 30-77
(01)
Testing and adjusting differential lock oil pressure (differential lock specification) 30 Testing and adjusting
Testing and adjusting differential

lock oil pressure (differential lock
specification) 1
a Tools for testing and adjusting differential lock oil

pressure
Sym-
Part No. Part name
bol
1
2 799-401-2320 Gauge
M 790-301-1271 Joint
3 4) Start the engine and set the differential lock
07002-11023 O-ring switch to ON position.
4 799-401-3200 Adapter
5 791T-601-2220 Elbow

stop the engine.
moving.
a Perform testing and adjusting of differential lock oil
pressure under the following conditions.
q Final drive case oil temperature: 60 to 80°C
a When the differential lock is activated, the

Testing
differential lock pilot lamp lights up.
1. Testing differential lock pump discharge pres-
sure 5) Measure the differential lock pump discharge
pressure with the engine running at high idle.
1) Disconnect differential lock valve hose (1) on
the inlet side.
machine".
2. Testing differential lock valve outlet pressure

1) Remove oil pressure pickup plug (2) on the
outlet side of the differential lock valve.
2) Install adapter M4 and connect disconnected

hose (1) again.
3) Install nipple [1] of hydraulic tester M1 and
connect gauge M2 to it.
a Use a 6-MPa {60-kg/cm2} gauge.
30-78 GD535-5
(01)
30 Testing and adjusting Testing and adjusting differential lock oil pressure (differential lock specification)
2) Install joint M3, elbow M5, and nipple [1] of Adjusting

hydraulic tester M1, and connect gauge M2 to Adjusting differential lock oil pressure
it. a If both the differential lock pump discharge pres-
a Use a 6-MPa {60 kg/cm2} gauge. sure and valve outlet pressure are not normal,
adjust differential lock relief valve (3) according to
the following procedure.
1. Loosen lock nut (5) with adjustment screw (4)

fixed.
2. Turn adjustment screw (4) to adjust the oil pres-

sure.
a Rotate the adjustment screw:
q clockwise to increase the pressure.
q counterclockwise to decrease the pres-
sure.
a Quantity of pressure adjustment per turn of
adjustment screw (4): 3.7 MPa {37.8 kg/
3) Start the engine and set the differential lock cm2}
switch to ON position.
3. Tighten lock nut (5) with adjustment screw (4)
fixed.
3 Lock nut (5): 10 to 15 Nm {1.0 to 1.5 kgm}
a When the differential lock is activated, the

differential lock pilot lamp lights up.
4) Measure the differential lock valve outlet pres-
sure with the engine running at high idle. 4. After the adjustment, check that the pump
a For standard values, see the Standard discharge pressure and valve outlet pressure are
value table, "Standard value table for normal referring to "Testing".
machine".
GD535-5 30-79
(01)
Testing and adjusting steering oil pressure 30 Testing and adjusting
Steering system 1
2. Install nipple [1] of hydraulic tester N1 and connect
gauge [2] to it.
Testing and adjusting steering oil a Use a 40-MPa {400-kg/cm2} gauge.
pressure 1
3. Start the engine and operate the steering cylinder
to the stroke end.
a Tools for testing and adjusting steering oil pres-
sure 4. While running the engine at high idle, relieve the
Sym- steering cylinder and measure the oil pressure.
Part No. Part name a For standard values, see the Standard value
bol
1
N
790-301-1271 Joint
2
07002-11023 O-ring

stop the engine.
moving.
a Perform the testing and adjusting of the steering
oil pressure under the following conditions.
Testing and restore the machine.
1. Remove steering oil pressure pickup plugs (1) or
(2), and install joint N2. Adjusting
a You cannot adjust the steering oil pressure (the
relief valve of the priority valve).
30-80 GD535-5
(01)
30 Testing and adjusting Testing oil leakage of steering cylinder
Testing oil leakage of steering 5. After finishing the measurement, restore the
cylinder 1
machine.
a Tools for testing oil leakage of steering cylinder

Sym-
Part No. Part name
bol
Commercially
P Measuring cylinder
available

stop the engine.
moving.
a Perform the testing and adjusting of the steering
oil pressure under the following conditions.
1. Start the engine, and extend the cylinder to

measure to the stroke end.
2. Disconnect hose (1) on the cylinder head side and

block the hose by using a plug.
k Be careful not to disconnect the hose on the
cylinder bottom side.
a Use the following parts to block the hose.
07376-70422 (Plug #04)
3. Start the engine, run it at high idle, and relieve the

steering cylinder.
k Operate the cylinder to measure to exten-
sion side to relieve it hydraulically. Be care-
ful not to operate it to the opposite
direction.
4. Measure the amount of oil leakage by using

measuring cylinder P for a minute after a lapse of
30 seconds from starting relief.
GD535-5 30-81
(01)
Bleeding air from steering circuit 30 Testing and adjusting
Bleeding air from steering circuit 1
a If the steering cylinder has been removed and

installed or its cylinder piping has been discon-
nected and connected, bleed air according to the
following procedure.
a While bleeding air, make sure that the oil level in
the hydraulic tank does not decrease below the
specified level.
1. While running the engine at low idle, extend and

retract the cylinder 4 to 5 times.
k Stop the piston rod at approximately 50 mm
before stroke end to avoid relieving.
2. While running the engine at low idle, move the

piston rod to the stroke end to relieve the circuit.
30-82 GD535-5
(01)
30 Testing and adjusting Releasing remaining pressure from brake circuit
Brake system 1
Releasing remaining pressure from

brake circuit 1

stop the engine.
moving.
k High pressure in the accumulator is normally
applied to the circuit from the charge valve,
through accumulator to brake valve as well as
parking brake valve of the brake circuit. Before
disconnecting or connecting piping, or remov-
ing or installing tools, release the remaining
pressure according to the following proce-
dures.
k The pressurized oil in the accumulator is
applied to the circuit between the brake valve
and wheel brake only when the brake pedal is
depressed.
k The pressurized oil in the accumulator is
applied to the circuit between the parking
brake valve and parking brake only when the
gear shift lever is operated to a position other
than P with the starting switch set to ON posi-
tion.
1. Depress and release the brake pedal repeatedly

until no brake operation sound is heard.
2. When there is no brake operation sound, depress

and release the brake pedal repeatedly for several
tens of times.
a Bleeding of remaining pressure is complete. To

check if there is no remaining pressure, discon-
nect pipings slowly.
GD535-5 30-83
(01)
Testing and adjusting brake oil pressure 30 Testing and adjusting
Testing and adjusting brake oil 3) Remove oil pressure pickup plug (2) of the
pressure 1
charge valve.
a Tools for testing and adjusting brake oil pressure

Sym-
Part No. Part name
bol
1
2 793-520-1805 Brake test kit
Q 3 799-401-3100 Adapter
790-301-1271 Joint
4
07002-11023 O-ring
5 791T-601-2220 Elbow 4) Install joint Q4 and elbow Q5, and then connect
gauge [2] of hydraulic tester Q1 to it.
stop the engine.
moving.
a Perform the testing and adjusting of the brake oil
pressure under the following conditions.
Testing
1. Measuring charge valve cut-in pressure and
cut-out pressure
1) Release the remaining pressure in the wheel
brake circuit. For details, see "Releasing
remaining pressure from wheel brake circuit".
k Do not perform measurement prepara-
tion without releasing the remaining
pressure because high pressure is accu-
mulated in the accumulator.
2) Open the cover on the right side of the machine
and remove cover (1).
5) Start the engine and run it at low idle to accu-

mulate pressure in the accumulator.
a Run the engine at low idle for further 1 to 2
minutes because the pressure is below the
cut-in pressure when the brake oil pressure
caution lamp of the machine monitor goes
out.
6) Measure the cut-in pressure with the engine
running at high idle.
1] Repeat depressing and releasing of the
brake pedal to gradually decrease the oil
pressure in the accumulator.
30-84 GD535-5
(01)
30 Testing and adjusting Testing and adjusting brake oil pressure
2] Measure the oil pressure at the time that the

pointer of gauge [2] turns from descent to
ascent.
machine".
7) Measure the cut-out pressure with the engine
running at high idle.
1] Stop the brake pedal operation when the oil
pressure starts rising from the cut-in pres-
sure.
2] Measure the oil pressure at the time that the
pointer of gauge [2] stops rising.
a For standard values, see the Standard 5) Measure the operating pressure of the wheel
value table, "Standard value table for brake.
machine". 1] Run the engine at low idle for several
8) After finishing the test, remove the testing tools, minutes to accumulate pressure in the
and restore the machine. accumulator, and stop the engine.
2] Measure the operating pressure when the
2. Testing wheel brake operating pressure and
brake pedal is depressed to the stroke end.
amount of pressure drop
k Do not operate the brake pedal when install-
ing or removing the testing tools because
machine".
high pressure is accumulated in the accu-
mulator. 6) Measure the drop in the wheel brake operating
a Test the front, rear, right, and left brakes pressure.
according to the same procedure. a Check that the operating pressure of the
wheel brake is normal before measure-
1) Release the remaining pressure in the wheel
ment.
brake circuit. For details, see "Releasing
remaining pressure from wheel brake circuit". 1] Run the engine at low idle for several
2) Remove the brake piping cover of the tandem minutes to accumulate pressure in the
case, and remove air bleeder (1). accumulator, and stop the engine.
2] Depress the brake pedal to the stroke end
and wait for 1 minute. Then, measure the
pressure drop in 5 minutes.
a Keep on depressing the brake pedal for
5 minutes.
machine".
k After removing the testing tools, make
sure to bleed air from the wheel brake
circuit.
3) Install brake test kit Q2.

4) Bleed air from the wheel brake circuit. For
details, see "Bleeding air from brake circuit".
a Use the air bleeder of brake test kit Q2 for
bleeding air.
GD535-5 30-85
(01)
Testing and adjusting brake oil pressure 30 Testing and adjusting
3. Testing parking brake operating pressure k After removing the testing tools, make
k Do not operate the gear shift lever to a posi- sure to bleed air from the parking brake
tion other than P position when installing or circuit.
removing the testing tools because high
pressure is accumulated in the accumula- Adjusting
tor. Adjusting charge valve cut-out pressure
1) Release the remaining pressure in the wheel a If the cut-out pressure of the charge valve is not
brake circuit. For details, see "Releasing normal, adjust relief valve (R2) of the charge valve
remaining pressure from wheel brake circuit". according to the following procedure.
2) Disconnect hose (1) of the parking brake cali- a The cut-out pressure varies according to adjust-
pers. ment of relief valve (R2).
3) Install adapter Q3 and connect the discon- 1. Loosen lock nut (1) with adjustment screw (2)
nected hose again. fixed.
4) Install nipple [1] of hydraulic tester Q1 and
2. Turn adjustment screw (2) to adjust oil pressure.
connect gauge [2] to it.
a Rotate the adjustment screw:
q clockwise to increase the pressure.
q counterclockwise to decrease the pres-
sure.
a Quantity of pressure adjustment per turn of
adjustment screw:
2.49 MPa {25.4 kg/cm2}
3. Tighten lock nut (1) with adjustment screw (2)

fixed.
3 Lock nut: 11.8 to 16.7 Nm {1.2 to 1.7 kgm}
4. After the adjustment, be sure to test the charge

valve cut-in pressure and cut-out pressure again.
For details, see "Testing".
5) Run the engine at low idle for several minutes

to accumulate pressure in the accumulator.
6) While running the engine at low idle, depress
the brake pedal to the stroke end and hold it
there surely.
7) Move the gear shift lever to N position and
measure the oil pressure at that moment.
machine".
30-86 GD535-5
(01)
30 Testing and adjusting Bleeding air from brake circuit
Bleeding air from brake circuit 1 2. Bleeding air from parking brake circuit
1) Connect air bleeding hose [1] to air bleeder (2)
k Park
of the parking brake calipers.
the machine on flat ground, place the
stop the engine.
moving.
a When brake circuit equipment is removed or
installed, bleed air from the brake circuit according
1. Bleeding air from wheel brake part of wheel

brake circuit
a Bleed air from the front, rear, right, and left
brakes according to the same procedure.
1) Remove the brake piping cover of the tandem 2) Start the engine, and run it at low idle.
case, and install air bleeding hose [1] to air 3) Set the gear shift lever to N position, and hold it
bleeder (1). there.
4) Loosen air bleeder (2) by approximately 1/2
turn to drain oil mixed with air.
5) When oil without air starts to flow out, tighten air
bleeder (2).
3 Air bleeder:
22.6 to 28.3 Nm {2.3 to 2.9 kgm}
(Target: 25.5 Nm {2.6 kgm})
6) After bleeding air, restore the machine.
2) Start the engine, and run it at low idle.

3) Depress the brake pedal to the stroke end, and
keep it.
4) Loosen air bleeder (1) by approximately 1/2
turn to drain oil mixed with air.
5) When oil without air starts to flow out, tighten air
bleeder (1).
6) After bleeding air, restore the machine.
GD535-5 30-87
(01)
Testing wear of wheel brake disc 30 Testing and adjusting
Testing wear of wheel brake disc 1
a Tools for testing wear of wheel brake disc
Sym-
Part No. Part name
bol
Commercially
R Vernier calipers
available
k Park the machine on a flat ground, place the

stop the engine.
k Chock the tires to prevent the machine from Restore the machine after finishing the test.
moving. 3 Cap (1): 29.4 to 39.2 Nm {3 to 4 kgm}
a Each wheel brake has a testing gauge. Be sure to
perform the check at the 4 places in a similar man-
ner.
1. Remove cap (1).

a Do not loosen nut (3) on the tandem case side
because it is for fixing the wear gauge.
2. Start the engine.
3. Run the engine for several minutes without

depressing the accelerator pedal (at low idle) to
accumulate pressure in the accumulator, and stop
the engine.
4. Depress the brake pedal to the stroke end, and

keep it for a while.
5. Push in shaft (2) of the wear gauge to the tandem

case, and measure protrusion (a).
a If protrusion (a) comes to 0 mm, the brake disc
has reached its wear limit. Replace it with a
new one in this case.
For standard values, see Standard value table,
"Standard value table for machine".
30-88 GD535-5
(01)
30 Testing and adjusting Testing and adjusting parking brake pad
Testing and adjusting parking

brake pad 1
a Tools for testing and adjusting parking brake pad

Sym-
Part No. Part name
bol
1 792-454-1100 Pump assembly
2 792-454-1120 Valve
3 792-454-1110 Pump
4 790-425-1240 Nipple
5 416-62-11480 O-ring
S
6 790-612-5110 Adapter
7 790-190-2310 Hose
Commercially
8 Hose
available
Commercially
9 Oil container
available

stop the engine.
moving.
k Take extra care to prevent adhesion of oil and
grease to the surface of brake pads and discs.
Testing wear of parking brake pad
GD535-5 30-89
(01)
Testing and adjusting parking brake pad 30 Testing and adjusting
Measuring pad thickness

Measure thicknesses (a) and (b) of pad (1) with the
engine stopped.
For standard values, see "Standard value table for
machine" of Standard value table.
Measuring pad clearance

2. Run the engine for several minutes without
depressing the accelerator pedal (at low idle) to
accumulate pressure in the accumulator.
3. Depress the brake pedal to the stroke end, and
keep it there.
4. Move the gear shift lever to N position and hold it
there, and then measure clearances (c) and (d)
between pad (1) and disc (2).
For standard values, see Standard value table,
"Standard value table for machine".
Adjusting parking brake pad clearance

When the parking brake does not work properly or the pad is replaced with a new one, the clearance must be
adjusted.
30-90 GD535-5
(01)
30 Testing and adjusting Testing and adjusting parking brake pad
1. Disconnect hose (13) from the parking brake cali- 12. Tighten bolt (8) until it touches urethane spring
pers. (10), and then tighten it further by 1/2 turn.
2. Remove nipple (14) from the parking brake cali- 13. Tighten lock nut (7) to mount bracket side.
pers. 3 Lock nut (7):
242 to 302 Nm {24.7 to 30.8 kgm}
14. Loosen adjustment bolt (9) and adjust the clear-
ances between front and rear pads (1) and disc (2).
a The adjusted clearance value is 1.5 to 1.8 mm
for the total of clearances (c) and (d).
15. With the tip of bolt (6) touching bracket (11), adjust
clearances (c) and (d) between front and rear pads
(1) and disc (2) to make the clearances equal by
using double nut (5), and secure double nut (5).
3 Double nut (5):
24.1 to 30.1 Nm {2.46 to 3.07 kgm}
16. Secure adjustment bolt (9) with lock nut (4).
3 Lock nut (4):
102.8 to 128.2 Nm {10.5 to 13.1 kgm}
3. Install nipple S4 to the parking brake calipers, and 17. Measure clearances (c) and (d) between front and
connect adapter S6 and hose S7 to it. rear pads (1) and disc (2).
a When installing nipple S4, be sure to install O- 18. Operate pump S3 to release the pressure.
ring S5. 19. Check that the clearances (c) and (d) between
4. Connect hose S7 to valve S2 in pump assembly front and rear pads (1) and disc (2) come to 0.
S1. 20. Install cover plug (3).
5. Connect hose S8 to air bleeder (12) and put the 3 Cover plug (3):
other end of hose S8 into oil container S9. 59.0 to 128.2 Nm {10.5 to 13.1 kgm}
After finishing the adjustment, remove the tools used,

k After connecting hose (13) to the parking
brake calipers, be sure to bleed air from the
parking brake circuit. For details, see "Bleed-
ing air from brake circuit".
6. Operate pump S3 to raise the pressure up to 8.2

MPa.
7. Loosen air bleeder (12) by approximately 1/2 turn
to drain oil mixed with air.
8. When oil without air starts to flow out, tighten air
bleeder (12).
3 Air bleeder (12):
22.6 to 28.3 Nm {2.3 to 2.9 kgm}
9. Remove cover plug (3) and loosen lock nut (4).
10. Release the fixed brake calipers once according to
1) Loosen double nut (5), and loosen bolt (6) by
approximately 5 turns.
2) Loosen lock nut (7), and loosen bolt (8) by
approximately 3 turns.
a Move lock nuts (5) and (7) to bracket (11)
side.
11. Tighten adjustment bolt (9) until front and rear pads
(1) touch disc (2).
GD535-5 30-91
(01)
Releasing parking brake manually 30 Testing and adjusting
Releasing parking brake manually 1
k If a failure occurs in the hydraulic system, the

wheel brake probably does not work normally.
So, after releasing the parking brake manually,
tow and move the machine at a low speed.
k Park the machine on flat ground and confirm
the safety of its surrounding area before start-
ing manual releasing operations of the parking
brake. When it is forced to release the parking
brake on a slope, chock the tires positively.
gear shift lever to P (PARK) position, and then 4. Tow the machine at a low speed to a safe place.
stop the engine. k After moving the machine, be sure to chock
When the parking brake cannot be released due to a the tires.
failure in its electrical or hydraulic system, refer to the Restore the machine after finishing the work.
procedure shown in this section so that you can 3 Lock nut (3):
release the brake manually and move the machine. 102.8 to 128.2 Nm {10.5 to 13.1 kgm}
3 Cover plug (2):
Parking brake manual releasing procedure 59.0 to 73.5 Nm {6.0 to 7.5 kgm}
1. Remove cover plug (2) from parking brake calipers
(1).
2. Loosen lock nut (3), and turn adjustment bolt (4)

counterclockwise.
3. Check that there are clearances (c) and (d)

between front and rear pads (5) and disc (6) .
30-92 GD535-5
(01)
30 Testing and adjusting Charging brake accumulator with gas
Charging brake accumulator with 3. Installing charging tool T

gas 1
1) Remove plug (1) of the accumulator and
remove the cap of valve (2).
a Tools for charging brake accumulator with gas
Sym-
Part No. Part name
bol
T 792-610-1702 Charging tool
a When the gas in the brake accumulator is

released or gas pressure drops, charge the accu-
mulator with nitrogen gas according to the follow-
ing procedure.
1. Releasing remaining pressure from brake

circuit
1) Release the remaining pressure in the brake 2) Screw in charging tool T into valve (2) of the
circuit. For details, see "Releasing remaining accumulator.
pressure from brake circuit". 3) Connect hose [3] to charging tool T and
a This operation is not required when charg- nitrogen gas cylinder (3).
ing an independent accumulator with gas.
2. Preparing charging tool T

1) Turn handle [1] counterclockwise until it stops.
2) Turn handle [2] counterclockwise until it stops.
3) Check that the connection parts of charging
tool T are tightened completely.
GD535-5 30-93
(01)
Charging brake accumulator with gas 30 Testing and adjusting
4. Charging with nitrogen gas

1) Slightly open the valve of the nitrogen gas
cylinder to discharge nitrogen gas at extremely
low pressure, and gas starts to come out of
handle [2]. Turn handle [2] clockwise to stop
discharge of the gas.
a Operate the valve of the nitrogen gas cylin-
der gradually and slowly.
a Discharge start pressure:
Approximately 0.2 to 0.3 MPa {2 to 3 kg/cm2}
2) Turn handle [1] clockwise slowly so that it
presses valve (2) of the accumulator.
3) Open the valve of the nitrogen gas cylinder
gradually to charge the accumulator with
nitrogen gas.
a Close the valve of the nitrogen gas cylinder
occasionally, and check the indicated value
when the pointer of pressure gauge [4] of
the charging tool is stabilized.
4) After charging the accumulator with nitrogen
gas at the specified pressure, make sure to
close the valve of the nitrogen gas cylinder.
q Charge pressure:
3.4 ± 0.1 MPa {35 ±1 kg/cm2} (at 20 ± 5°C)
q Charge amount: 3.75 l (for reference)
a The relation between the charge pressure
of nitrogen gas and gas temperature (≈
ambient temperature) is as follows.
Px = 35 x (273 + t) / (273 + 20)
(Px: Charge pressure [kg/cm2], t: Gas tem-
perature [°C])
a If the accumulator is charged with nitrogen
gas at a higher pressure, turn handle [2]
counterclockwise gradually to release gas.
5) Turn handle [1] counterclockwise fully to close
valve (2), and turn handle [2] counterclockwise
to release the nitrogen gas in charging tool T.
5. Removing charging tool T

1) Remove charging tool T from the accumulator
and nitrogen gas cylinder.
2) Apply water or soap water on valve (2) to check
for gas leakage, and install the cap and cover
(1) of valve (2).
6. Checking after gas charge

q For approximately 1 week after gas charge,
check if the charge pressure is maintained by
using charging tool T.
q After that, check the pressure once per month
or once per 6 months depending on the operat-
ing conditions.
q Charged gas decreases slightly and the pres-
sure drops during a pressure check. Supply
gas accordingly.
30-94 GD535-5
(01)
30 Testing and adjusting Testing work equipment oil pressure
Hydraulic system 1
3. Install joint U3, and then install elbow U2.
Testing work equipment oil
pressure 1
a Tools for testing work equipment oil pressure

Sym-
Part No. Part name
bol
1
U 2 790-301-1530 Elbow
790-301-1271 Joint
3
07002-11023 O-ring 4. Install nipple [1] of hydraulic tester U1 and connect
gauge [2] to it.
k Park the machine on flat ground, place the a Use a 40-MPa {400-kg/cm2} gauge.
stop the engine.
moving.
a Perform the testing of the work equipment oil pres-
sure under the following conditions.
Testing
1. Remove cover (1) on the right side of the machine.
5. Testing work equipment circuit relief pressure

(cylinder)
1) Start the engine and operate the cylinder to
measure to the stroke end.
2) While running the engine at high idle, relieve
the cylinder and measure the oil pressure.
a The pressure at the time when the main
relief valve of the control valve is relieved is
displayed.
2. Remove work equipment pump pressure pickup
plug (2).
machine".
6. Testing work equipment circuit relief pressure

(motor)
1) Start the engine and make the blade dig into the
ground without fail.
2) While running the engine at high idle, relieve
the circle rotation motor and measure the oil
pressure.
a The pressure at the time when the main
relief valve of the control valve is relieved is
displayed.
GD535-5 30-95
(01)
Testing work equipment oil pressure 30 Testing and adjusting

machine".
7. Work after finishing the testing

After finishing the test, remove the testing tools,
30-96 GD535-5
(01)
30 Testing and adjusting Testing lifter lock pin circuit pressure
Testing lifter lock pin circuit

pressure 1
a Tools for testing lifter lock pin circuit pressure

Sym-
Part No. Part name
bol
1
V 790-261-1205 Digital hydraulic tester
2 799-401-3100 Adapter (size: 02)

work equipment on the ground surely, set the 5. Start the engine, run it at high idle, and measure
gear shift lever to P (PARK) position, and then the oil pressure at the time that the lifter lock pin
stop the engine. switch is operated.
moving.
a Measure the lifter lock pin circuit oil pressure
under the following condition.
1. Release the remaining pressure in the brake

circuit. For details, see "Releasing remaining pres-
sure from brake circuit".
k Do not perform measurement preparation
without releasing the remaining pressure
because the pressurized oil in the brake ac-
cumulator is acting on the lifter lock pin cir-
cuit even when the starting switch is turned
to OFF position. a The lifter lock pin circuit pressure is normal if
conditions shown in the following table are
2. Remove hoses (1) and (2) from the lifter lock pin. met.
a Measure the pressure in the head side and
Lifter lock pin
bottom side simultaneously because the lifter Lifter lock pin circuit pressure
pilot lamp
lock pin operates by the pressure difference
between the head side and bottom side. Pressure of both sides is equal to
When lamp is the parking brake operating
OFF pressure. (See Standard value
table.)
Bottom side: Pressure lower than
the head side pressure
When lamp is
Head side: Almost equal to or
ON
lower than the parking brake
operating pressure
3. Install adapter V2 and connect the disconnected

hose again.
4. Install nipple [1] of hydraulic tester V1 and connect

gauge [2] to it.
GD535-5 30-97
(01)
Testing lifter lock pin circuit pressure 30 Testing and adjusting

30-98 GD535-5
(01)
30 Testing and adjusting Testing cooling fan speed
Testing cooling fan speed 1
k Stop the machine on a level ground, lower the

stop the engine.
from moving.
a Check this item under the following conditions.
Maximum fan speed of cooling fan
Fan 100% speed adjustment mode
Minimum fan speed of cooling fan
q Satisfy all of the following temperature condi-
tions for the engine coolant temperature and 4. Depress the accelerator pedal to the full stroke
each oil temperature. (high idle) position, and check “Radiator Fan
Engine coolant temperature: Max. 80 °C Speed”.
Hydraulic oil temperature: Max. 70 °C a For standard values, see STANDARD VALUE
Torque converter oil temperature: Max. 85 °C TABLE, “STANDARD VALUE TABLE FOR
a For checking cooling fan speed to perform trouble- MACHINE”.
shooting, Pm Clinic, or periodic maintenance,
refer to this section. Method for testing minimum cooling fan speed
Method for testing cooling fan speed 2. Select the next monitoring item, and display it. For
Method for testing maximum cooling fan speed details, see “SET AND OPERATE MACHINE
1. Start the engine. MONITOR”.
2. Select the power mode by the power mode q Monitoring code: 04107 “Coolant Temperature”
selector switch. q Monitoring code: 04401 “Hydraulic Oil Temper-
If you select P mode, power mode display A lights ature”
up on the machine monitor. q Monitoring code: 30100 “T/C Oil Temperature”
q Monitoring code: 10009 “Radiator Fan Speed”
3. Select “Fan 100% Speed Adjustment” and select

the fan 100% speed adjustment mode. For details, 3. Check that the engine coolant temperature and
see “SET AND OPERATE MACHINE MONITOR”. each oil temperature are in the range of test condi-
a When “1” is displayed in (a), the fan 100% tion.
speed adjustment mode is enabled. 4. Check “Radiator Fan Speed” when the acceler-
a The set mode is disabled when the screen is ator pedal is not depressed (low idle).
returned to “Adjustment” screen by pressing a For standard values, see STANDARD VALUE
F3. TABLE, “STANDARD VALUE TABLE FOR
MACHINE”.
GD535-5 30-99
(01)
Testing cooling fan circuit oil pressure 30 Testing and adjusting
Testing cooling fan circuit oil 3. Disconnect hose (2).

pressure 1
a Tools for testing cooling fan pump circuit oil pres-

sure
Sym-
Part No. Part name
bol
- 799-101-5002 Hydraulic tester
1 799-101-5120 Gauge
2 790-261-1205 Digital hydraulic tester
W
3 799-401-3400 Adapter
4 799-101-5220 Nipple
4. Install adapter W3 and connect disconnected hose
5 07002-11023 O-ring (2) again.
5. Install nipple W4, and connect it to gauge W1 of
k Stop the machine on a level ground, lower the hydraulic tester W.
stop the engine.
from moving.
a Check this item under the following conditions.
“Fan 100% speed adjustment” mode
a For checking of cooling fan circuit pressure to per-
form troubleshooting or Pm Clinic, refer to this
section.
Method for testing cooling fan circuit oil pressure

1. Remove the radiator grille.
2. Remove cover (1).
a Gauge in digital hydraulic tester W2 can also

be used in place of gauge W1.

7. Select “Fan 100% Speed Adjustment” and select
the fan 100% speed adjustment mode. For details,
see “SET AND OPERATE MACHINE MONITOR”.
a When “1” is displayed in (a), the fan 100%
speed adjustment mode is enabled.
a The set mode is disabled when the screen is
returned to “Adjustment” screen by pressing
F3.
30-100 GD535-5
(01)
30 Testing and adjusting Testing cooling fan circuit oil pressure
8. Measure the oil pressure while depressing the

accelerator pedal to the full stroke position (high
idle).
For standard values, see STANDARD VALUE
TABLE, “STANDARD VALUE TABLE FOR
MACHINE”.
After finishing the test, remove the testing tools and

restore the machine.
GD535-5 30-101
(01)
Testing oil leakage of work equipment cylinder 30 Testing and adjusting
Testing oil leakage of work 6) After finishing the adjustment, restore the
equipment cylinder 1
machine.
2. Testing oil leakage of drawbar side shift

a Tools for testing oil leakage of work equipment cyl- cylinder
inder 1) Start the engine, and operate the drawbar side
Sym- shift control lever to the right shifting side to
Part No. Part name
bol extend drawbar side shift cylinder (2) to the
Commercially stroke end.
Y Measuring cylinder 2) Disconnect hose (3) on the cylinder head side
available
and block the hose by using a plug.
k Be careful not to disconnect the hose on
the cylinder bottom side.
a Use the following parts to block the hose.
07376-70315 (Plug #03)
stop the engine.
moving.
a Perform testing of oil leakage of work equipment
cylinder under the following conditions.
1. Testing oil leakage of blade lift cylinder

1) Start the engine, and operate the right and left
blade lift cylinder control levers to LOWER side
to lower the blade horizontally to the ground.
2) Disconnect the connection of the tip of the rod
and drawbar of the cylinder to check, and
extend the cylinder to the stroke end.
3) Disconnect head side hose (1) of the cylinder to
check and block the hose by using a plug 3) Start the engine, run it at high idle, and relieve
k Be careful not to disconnect the hose on the cylinder in Drawbar RIGHT shift operation.
the cylinder bottom side. k Be careful not to operate the lever to
a Use the following parts to block the hose. "Drawbar LEFT shift" side.
07376-70315 (Plug #03) 4) Measure the amount of oil leakage by using
measuring cylinder Y for a minute after a lapse
of 30 seconds from starting relief.
5) After finishing the adjustment, restore the
machine.
4) Start the engine, run it at high idle, and relieve

the cylinder in Blade LOWER operation.
k Be careful not to operate the lever to
"Blade RAISE" side.
5) Measure the amount of oil leakage by using
measuring cylinder Y for a minute after a lapse
of 30 seconds from starting relief.
30-102 GD535-5
(01)
30 Testing and adjusting Testing oil leakage of work equipment cylinder
3. Testing oil leakage of blade side shift cylinder 4. Testing oil leakage of power tilt cylinder [power
1) Start the engine, and operate the blade side tilt specification]
shift control lever to the left shifting side to 1) Start the engine, and operate the power tilt
extend blade side shift cylinder (4) to the stroke control lever to the large cutting angle side to
end. extend power tilt cylinder (6) to the stroke end.
2) Remove the cylinder cover (left), disconnect 2) Disconnect head side hose (7) from the
head side hose (5) from the cylinder and block cylinder and block the hose by using a plug.
the hose by using a plug. k Be careful not to disconnect the hose on
k Be careful not to disconnect the hose on the cylinder bottom side.
the cylinder bottom side. a Use the following parts to block the hose.
a Use the following parts to block the hose. 07376-70315 (Plug #03)
07376-70315 (Plug #03)
3) Start the engine, run it at high idle, and relieve

3) Start the engine, run it at high idle, and relieve the cylinder in Power tilt cutting angle LARGE
the cylinder in Blade LEFT shift operation. operation.
k Be careful not to operate the lever to k Be careful not to operate the lever to
"Blade RIGHT shift" side. "Power tilt cutting angle SMALL" side.
4) Measure the amount of oil leakage by using 4) Measure the amount of oil leakage by using
measuring cylinder Y for a minute after a lapse measuring cylinder Y for a minute after a lapse
of 30 seconds from starting relief. of 30 seconds from starting relief.
5) After finishing the adjustment, restore the 5) After finishing the adjustment, restore the
machine. machine.
GD535-5 30-103
(01)
Testing oil leakage of work equipment cylinder 30 Testing and adjusting
5. Testing oil leakage of articulate cylinder 6. Testing oil leakage of leaning cylinder
1) Start the engine, and operate the articulate 1) Start the engine, and operate the leaning
control lever to extend articulate cylinder (8) to control lever to the right leaning side to extend
check to the stroke end. leaning cylinder (10) to the stroke end.
2) Disconnect head side hose (9) of the cylinder to 2) Disconnect head side hose (11) from the
check and block the hose by using a plug cylinder and block the hose by using a plug.
k Be careful not to disconnect the hose on k Be careful not to disconnect the hose on
the cylinder bottom side. the cylinder bottom side.
a Use the following parts to block the hose. a Use the following parts to block the hose.
07376-70315 (Plug #03) 07376-70315 (Plug #03)
3) Start the engine, run it at high idle, and relieve 3) Start the engine, run it at high idle, and relieve
the cylinder in Cylinder EXTEND operation. the cylinder in Cylinder EXTEND operation.
k Be careful not to operate the lever to k Be careful not to operate the lever to
"Cylinder Retract" side. "Leaning LEFT" side.

4) Measure the amount of oil leakage by using 4) Measure the amount of oil leakage by using
measuring cylinder Y for a minute after a lapse measuring cylinder Y for a minute after a lapse
of 30 seconds from starting relief. of 30 seconds from starting relief.
5) After finishing the adjustment, restore the 5) After finishing the adjustment, restore the
machine. machine.
30-104 GD535-5
(01)
30 Testing and adjusting Bleeding air from work equipment circuit
Bleeding air from work equipment

circuit 1

stop the engine.
moving.
Bleeding air from hydraulic cylinder

a If the cylinder has been removed and installed or
its cylinder piping has been disconnected and
connected, bleed air according to the following
procedure.
a While bleeding air, make sure that the oil level in
the hydraulic tank does not decrease below the
specified level.
1. While running the engine at low idle, extend and
retract the cylinder 4 to 5 times.
k Stop the piston rod at approximately 50 mm
before the stroke end to avoid relieving.
2. While running the engine at low idle, move the

piston rod to the stroke end to relieve the cylinder.
GD535-5 30-105
(01)
Adjusting drawbar ball joint clearance 30 Testing and adjusting
Work equipment 1
Adjusting drawbar ball joint

clearance 1

stop the engine.
moving.
a After replacing the parts related to drawbar ball
joint, or if the drawbar does not move smoothly,
adjust the drawbar ball joint clearance according
1. Temporarily install ball joint (1) and holder (2) to

frame (3) with nut (4) without inserting any shim.
a Tighten 4 nuts (4) to the following torque.
3 Mounting nut:
58.8 to 73.6 Nm {6 to 7.5 kgm}
2. Measure clearance (a) of the nut (4) tightening part

at 4 locations, and calculate the average value.
3. Select the number of shims to insert based on the

average value of clearance (a).
q Shim pack thickness (mm): Average value of
clearance (a) + thickness of 2 shims
q Available shims: 0.3 mm
4. Remove holder (2) and ball joint (1) from frame (3)
once.
5. Fit selected shims and apply grease to ball joint (1)

and holder (2), and install them to frame (3).
3 Mounting nut:
785 to 980 Nm {80 to 100 kgm}
6. Check that ball joint (1) can move smoothly.

a No unusual noise due to backlash must be
heard.
30-106 GD535-5
(01)
30 Testing and adjusting Testing and adjusting circle guide clearance
Testing and adjusting circle guide

clearance 1
k If the following conditions occur after adjust-

ment, replace the circle guide.
q When there is no longer clearance (R) between
the circle and circle guide
q When the clearance between the tip of the gear
teeth (or tooth bottom) of the circle gear and the
tooth bottom (or tip of the gear teeth) of the pinion
of the circle rotator is 0.
Testing
1. Measuring vertical clearance
q With the blade suspended, measure clearance
(P) between the upper surface of the circle and
lower surface of the drawbar as shown in the
figure.
Standard clearance (P): 1.0 to 2.0 mm
2. Measuring longitudinal clearance

q With the blade suspended and load is applied
to the rear, measure clearances (QF) and (QR)
between the circle and circle guide as shown in
the figure.
Standard clearance
QF (front): 0 mm
QR (rear): 1.5 mm
Or, QF = QR = 1 mm
GD535-5 30-107
(01)
Testing and adjusting circle guide clearance 30 Testing and adjusting
Adjusting
1. Adjusting vertical clearance
1) Raise the blade, remove bolts (1) and (5),
remove circle guides (2) and (6), and then
adjust the clearance by using shims.
a Available shims: 1mm and 0.5 mm
a Adjust the circle guide 1 place at a time.
2. Adjusting longitudinal clearance

1) Lower the blade to the ground lightly, loosen
bolt (1) and lock nut (4), and loosen bolt (3) to
open circle guides (2) so that QF = 0 holds.
a Open right and left circle guides (2) evenly.
2) Adjust clearance (D) between the lower flange
end surface of the circle drive and the sliding
surface of the circle inner periphery.
Standard clearance (D): 27.3 mm
3) With QF = 0 state, tighten lock nut (4), and

tighten bolt (1).
3 Bolt (1): 455 to 565 Nm {46.5 to 58 kgm}
3. Adjusting lateral clearance

1) Loosen bolt (5) and lock nut (8), loosen bolt (7)
to open circle guides (6) so that QR = 0 holds.
a Open right and left circle guides (6) evenly.
2) With QR = 0 state, loosen bolt (7) by half turn,
tighten lock nut (8), loosen circle guides (6) until
it touches bolt (7), and tighten bolt (5).
3 Bolt (5): 455 to 565 Nm {46.5 to 58 kgm}
3) The standard clearance between the tip of the
gear teeth of the circle gear and the tooth
bottom of the pinion gear of the circle drive is
1.5 to 3.0 mm.
4) Check that the circle can rotate with the blade
at 90 deg. high bank position to right or left.
30-108 GD535-5
(01)
30 Testing and adjusting Testing and adjusting slip clutch type circle drive
Testing and adjusting slip clutch

type circle drive 1

stop the engine.
moving.
Testing
1. Remove mounting bolts (1), and remove cover (2).
2. Check that the internal teeth of worm wheel (3) can q Make judgments depending on whether worm
be seen through the hole of part (P). wheel (3) rotates.
a Check the slip state of the clutch based on the q If worm wheel (3) rotates but the blade does
rotation of the worm wheel. not rotate, the clutch slips.
q If the worm wheel (3) does not rotate, the
motor circuit is relieved and clutch does not
slip.
Adjusting
1. When the clutch does not slip
1) Remove bolt (4) and holder (5), and add one
0.2-mm shim (6).
2) Tighten holder (5) and bolt (4).
3 Bolt (4): 98 to 123 Nm {10 to 12.5 kgm}
3. To prevent the circle from rotating, thrust the blade

against the ground and raise the front wheels off
ground or immobilize one end of the blade.
q How to raise front wheels off ground
1] Lower the blade to the ground and extend
blade lift cylinders until front wheels are
raised off ground.
2] Apply the parking brake.
3) Check whether the clutch slips by following the

testing procedure.
4) Repeat steps 1) to 3) until the clutch comes to
slip so that the clutch is set to its slip limit.
5) If the clutch comes to slip, remove one 0.2-mm
shim (6).
a After the shim adjustment is complete, the
clutch does not slip.
4. Run the engine at high idle, and operate the circle

rotation control lever slowly to check whether the
clutch slips.
GD535-5 30-109
(01)
Testing and adjusting slip clutch type circle drive 30 Testing and adjusting
2. When the clutch slips Clutch running-in operation

1) Remove bolt (4) and holder (5), and remove q After replacing the clutch disc with a new one, per-
one 0.2-mm shim (6). form clutch running-in operation according to the
2) Tighten holder (5) and bolt (4). following procedure.
3 Bolt (4): 98 to 123 Nm {10 to 12.5 kgm} a When installing the disc, apply GO80W90 oil to
its both sides.
1) Set the clutch to its slip limit by following
"adjusting" steps 1 and 2.
2) Add one 0.2-mm shim so that the clutch comes
to slip.
3) Make the clutch slip for 3.5 to 4.0 seconds.
q Engine speed: At High idle
q The clutch rotates by 1 turn when it slips for
3.5 to 4.0 seconds.
4) Repeat step 3) for 20 to 25 times every 3
minutes.
k If the temperature of the clutch housing
exceeds 50 °C, stop the operation until
it drops to the normal temperature.
k If it stops slipping in the middle of the
3) Check whether the clutch slips by following the
"testing" procedure. operation, add one 0.2-mm shim.
4) Repeat steps 1) to 3) until the clutch comes not 5) Wail until the temperature of the clutch drops to
to slip so that the clutch is set to its slip limit. the normal temperature.
5) With the clutch set at its slip limit, remove one 6) Set the clutch to its slip limit again (adjusting
0.2-mm shim (6). steps 1 and 2.
a After the shim adjustment is complete, the
7) Remove one 0.2-mm shim to realize the shim
clutch does not slip.
pack thickness with which the clutch comes not
to slip.
a The running-in operation is complete.
3. Installing cover
1) Install cover (2) and tighten bolts (1).
3 Bolt (1): 59 to 74 Nm {6 to 7.5 kgm}
30-110 GD535-5
(01)
30 Testing and adjusting Procedure for testing diodes
Electrical system 1 How to test diodes by using analog multi-

meter
Procedure for testing diodes 1 1. Selects the resistance range mode.
2. Apply the red (+) lead of the multimeter to the
a The direction of the continuity of a single diode is anode (P) side of the diode and apply the black (-)
indicated on the surface of the diode as shown in lead to the cathode (N) side and check the deflec-
the figure below. tion of the pointer.
3. Apply the red (+) lead of the multimeter to the
cathode (N) side of the diode and apply the black
(-) lead to the anode (P) side and check the deflec-
tion of the pointer.
4. Evaluate the condition of the diode by the deflec-
tion of the pointer.
Resulting deflection of
pointer Quality judgment
Step 2. Step 3.
Normal (Note that amplitude
of deflection depends on
Does not
Deflects multimeter type and
deflect
selected measurement
How to test diodes by using digital multimeter range.)
1. Select the diode range mode to check the
Defective (internal short
displayed values. Deflects Deflects
circuit)
a When an ordinary multimeter is used, the volt-
age of the internal battery is indicated. Does not Does not Defective (internal open
2. Apply the red (+) lead of the multimeter to the deflect deflect circuit)
anode (P) side of the diode and apply the black (-)
lead to the cathode (N) side and check the indi-
cated value.
3. Evaluate the condition of the diode by the indicated
value.
Indicated value does not change: No continuity
(defective)
Indicated value changes: Continuity (normal) (*)
*: In the case of a silicon diode, a value in the range
from 460 to 600 mV is indicated.
GD535-5 30-111
(01)
Procedure for testing diodes 30 Testing and adjusting
Setting and adjusting various equipment

When having performed operations shown in the following table, such as replacement, disassembly and assem-
bly, and retrofitting of equipment, be sure to implement needed setting and adjustment with the machine monitor.
Contents of operation Needed setting and adjusting items Reference page

Setting of machine model selection Default (Machine Model Select) (30-139 page)
Replacement of monitor Setting of option selection Default (Option Selection) (30-140 page)
controller
Zero point adjustment of articulated Adjustment (Zero Point Adjustment For Art Angle) (30-
angle indicator 154 page)
Replacement or Adjustment of transmission ECMV Adjustment (ECMV Automatic Compensation) (30-143
disassembly/assembly of current page)
transmission unit or
transmission ECMV solenoid Reset of transmission initial learning
Adjustment (T/M Initial Learning) (30-146 page)
valve and implementation of learning
Setting of machine model selection Default (Machine Model Select) (30-139 page)
Setting of option selection Default (Option Selection) (30-140 page)
Adjustment of transmission ECMV Adjustment (ECMV Automatic Compensation) (30-143
current page)
Replacement of transmission Reset of transmission initial learning
controller Adjustment (T/M Initial Learning) (30-146 page)
and implementation of learning
Adjustment (Inching Pedal 0% Adjustment) (30-150
page)
Adjustment of inching pedal voltage
page)
Retrofit and removal of
Setting of option selection Default (Option Selection) (30-140 page)
optional equipment
Replacement of articulate Zero point adjustment of articulated Adjustment (Zero Point Adjustment For Art Angle) (30-
angle sensor angle indicator 154 page)
Replacement of inching page)
Adjustment of inching pedal voltage
pedal Adjustment (Inching Pedal 100% Adjustment) (30-151
page)
When having received comments or requests that apply to the following from our customers, implement setting and
adjustment shown below with the machine monitor.
Comment or request Testing/Adjusting item Reference page
Hope to change the
Setting of unit selection Default (Unit Selection) (30-142 page)
expressive unit of indicators
Indicated travel speed is too
Correction of tire size Default (Option Selection) (30-140 page)
fast or too slow.
30-112 GD535-5
(01)
30 Testing and adjusting Special functions of machine monitor
Special functions of machine monitor 1
Machine monitor section (monitor panel section) Machine monitor section (switch section)
(a): Multi-display F1: Function switch F1
At engine start, the battery voltage can drop rapidly F2: Function switch F2
depending on ambient temperature or battery condi- F3: Function switch F3
tion. Under such conditions, the display screen of the F4: Function switch F4
machine monitor may turn off temporarily, but this is F5: Function switch F5
not a defect. F6: Function switch F6
F7: Function switch F7
F8: Function switch F8
The function assigned to each function switch is dis-
played by using a graphic symbol in a position within
multi-display (a); over the function switch for F1 to F4
and on the left of function switch for F5 to F8.
Function switches without graphic symbols do not
work.
GD535-5 30-113
(01)
Special functions of machine monitor 30 Testing and adjusting
Operator mode and service mode of

machine monitor
The machine monitor has 2 functions of the operator
mode and service mode and displays various infor-
mation on multi-display (a).
Some items are displayed automatically according to
the internal setting of the machine monitor and the
others are displayed according to the operation of the
switches.
q Operator mode
q Service mode
The information items in this mode are displayed The information items in this mode are not dis-
ordinarily. The operator can display and set them played ordinarily. Each technician can display
by operating the switches (display and setting of them by operating specified switches. Use this
some items need specific operations of the mode for testing, adjusting, and troubleshooting.
switches). Service mode
For the details, see the Operation and Mainte-
nance Manual. 01 Monitoring/defined (30-119 page)
02 Monitoring/Custom (30-123 page)
Operator mode
Abnormality Record (Mechanical System) (30-130
Display of KOMATSU logo
03 page)
Display of results of check before starting
Abnormality Record (Electrical System) (30-131 page)
Display of warning after check before starting
04 Maintenance Time Reset (30-133 page)
Display of maintenance due time over
05 Maintenance Record (30-134 page)
Display of standard screen
06 Maintenance Mode Setting (30-135 page)
Display of end screen
07 Phone Number Entry (30-138 page)
Operation to switch between clock display and service
Default (Machine Model Select) (30-139 page)
meter display
08 Default (Option Selection) (30-140 page)
Check of maintenance information
Default (Unit Selection) (30-142 page)
User mode setting and display (including KOMTRAX
message to users) 09 Diagnostic Tests (Cylinder Cut-out) (30-142 page)
Display of ECO Guidance Adjustment (ECMV Automatic Compensation) (30-
143 page)
Display of machine setting
Display function of caution monitor
Adjustment (T/M Initial Learning Reset) (30-149
Display of action level and failure code
page)
Following functions require specific operations.
Checking function of LCD display (30-115 page) 10 page)
Confirmation function of service meter and odometer (30- Adjustment (Inching Pedal 100% Adjustment) (30-
115 page) 151 page)
Function of usage limitation setting / changing password Adjustment (T/C Stall) (30-153 page)
(30-115 page)
Adjustment (Zero Point Adjustment For Art Angle)
(30-154 page)
Adjustment (Fan 100% Adjustment) (30-155 page)
11 No Injection (30-156 page)
KOMTRAX Settings (Terminal Status) (30-158 page)
KOMTRAX Settings (GPS & Communication
12
Status) (30-159 page)
KOMTRAX Settings (Modem Status) (30-159 page)
13 Service Message (30-160 page)
30-114 GD535-5
(01)
Operator mode Confirmation function of service meter and odom-

This section describes only function items that require eter
special operations in the operator mode. To check the readings of the service meter and odom-
For detailed contents and operation procedures of eter with the starting switch set at OFF position, oper-
each function and display, see "Structure and func- ate function switches as described below to display
tion" or "Operation and Maintenance Manual". readings of the service meter and odometer.
Switch operation (press the switches in order while
Checking function of LCD display pressing F2): F2 + F3
With the LCD displaying the standard screen, operate
numeric input switches and function switches as
described below to display the full-screen in white.
Switch operation (press the switches in order while
pressing F8): F8 + F6
q When finishing the switch operation, release your
finger from F6 switch first.
q If the LCD has any display error, the defective part
alone is displayed in black.
q One of the features of the liquid crystal unit is that
there may be black spots (spots that do not light
up) or white spots (spots that stay lit) on the
screen.
LCD with black spots and bright spots not more
a Keep pressing the switches until the readings are
than 10 spots is not deemed to be a failed or
displayed because the LCD has a little time lag of
defective display.
start-up.
q Press any function switch to return the screen dis-
a If either of the switches is released, the machine
play to the original one.
monitor goes out.
a For the machine monitor being used for a long
term, blue bright spots may be seen on this screen
display. But this phenomenon does not indicate
any failure or defect.
Function of usage limitation setting / changing

password
The machine monitor allows for setting a password as
its usage limitation setting function. Once a password
is set, the password entry screen appears when
Maintenance Time Reset is tried.
Set the usage limitation or change the password
1. With the standard screen being displayed, operate
function switches as described below.
Switch operation: While keep pressing F8, press
F5 three times (simultaneously).
a This switch operation cannot be accepted until
10 minutes or more has elapsed after the start-
ing switch is turned to ON position.
GD535-5 30-115
(01)
2. When "Usage Limitation Password" screen "Enable": Password input screen appears when
appears, operate function switches to input the implementing Option Setting or Maintenance Time
current password. Reset.
F1: Decreases number by 1. F1: Moves selection downward.
F2: Increases number by 1. F2: Moves selection upward.
F3: Returns the screen to standard screen. F3: Cancels selection and returns screen to previ-
F4: Enters input password. ous one.
F6: Moves input position to left. F4: Enters selection.
F7: Moves input position to right.
F8: Clears all input numbers.
a Default password: 000000
a When the input password is correct, the screen
switches to the next one.
a When the input password is incorrect, an indi-
cation that requires retyping appears.
a The Usage limitation password differs from the
Engine start Lock password.
5. When "Usage Limitation Setting" screen appears,

operate function switches to select "Change Pass-
word"".
F1: Moves selection downward.
F2: Moves selection upward.
F3: Cancels selection and returns screen to previ-
ous one.
F4: Enters selection.
3. When "Usage Limitation Setting" screen appears,

operate function switches to select "Usage Limita-
tion ON/OFF".
F3: Cancels selection and returns screen to previ-
ous one.
6. When "New Password" screen for Usage Limita-

tion appears, operate function switches to input
and enter a new password.
F1: Decreases number by 1.
F2: Increases number by 1.
F3: Returns screen to "Usage Limitation" menu
screen.
F4: Enters new password.
F6: Moves input position to left.
4. When "Usage Limitation ON/OFF" screen F7: Moves input position to right.
appears, operate function switches to select the F8: Clears all input numbers.
desired setting.
"Disable": Password input screen is not displayed.
30-116 GD535-5
(01)
a Default password: 000000

a When the input password is correct, the screen
switches to the next one.
a When the input password is incorrect, an indi-
cation that requires retyping appears.
a Set a new password of 4 to 6 digits (If it has
only 3 or less digits or has 7 or more digits, it is
not accepted).
7. When "New Password" screen for Usage Limita-

tion appears, operate function switches to input
and enter a new password.
F3: Returns screen to "Usage Limitation" menu
screen.
F4: Enters new password.
F8: Clears all input numbers.
a If a password different from the first one is

input, an indication that requires retyping
appears.
Change of password is complete if the stan-
dard screen appears after a screen to give
notice of setting completion is displayed.
GD535-5 30-117
(01)
Service mode
To change the operator mode to the service mode,
perform the following operation.
This operation is always required when you use the
service mode.
1. With the standard screen being displayed, keep
pressing function switch F8 and press F1, F2, and
F3 in order.
a The switch operation to use the service mode
is accepted only while the standard screen is
being displayed.
a A menu item with a code (2 digits) is displayed

on the "Service Menu" screen. An item dis-
played on the right is a menu item of 1-rank
lower layer.
The following shows the items selectable from the

"Service Menu" (including some items which need
specific switch operations).
2. When "Service Menu" screen is displayed, the

mode is switched to the service mode. On this
screen, select a service menu item to use.
F3: Returns screen to standard screen (operator
mode).
F8: Moves screen to code entry screen.
a On the code entry screen, you can select a

menu item directly by inputting the code with
the function switches.
F3: Cancels selection and return screen to
"Service Menu" screen.
F4: Enters input code.
30-118 GD535-5
(01)
Items selectable from service menu Monitoring/defined

The machine monitor can monitor the condition of the
Service mode machine in real time by receiving signals from various
01 Monitoring/defined (30-119 page) switches, sensors, and actuators installed to various
parts of the machine and the information from the
02 Monitoring/Custom (30-123 page)
controllers which is controlling switches, etc.
Abnormality Record (Mechanical System) (30-130 In the Monitoring/defined, monitoring items that are
page) more commonly used are selected in advance.
03 1. Select "Monitoring/defined" on "Service Menu"
Abnormality Record (Electrical System) (30-131
page) screen.
a For the selection method, see relevant section
04 Maintenance Time Reset (30-133 page) in "Service mode".
05 Maintenance Record (30-134 page)
06 Maintenance Mode Setting (30-135 page)
07 Phone Number Entry (30-138 page)
Default (Machine Model Select) (30-139 page)
08 Default (Option Selection) (30-140 page)
Default (Unit Selection) (30-142 page)
09 Diagnostic Tests (Cylinder Cut-out) (30-142 page)
Adjustment (ECMV Automatic Compensation) (30-
143 page)
2. When "Monitoring/defined" screen is displayed,
Adjustment (T/M Initial Learning Reset) (30-149
you can check the items to be displayed in the
page)
screen by using function switches.
Adjustment (Inching Pedal 0% Adjustment) (30-150 F1: Switches gauge type to be displayed at bottom
10 page) of screen (fuel level gauge, coolant temperature
Adjustment (Inching Pedal 100% Adjustment) (30- gauge, torque converter oil temperature gauge).
151 page) F2: Switches setting between HOLD and HOLD
CANCELED. (If HOLD is selected, a diagonal
Adjustment (T/C Stall) (30-153 page) appears in HOLD box.)
Adjustment (Zero Point Adjustment For Art Angle) F3: Returns screen to "Service Menu" screen.
(30-154 page) F6: Moves screen to next page (screen).
F7: Moves screen to previous page (screen).
Adjustment (Fan 100% Adjustment) (30-155 page)
11 No Injection (30-156 page)
KOMTRAX Settings (Terminal Status) (30-158
page)
12 KOMTRAX Settings (GPS & Communication
Status) (30-159 page)
KOMTRAX Settings (Modem Status) (30-159 page)
13 Service Message (30-160 page)
a For the items not displayed in "Monitoring/

defined", you can freely select and check them
from "Monitoring/Custom" items.
GD535-5 30-119
(01)
Monitoring item list in Monitoring/defined

Monitoring/defined (01/13) Relating to machine basics (1)
Unit Associated
No. ID Item name
SI Non SI equipment
1 01002 Engine Speed r/min rpm ENG

2 04107 Coolant Temperature °C °F ENG
3 03203 Battery Voltage V V ENG
4 30100 T/C Oil Temperature °C °F T/M

Unit Associated
No. ID Item name
SI Non SI equipment
1 04401 Hydraulic Oil Temperature °C °F T/M

Unit Associated
No. ID Item name
SI Non SI equipment

2 36500 Boost Pressure kPa PSI ENG
3 18500 Boost Temperature °C °F ENG
Monitoring/defined (04/13) Relating to fuel injection

Unit Associated
No. ID Item name
SI Non SI equipment

2 36400 Common Rail Pressure MPa PSI ENG
3 36200 Rail Pressure Command MPa PSI ENG
Monitoring/defined (05/13) Relating to engine temperature

Unit Associated
No. ID Item name
SI Non SI equipment

3 18500 Boost Temperature °C °F ENG
Monitoring/defined (06/13) Relating to intake and exhaust pressure

Unit Associated
No. ID Item name
SI Non SI equipment

2 37400 Ambient Pressure kPa PSI ENG
3 36500 Boost Pressure kPa PSI ENG
30-120 GD535-5
(01)
Monitoring/defined (07/13) Relating to transmission clutch (1)

Unit Associated
No. ID Item name
SI Non SI equipment
1 41802 Fill Time (1st) msec msec T/M

2 41803 Fill Time (2nd) msec msec T/M
3 41804 Fill Time (3rd) msec msec T/M
4 41805 Fill Time (4th) msec msec T/M

Unit Associated
No. ID Item name
SI Non SI equipment
1 41807 Fill Time (Forward_L) msec msec T/M

2 41808 Fill Time (Forward_H) msec msec T/M
3 41806 Fill Time (Reverse) msec msec T/M

Unit Associated
No. ID Item name
SI Non SI equipment
1 31602 ECMV Current (1st) mA mA T/M

2 31603 ECMV Current (2nd) mA mA T/M
3 31604 ECMV Current (3rd) mA mA T/M
4 31605 ECMV Current (4th) mA mA T/M

Unit Associated
No. ID Item name
SI Non SI equipment
1 31607 ECMV Current (Forward_L) mA mA T/M

2 31608 ECMV Current (Forward_H) mA mA T/M
3 31606 ECMV Current (Reverse) mA mA T/M
Monitoring/defined (11/13) Hydraulic fan (1)

Unit Associated
No. ID Item name
SI Non SI equipment
1 01002 Engine speed r/min rpm ENG

3 04401 Hydraulic Oil Temperature °C °F T/M
4 30100 T/C Oil Temperature °C °F T/M
GD535-5 30-121
(01)

Unit Associated
No. ID Item name
SI Non SI equipment
1 10007 Radiator Fan Speed Command r/min rpm T/M

2 10009 Radiator Fan Speed r/min rpm T/M

Unit Associated
No. ID Item name
SI Non SI equipment
1 01002 Engine speed r/min rpm ENG

2 10007 Radiator Fan Speed Command r/min rpm T/M
3 10009 Radiator Fan Speed r/min rpm T/M
4 41400 Fan Reverse EPC Sol Curr Command mA mA T/M
30-122 GD535-5
(01)
Monitoring/Custom q To select monitoring items by using function

The machine monitor can monitor the condition of the switches, use F6 or F7 switch to select associ-
machine in real time by receiving signals from various ated equipment first, use F1 or F2 switch to
switches, sensors, and actuators installed to various select monitoring items, and then use F4
parts of the machine and the information from the switch to enter the selection.
controllers which is controlling switches, etc. q On the Monitoring/Custom screen, if you press
With "Monitoring/Custom", monitoring items can be F8 and input ID, you can select a monitoring
selected arbitrarily. item directly.
1. Select "Monitoring/Custom" on "Service Menu" F2: Increases number by 1.
screen. F3: Cancels input and return screen to " Moni-
a For the selection method, see relevant section toring/Custom" screen.
in "Service mode". F4: Enters input number.
F6: Moves selection leftward
F7: Moves selection rightward
q If the color of the selected box changes from
yellow to red, the selection of the item of that
box is entered.
q Up to 4 monitoring items can be selected at a
time. The items, however, may not be set up to
4 items depending on the display formats of
the selected items.
2. When "monitoring item selection menu" screen is

displayed, select items to monitor by using function
switches.
F3: Returns screen to "Service Menu" screen.
F6: Moves selection leftward
F7: Moves selection rightward
F8: Moves screen to "ID Input" screen. 3. After selecting monitoring items, execute moni-
toring with a function switch.
q To execute monitoring with a function switch,
double click F4 or keep pressing it for approxi-
mately 2 seconds.
q To execute monitoring by inputting ID, use
function switches to input "99999" after the ID
is entered, and then use F4 to enter the input
to start monitoring.
q In the process of setting Monitoring/Custom,

each time function switch F7 is pressed, the
displayed name of equipment that is associ-
ated with the monitoring items changes in the
order of "ENG" o "T/M" o "MON" o "ENG".
(When function switch F6 is depressed, it
changes in the reverse order.)
GD535-5 30-123
(01)
F3: Cancels input and return screen to " Moni- 6. Selected monitoring items can be saved and
toring/Custom" screen. cleared by using function switches.
F4: Enters input number. F6: Clears selected monitoring item.
F6: Moves selection leftward F7: Saves selected monitoring item.
F7: Moves selection rightward q When any saved item exists, if "Monitoring/
q During selection of monitoring items, if the Custom" is selected on "Service Menu"
number of selected items reaches the limit screen, a confirmation screen with a message
number, the machine monitor automatically of "Display the memorized items?" is dis-
switches to monitoring execution state. played. When F4 switch is pressed, the screen
a When monitoring only two items, for example, moves to "Monitoring" screen for the saved
select respective items and enter them with monitoring item.
F4. After the selection is complete, press F4
once again to switch the machine monitor to
monitoring execution state.
4. After "Monitoring" screen is displayed, perform the

necessary operation of the machine and check the
monitoring information.
a Monitoring information is indicated by value,
ON/OFF, or special display.
a The display unit can be set to "SI" or "Non SI"
unit by using "Unit Selection" of "Default"
menu.
q When an item is saved, it can be displayed as

many times as required unless it is cleared.
q If another item is saved while having the previ-
ous item saved, the previously saved item is
overwritten by the latest one.
q A saved item can be cleared by pressing F6
and F4 to enter the designation.
5. You can hold and release holding of the monitoring

information by using the function switches.
F1: Switches gauge type to be displayed at bottom
of screen (fuel level gauge, coolant temperature
gauge, torque converter oil temperature gauge).
F2: Switches setting between HOLD and HOLD
CANCELED. (If HOLD is selected, a diagonal
appears in HOLD box.)
F3: Returns screen to Monitoring/Custom screen.
F7: Saves monitoring item currently displayed.
30-124 GD535-5
(01)
Monitoring item list

Monitoring Unit Associated
Monitoring item (Display on screen) Remarks
code SI Non SI equipment
00201 Machine ID - - ENG

20216 Engine Controller Software Version - - ENG
20217 Engine Controller Data Version - - ENG
18900 Engine Controller Internal Temperature °C °F ENG
20400 Engine Controller S/N - - ENG
01002 Engine Speed r/min rpm ENG
36700 Engine Output Torque Ratio % % ENG
31701 Throttle Position % % ENG
03000 Throttle Position Sensor Voltage V V ENG
17500 Engine Power Mode Selection - - ENG
36400 Common Rail Pressure MPa PSI ENG
36401 Common Rail Pressure Sensor Voltage V V ENG
36200 Rail Pressure Command MPa PSI ENG
04107 Coolant Temperature °C °F ENG
04105 Coolant Temperature Sensor Voltage V V ENG
37400 Ambient Pressure kPa PSI ENG
37401 Ambient Pressure Sensor Voltage V V ENG
Indicated in
absolute figure
36500 Boost Pressure kPa PSI ENG
(Including ambient
pressure)
36501 Boost Pressure Sensor Voltage V V ENG
03203 Battery Voltage V V ENG
37300 Fuel Rate ℓ/h gal/sec ENG (*1)
31706 Final Throttle Position % % ENG
18500 Boost Temperature °C °F ENG
18501 Boost Temperature Sensor Voltage V V ENG
18300 Idle Validation SW1 - - ENG
18301 Idle Validation SW2 - - ENG
18600 Final Inject Fueling Command (in quantity) mg/st mg/st ENG
18700 Engine Output Torque Nm lbft ENG
18800 WIF Sensor State - - ENG
08402 Droop SW selection - - ENG
48900 Engine Operation Mode - - ENG
41600 Engine Power Mode Selection - - T/M
31200 T/M Input Shaft Speed r/min rpm T/M
31300 T/M Intermediate Shaft Speed r/min rpm T/M
31400 T/M output Shaft Speed r/min rpm T/M
GD535-5 30-125
(01)

10009 Radiator Fan Speed r/min rpm T/M

10007 Radiator Fan Target Speed r/min rpm T/M
30100 T/C Oil Temperature °C °F T/M
30101 T/C Oil Temperature Sensor Voltage V V T/M
04401 Hydraulic Oil Temperature °C °F T/M
04404 Hydraulic Oil Temperature Sensor Voltage V V T/M
32500 T/M Oil Temperature °C °F T/M
32501 T/M Oil Temperature Sensor Voltage V V T/M
31909 Differential oil temperature °C °F T/M
31910 Differential Oil Temperature Sensor Voltage V V T/M
32601 Torque Converter Oil Pressure MPa PSI T/M
32603 T/C Oil Pressure Sensor Voltage V V T/M
04200 Fuel Level Sensor [V] V V T/M
04201 Fuel Level Sensor [ohm] Ω Ω T/M
43900 Articulate Sensor Voltage V V T/M
44105 Inching Potentiometer Input Voltage V V T/M
31602 ECMV Current (1st) mA mA T/M
31603 ECMV Current (2nd) mA mA T/M
31604 ECMV Current (3rd) mA mA T/M
31605 ECMV Current (4th) mA mA T/M
31606 ECMV Current (Reverse) mA mA T/M
31607 ECMV Current (Forward_L) mA mA T/M
31608 ECMV Current (Forward_H) mA mA T/M
31609 ECMV Current (L/U) mA mA T/M
41400 Radiator Fan EPC Solenoid Current mA mA T/M
38902 Clutch Trigger Compensation (1st) - - T/M
38903 Clutch Trigger Compensation (2nd) - - T/M
38904 Clutch Trigger Compensation (3rd) - - T/M
38905 Clutch Trigger Compensation (4th) - - T/M
38906 Clutch Trigger Compensation (Reverse) - - T/M
38907 Clutch Trigger Compensation (Forward_L) - - T/M
38908 Clutch Trigger Compensation (Forward_H) - - T/M
38700 Gear shift mode state - - T/M
44100 Inching Clutch Overload Times 1 - - T/M
41802 Fill Time (1st) msec msec T/M
41803 Fill Time (2nd) msec msec T/M
30-126 GD535-5
(01)

41804 Fill Time (3rd) msec msec T/M

41805 Fill Time (4th) msec msec T/M
41806 Fill Time (Reverse) msec msec T/M
41807 Fill Time (Forward_L) msec msec T/M
41808 Fill Time (Forward_H) msec msec T/M
44201 Throttle Lower Limit Command % % T/M
44200 Throttle Upper Limit Command % % T/M
36000 Throttle Modification Value % % T/M
03208 Controller Power Voltage (T/M) V V T/M
03216 Solenoid Power Supply Voltage (T/M) V V T/M
04307 Battery Charge Voltage (T/M) V V T/M
Forward_L Clutch ON/OFF ON/OFF T/M
Trigger Initial Learning
94110 Forward_H Clutch ON/OFF ON/OFF T/M
Flag 1
Reverse Clutch ON/OFF ON/OFF T/M
1st Clutch ON/OFF ON/OFF T/M
Trigger Initial Learning 2nd Clutch ON/OFF ON/OFF T/M

94120
Flag 2 3rd Clutch ON/OFF ON/OFF T/M
4th Clutch ON/OFF ON/OFF T/M
Forward_L Clutch ON/OFF ON/OFF T/M
02216 Clutch Fill Switch Input 1 Forward_H Clutch ON/OFF ON/OFF T/M
Reverse Clutch ON/OFF ON/OFF T/M
1st Clutch ON/OFF ON/OFF T/M
2nd Clutch ON/OFF ON/OFF T/M
02217 Clutch Fill Switch Input 2
3rd Clutch ON/OFF ON/OFF T/M
4th Clutch ON/OFF ON/OFF T/M
Shift Lever 1 ON/OFF ON/OFF T/M
02211 T/M Con. Switch Input 1
Shift Lever P ON/OFF ON/OFF T/M
02213 T/M Con. Switch Input 3 Shift Lever N ON/OFF ON/OFF T/M
Shift Lever NP ON/OFF ON/OFF T/M
GD535-5 30-127
(01)

Shift Lever F ON/OFF ON/OFF T/M

Shift Lever R ON/OFF ON/OFF T/M
Gear Shift Mode
ON/OFF ON/OFF T/M
Switch
RPMSet MODE-
ON/OFF ON/OFF T/M
AUTO
RPMSet MODE-
ON/OFF ON/OFF T/M
MANU
RPMSet ACCEL/
ON/OFF ON/OFF T/M
SET
RPMSet DECELL/
ON/OFF ON/OFF T/M
RESUM
Differential Switch ON/OFF ON/OFF T/M
Engine Power Mode
ON/OFF ON/OFF T/M
02218 T/M Con. Switch Input 6 Selector Switch
Engine Starter ON/OFF ON/OFF T/M
Stop Lamp Switch ON/OFF ON/OFF T/M
Night Lighting SW ON/OFF ON/OFF T/M
Front Brake Oil
ON/OFF ON/OFF T/M
02231 T/M Con. Switch Input 7 Press
Rear Brake Oil
ON/OFF ON/OFF T/M
Press
Fan Reverse
ON/OFF ON/OFF T/M
Solenoid Command
Parking Brake
ON/OFF ON/OFF T/M
03705 T/M Con. Switch Output 1 Operating Relay
Differential Control
ON/OFF ON/OFF T/M
Relay
Backup Lamp Relay ON/OFF ON/OFF T/M
Engine Starter Relay ON/OFF ON/OFF T/M
03706 T/M Con. Switch Output 2 T/M Con. Self-
ON/OFF ON/OFF T/M
Holding Relay
20414 Assembly P/N (T/M Con.) - - T/M
20413 Serial Number (T/M Con.) - - T/M
20201 Software P/N (T/M Con.) - - T/M
20223 Application Version (T/M Con.) - - T/M
20224 Data Version (T/M Con.) - - T/M
01001 Engine Speed (Tachometer) r/min rpm MON
40000 Travel Speed (Speedometer) km/h MPH MON
04202 Fuel Level Sensor [%] % % MON
43910 Articulate Angle deg. deg. MON
03220 Controller Power Voltage (MON) V V MON
30-128 GD535-5
(01)

04306 Battery Charge Voltage (MON) V V MON

F1 ON/OFF ON/OFF MON
04508 Monitor Input 1
04509 Monitor Input 2
Buzzer ON/OFF ON/OFF MON
04700 Monitor Output Personal Code
ON/OFF ON/OFF MON
Relay
00205 Selected Machine (MON) - - MON
20227 Assembly P/N (MON) - - MON
20402 Serial No. (MON) - - MON
20228 Software P/N (MON) - - MON
20221 Application version (MON) - - MON
20278 Data Version 1 (MON) - - MON
20260 Assembly P/N (KOMTRAX) - - MON
20418 Serial No. (KOMTRAX) - - MON
20261 Software P/N (KOMTRAX) - - MON
20273 Program Version (KOMTRAX) - - MON
20262 Assembly P/N (ID Key Con.) - - MON
20419 Serial No. (ID Key Con.) - - MON
20263 Software P/N (ID Key Con.) - - MON
*1: "Fuel Rate" (code No. 37300) is theoretical fuel consumption. (It can slightly differ from actual fuel consumption
rate because it is a theoretical value.)
q Listing order in table
Monitoring items are arranged in the order they are displayed on the monitoring item selection menu screen.
q Unit
The display unit can be set to either of "SI" or "Non SI" unit you prefer. (Switch the display unit to a desired one
from "Unit Selection" of "Default" in the service menu.)
"mg/st" of the display unit is an abbreviation for milligram/stroke.
q Associated equipment
ENG: The engine controller is responsible for collection of the monitoring information.
T/M: The transmission controller is responsible for collection of the monitoring information.
MON: The machine monitor is responsible for collection of the monitoring information.
GD535-5 30-129
(01)
Abnormality Record (Mechanical System) F3: Returns screen to "Abnormality Record"

The machine monitor records the past and currently screen.
occurring failures, classifying them into mechanical
system abnormality and electrical system abnormal-
ity.
Check the information of "Mechanical system abnor-
mality record" according to the following procedure.
For the failure code list, see "Failure code list" in Trou-
bleshooting.
1. Select "Abnormality Record" on "Service Menu"
screen.
in "Service mode".
a If no abnormality is recorded, the message "No

Error" is displayed.
a For the mechanical system abnormality record,
up to 20 abnormalities in the record are dis-
played.
a When the number of occurrences of an abnor-
mality is 1 (first occurrence), the service meter
reading at latest occurrence is the same as
that at first occurrence.
Since the value at the recovery is displayed as
the service meter reading at latest occurrence,
2. When "Abnormality Record" screen appears, this may not apply.
operate function switches to select "Mechanical a If "E" is displayed on the left of a failure code,
Systems". the abnormality is still occurring or correction
a For the selection method, see relevant section of it is not confirmed.
in "Service mode". a For all of the failure codes that the machine
monitor can record, see "Failure code list" in
Troubleshooting.
a If the number of characters to be displayed in
the field for Detail of failure is large, the char-
acter string scrolls.
a Abnormality record of the mechanical system
cannot be deleted.
3. When the screen switches to "Mechanical

Systems" screen, check the following information
being displayed.
a: Occurrence order of abnormalities from latest
one/ Total number of records
b: Failure code
c: Detail of failure
d: Number of occurrences (display range: 0 to
65535 times)
e: Service meter reading at first occurrence
f: Service meter reading at latest occurrence
30-130 GD535-5
(01)
Abnormality Record (Electrical System) F3: Returns screen to "Abnormality Record"

The machine monitor records the past and currently screen.
occurring failures classifying them into the mechani-
cal system abnormality and electrical system abnor-
mality.
Check the information of "Electrical system abnormal-
ity record" according to the following procedure.
For all of the failure codes that the machine monitor
can record, see "Failure code list" in Troubleshooting.
1. Select "Abnormality Record" on "Service Menu"
screen.
in "Service mode".
a If no abnormality is recorded, the message "No

Error" is displayed.
a For the electrical system abnormality record,
up to 20 abnormalities in the record are dis-
played. If the number of records reaches 21 or
more, failure codes of later occurrences are
displayed and those of older occurrences are
cleared starting from the oldest one.
a When the number of occurrences of an abnor-
mality is 1 (first occurrence), the service meter
2. When "Abnormality Record" screen appears, reading at latest occurrence is the same as
operate function switches to select "Electrical that at first occurrence.
Systems". a If "E" is displayed on the left of a failure code,
a For the selection method, see relevant section the abnormality is still occurring or correction
in "Service mode". of it is not confirmed.
a For all of the failure codes that the machine
monitor can record, see "Failure code list" in
Troubleshooting.
a If the number of characters to be displayed in
the field for Detail of failure is large, the char-
acter string scrolls.
4. To clear the abnormality record information,

perform following operations by using function
switches with "Electrical Systems" screen being
displayed.
1) Switch operation (while keep pressing F8):
Press switches in the order of F1, F2, and F3.
3. When the screen switches to "Electrical Systems"
screen, check the following information being
displayed.
a: Occurrence order of abnormalities from latest
one/ Total number of records
b: Failure code
c: Detail of failure
d: Number of occurrences (display range: 0 to
65535 times)
e: Service meter reading at first occurrence
f: Service meter reading at latest occurrence
GD535-5 30-131
(01)
2) Check that the screen display is in the clear

mode, use function switches to clear a piece of a Screen display when deletion of all abnor-
information individually or to clear all informa- mality records is tried
tion collectively.
a If "CLEAR" appears on the left of F8, the
screen display comes to the clear mode.
F3: Returns screen to "Abnormality
Record" screen.
F4: Executes deletion of selected
abnormality records.
F8: Executes deletion of all abnormality
records.
4) If the screen to notify the completion of deletion

appears and then "Electrical Systems" screen
(clear mode)"is displayed, deletion of selected
abnormality record is complete.
a Screen display when deletion of selected
abnormality records is completed
a To clear a selected abnormality record,

select the abnormality record with F1 or F2,
and then press F4 to implement deletion of
the abnormality record.
a To clear all abnormality records together,
press F8, and then all the records are
cleared regardless of the selection.
a If "E" is displayed on the left of a failure
code, the clearing operation is accepted but
the item is not cleared. a Screen display when deletion of all abnor-
3) When "Electrical Sys. Error Reset" screen mality records is completed
appears, operate function switches to execute
deletion.
F3: Returns screen to "Electrical Systems"
screen (clear mode).
F4: Executes deletion.
a Screen display when deletion of selected
abnormality records is tried
30-132 GD535-5
(01)
Maintenance Time Reset Items maintenance remaining time of which can

The machine monitor allows reset of the maintenance be reset
remaining time of a maintenance item such as filter , Code Item
oil, etc. when maintenance of them have been per-
formed. 49 Air Cleaner Cleaning/Change
1. On "Service Menu" screen, select "Maintenance 60 Coolant
Time Reset".
a For the selection method, see relevant section 41 Fuel Pre Filter
in "Service mode". 01 Engine Oil
02 Engine Oil Filter
13 T/M Oil Filter
03 Fuel Main Filter
12 T/M Oil
15 Axle Oil
04 Hydraulic Oil Filter
10 Hydraulic Oil
37 Circle Case Oil
36 Tandem Case Oil
2. When "Maintenance Time Reset" screen is
displayed, select items to reset by using function 3. When "Maintenance Time Reset" confirmation
switches. screen is displayed, execute the reset by using
a For the selection method, see relevant section function switches.
in "Service mode". F3: Cancels reset and returns screen to "Mainte-
nance Time Reset" screen.
F4: Moves screen to "Maintenance Time Reset"
reconfirmation screen.
4. When "Maintenance Time Reset" reconfirmation

screen is displayed, execute the reset by using
function switches.
F3: Cancels reset and returns screen to "Mainte-
nance Time Reset" screen.
F4: Executes reset.
GD535-5 30-133
(01)
Maintenance Record
The machine monitor records maintenance informa-
tion of filters, oil, etc. The information can be dis-
played and checked according to the following
procedure.
When "Maintenance Time Reset" is executed in the
operator mode or service mode after the maintenance
of an item has been completed, the number of main-
tenance operations is recorded in this record.
1. On "Service Menu" screen, select "Maintenance
Record".
in "Service mode".
2. When "Maintenance Record" screen is displayed,

select items to check by using function switches.
30-134 GD535-5
(01)
Selectable items in Maintenance Record Maintenance Mode Setting

Code Item This menu item can specify whether to enable or dis-
able the maintenance item function and set the
49 Air Cleaner Cleaning/Change replacement time of a maintenance item.
60 Coolant q To enable or disable the maintenance item func-
tion
41 Fuel Pre Filter q To change the set time of replacement interval for
01 Engine Oil each maintenance item (by item)

q To initialize replacement interval settings of all
02 Engine Oil Filter maintenance items
13 T/M Oil Filter 1. On "Service Menu" screen, select "Maintenance
Mode Setting".
03 Fuel Main Filter
12 T/M Oil in "Service mode".
15 Axle Oil
10 Hydraulic Oil
37 Circle Case Oil
36 Tandem Case Oil
Items displayed on Maintenance Record screen

a: Maintenance item
b: Number of replacement times until now
c: SMR (service meter reading) at previous replace-
ment
d: Current SMR (service meter reading) 2. When "Maintenance Mode Setting" screen is
displayed, select items to select by using function
switches.
in "Service mode".
GD535-5 30-135
(01)
Selectable items in Maintenance Mode Setting Default: Maintenance notice time set in machine
Code Item monitor (unchangeable value recommended by
the manufacturer)
00 Maintenance Mode Change Set value: Maintenance interval that can be freely
49 Air Cleaner Cleaning/Change set. Maintenance reminder function works accord-
ing to this set time in operator mode (the time
60 Coolant increases or decreases in multiples of 10 hours).
41 Fuel Pre Filter F1: Decreases set value.
F2: Increases set value
01 Engine Oil F3: Cancels set value and returns screen to
02 Engine Oil Filter "Maintenance Mode Change" screen.
F4: Enters set value and returns screen to "Main-
13 T/M Oil Filter
tenance Mode Change" screen.
03 Fuel Main Filter F8: Cancels contents of setting not yet entered.
12 T/M Oil
15 Axle Oil
10 Hydraulic Oil
37 Circle Case Oil
99 All Default Value
3. When selected "Maintenance Mode Change"

screen is displayed, select "Maintenance Mode
On/Off", select "On" or "Off", and enter the selec-
tion by using function switches.
ON: Function of all maintenance items becomes
effective in operator mode.
OFF: Function of all maintenance items becomes
ineffective in operator mode.
F3: Cancels selection and returns screen to
"Maintenance Mode Setting" screen.
F4: Enters selection and Moves screen to "Mainte-
nance Mode On/Off" screen.
a Once this change of setting is entered, the set-
ting overrides the ON/OFF setting of each
item. a When F4 is pressed to enter the set value, the
screen returns to "Maintenance Mode Change"
screen and the set value becomes effective.
a If the set value of an item maintenance
reminder function of which is set to "ON" is
changed after 1 operating hour or more from
the setup, the change is recognized as a reset
of the remaining time.
5. When an individual maintenance item is selected

and the screen for the individual maintenance item
is displayed, select "OFF/ON Set".
4. When "Maintenance Notice TimeSet"is selected "Maintenance Mode Setting" screen.
and its screen is displayed, set the maintenance F4: Enters selection and moves screen to "ON" or
notice time by using the function switches. "OFF" screen for individual maintenance item
30-136 GD535-5
(01)
F3: Cancels set value and returns screen to the

screen for individual maintenance item.
F4: Enters set value and returns screen to the
F8: Cancels contents of setting not yet entered.
a The screen display is an example of "Engine

Oil replacement".
a For the selection method, see "Operation
method of service mode" in "Service mode".
6. When the screen for the individual maintenance

item is displayed, select "ON" or "OFF" by using
function switches.
ON: Function of individual maintenance item
becomes effective in operator mode.
OFF: Function of individual maintenance item
becomes ineffective in operator mode.
F3: Cancels selection and returns screen to the
F4: Enters selection and returns screen to the
a When F4 is pressed to enter the set value, the
screen returns to the screen for individual
maintenance item and the set value becomes
effective.
a If the set value of an item maintenance
reminder function of which is set to "ON" is
changed after 1 operating hour or more from
the setup, the change is recognized as a reset
of the remaining time.
8. When "All Default Value" is selected and its screen

is displayed, enter the setting by using function
switches.
If this menu item is executed, the set values of all
7. When "Set" is selected and "Set" screen for the the maintenance items are returned to their
individual maintenance item is displayed, set the default values.
maintenance interval by using the function F3: Returns screen to "Maintenance Mode Set-
switches. ting" screen.
Default: Maintenance notice time set in machine F4: Executes initialization.
monitor (unchangeable value recommended by a After F4 is pressed, in a short time, the initial-
the manufacturer) ization completion screen is displayed. When
Set value: Maintenance interval that can be freely "Maintenance Mode Setting" screen is dis-
set. Maintenance reminder function works accord- played, initialization is complete.
ing to this set time in operator mode (the time
increases or decreases in multiples of 25 hours).
F1: Decreases set value.
F2: Increases set value
GD535-5 30-137
(01)
Phone Number Entry

The telephone number, which is displayed together
with the "Error List" in the operator mode, can be
input and changed according to the following proce-
dure.
To allow the telephone number to appear in the oper-
ator mode, it is required to input it by using this func-
tion in advance.
1. Select "Phone Number Entry" on service menu
screen.
in "Service mode".
2. When "Phone Number Entry" screen appears,

register or correct the telephone number by using
function switches.
F1: Decreases number.
F2: Increases number.
F4: Enters input.
F6: Moves input position to left (except blank).
F7: Moves input position to right (except blank).
F8: Clears all input numerals.
a The telephone number can be input with up to
14 digits flush on the left. Leave unused boxes
blank.
a If an input numeral is wrong, move the input
position (orange background) to that digit and
overwrite it with the correct numeral.
a If F4 is pressed without inputting a digit, there
is no information of a telephone number.
Accordingly, no telephone number is displayed
in the operator mode.
30-138 GD535-5
(01)
Default (Machine Model Select) 4. Selection of machine model becomes possible.

Default menu items are used to check or change vari- Select a machine model of the machine.
ous settings of the machine monitor and machine. F1: Moves selection downward.
"Machine Model Select" function to make controllers F2: Moves selection upward.
recognize the current machine model. F3: Cancels selection and returns screen to
1. Select "Default" on the service menu screen. "Default" screen.
a For the selection method, see relevant section F4: Enters selection.
in "Service mode".
a Selectable machine model displayed is only

2. When "Default" screen appears, select "Machine GD535.
Model Select". a When the selection of machine model is
a For the selection method, see relevant section entered, respective settings become as fol-
in "Service mode". lows.
"Monitoring/Custom": Monitoring item being
held is cleared.
"Maintenance Mode Setting": Settings of "OFF/
ON" and "Maintenance Notice TimeSet" are
returned to their default for the machine.
"De faul t (O pt ion S ele cti on )" : S ett ing i s
returned to default for the machine.
"ECO Guidance": All fuel consumption data is
cleared.
a When the monitor controller is replaced with a
new one that has recognized no machine
model, if the service menu is opened for the
first time, "Machine Model Select" screen
shown below is displayed. Select the machine
3. With "Machine Model Select" screen being model first on the screen. (The screen display
displayed, operate function switches as described may be somewhat different from that when a
below. machine model has already been selected.)
Switch operation (while keep pressing F8): Press
switches in the order of F1, F2, and F3.
GD535-5 30-139
(01)
5. When the screen requesting key-off operation is Default (Option Selection)

displayed, turn the starting switch to OFF position. Default menu items are used to check or change vari-
6. Turn the starting switch to ON position again. ous settings of the machine monitor and machine.
When all settings of "Option Selection" are reset after
"Machine Model Select" in Default has been per-
formed or when an optional equipment is retrofitted,
"Option Selection" function in used to make the
optional equipment enabled.
1. Select "Default" on "Service Menu" screen.
in "Service mode".
Referring to the section in "Default (Option Selec-

tion)", perform "Default (Option Selection)".
2. When "Default" screen appears, select "Option

Selection".
in "Service mode".
3. When "Option Selection" screen appears, check

whether optional equipment are installed or not to
the machine, and select respective items.
"Default" screen.
a When the current settings are acceptable,
select either one of the items and press func-
tion switch F4 without changing the setting,
and the settings apply to the machine.
30-140 GD535-5
(01)
Item name Default Remarks

Battery dis-
Machine with battery disconnect,
connect Invalid
select "Valid".
setting
Hydraulic
Machine with hydraulic fan, select
fan selec- NO ADD
"45°C spec".
tion
5. Select "Tire Size Compensation" item to correct

the set value.
F1: Decreases set value by 1 %.
F2: Increases set value by 1 %.
4. When the setting screen of each item is displayed, F3: Cancels contents of setting not yet entered
select a setting by using function switches. and returns screen to "Option Selection" screen.
F1: Moves selection downward. F4: Enters selection and returns screen to "Option
F2: Moves selection upward. Selection" screen.
"Option Selection" screen.
6. When settings of respective items are complete,

press function switch F3 to return the screen from
"Option Selection" screen to "Default" screen.
Items that can be set by using Option Selection a When you have never pressed function switch
function F4 (no change is made) for any item setting,
Item name Default Remarks even if you exit "Option Selection" screen and
return to "Default" screen, this screen does not
Differential Select "ADD" when the option
NO ADD appear.
Control equipment is installed.
13.00- When 13.00-24-12PR tire is 7. When the screen requesting key-off operation is
Tire Type
24-12PR installed, select 13.00-24-12PR. displayed, turn the starting switch to OFF position.
If indicated travel speed is
deemed to be different from
actual speed, use this function
Tire Size
to adjust it. (Each time the set
Compen- 0%
value is increased by 1 %,
sation
indicated travel speed increases
by 1 % relative to that at 0 %.
See step 4.
"NO ADD"
E Mode It starts from key off state.
Default ADD "ADD"
Function It starts from E mode in key on
state.
Turning the starting switch to OFF position completes

setting of "Option Selection".
GD535-5 30-141
(01)
Default (Unit Selection)

Default menu items are used to check or change vari-
ous settings of the machine monitor and machine.
The Unit Selection function is used to select a display
unit for the data to be displayed in the monitoring.
1. Select "Default" on "Service Menu" screen.

in "Service mode".
Diagnostic Tests (Cylinder Cut-out)

Use Diagnostic Tests menu items to check the
machine monitor and machine or reset the settings.
Cylinder cutout mode operation means to run the
engine with one or more fuel injectors disabled electri-
cally to reduce the number of effective cylinders. This
operation is used to identify a cylinder that does not
output power normally (combustion in it is abnormal).
2. When "Default" screen is displayed, select "Unit 1. Select "Diagnostic Tests" on "Service Menu"
Selection" by using function switches. screen.
a For the selection method, see relevant section a For the selection method, see relevant section
in "Service mode". in "Service mode".
3. When "Unit Selection" screen is displayed, select 2. When "Diagnostic Tests" screen is displayed,
the display unit to be set by using function select "Cylinder Cut-out" by using function
switches. switches.
F1: Moves selection downward. a For the selection method, see relevant section
F2: Moves selection upward. in "Service mode".
"Default" screen.
F4: Enters selection and returns the display to
"Default" screen
30-142 GD535-5
(01)
3. When "Cylinder Cut-out" screen is displayed, inder, the background (a) of the cylinder num-
select a cylinder to be cut out by using the function ber becomes red.
switches. q The cylinder cut-out mode operation is not
F2: Switches setting between HOLD and HOLD automatically reset even if the machine moni-
CANCELED. (If HOLD is selected, a diagonal tor returns to the operator mode. Accordingly,
appears in HOLD box.) be sure to perform the reset operation after the
F3: Returns screen to "Diagnostic Tests" screen. cylinder cutout mode operation is finished.
F6: Moves selection leftward Adjustment (ECMV Automatic Compensation)
F7: Moves selection rightward k Park the machine on flat ground, place the
stop the engine.
moving.
Use Adjustment menu items to check various settings
or adjustment of the machine.
Perform this Adjustment item under the following con-
ditions.
"ECMV Automatic Compensation" function is used to
correct the variation in operational feeling among
ECMVs due to the individual difference so that the
variation is kept at a certain level through the trans-
a This operation is allowed while the engine is mission controller.
running. 1. Start the engine.
a If background (a) of the selected cylinder num- 2. Select "Adjustment" on "Service Menu" screen.
ber becomes white after you press F4, the cyl- a For the selection method, see relevant section
inder is cut out. in "Service mode".
a If the machine monitor cuts out a cylinder but
the engine controller cannot cut out that cylin-
der, the background (a) of the cylinder number
becomes yellow.
a One or more cylinders can be cut out.
a The HOLD function is available for a cylinder,
regardless of whether it is cut out or not.
If a normally operating cylinder is cut out, the fol-
lowing phenomena occur. If the engine is running
at near high idle, however, the engine speed may
not lower for the reason of engine control. In this
case, lower the engine speed with the accelerator
pedal and judge by increase of the injection rate
command.
q Lowered engine speed 3. When Adjustment screen is displayed, select "T/C
q Increased Fuel Inject Command (quantity) Stall" by using function switches.
4. When changing a cylinder to be cut out or when in "Service mode".
cylinder cutout operation is finished, select a cutout
cylinder to be reset with function switches.
q The method to select a cutout cylinder to be
reset is the same as that to select a cylinder to
be cut out.
q This operation is allowed while the engine is
running.
q When F4 is pressed, if background (a) of the
selected cylinder number becomes gray, the
cylinder is reset.
q If the machine monitor reset a cutout cylinder
but the engine controller cannot reset that cyl-
GD535-5 30-143
(01)
6. If "T/C Stall (01/02)" screen is displayed, confirma-

tion of the change is requested. In this case, press
F4 to enter the change.
(a): Current setting
(b): Revised setting
When "F4" is pressed, "1" is displayed for (a)
enabling the torque converter stall mode. The
transmission mode is fixed to torque converter
automatic mode (T/C AUTO) and the gear speed
is fixed to N (neutral) or F8 gear.
a If F3 is pressed and the screen is returned to
"Adjustment" screen, the set mode is disabled.
4. When "T/C Stall (01/02)" screen is displayed, press

function switches.
a If "5" (Out of Condition) is displayed for (a), the
gear shift lever is not set at P (PARK) position.
Move the gear shift lever to P (PARK) position.
7. Display "T/C Stall (02/02)" screen.

F6 and F7: Moves screen to "T/C Stall (02/02)"
screen.
8. Depress the brake pedal with your left foot surely.
5. When the screen with "revised value input box"

screen is displayed, input value 1 for the torque
converter stall mode and enter it by using function
switches.
F3: Cancels input.
F4: Enters input.
screen.
9. Move the gear shift lever to F8 position.

10. Depress the accelerator pedal gradually to stall the
torque converter so that the torque converter oil
temperature rises to 90°C.
k Do not keep stalling torque converter for
more than 20 seconds. Take care that
torque converter oil temperature does not
exceed 120°C.
11. When the torque converter oil temperature
reaches 90°C, release your right foot from the
accelerator pedal (low idle) immediately, and
return the gear shift lever to P (PARK) position.
30-144 GD535-5
(01)
k Do not operate the gear shift lever with the F2: Switches setting for monitoring value between
accelerator pedal kept depressed. Doing so HOLD and HOLD CANCELED. (If HOLD is
causes large gear shift shocks and short- selected, a diagonal appears in HOLD box.)
ens the service life of the machine as well.
12. Run the engine at medium speeds and release

your right foot from the accelerator pedal when the
torque converter oil temperature lowers to 80°C.
a Keep the gear shift lever set at P (PARK) posi-
tion.
13. Repeat steps 8. to 12. 4 to 5 times to equalize the
oil temperature of the torque converter and trans-
mission.
14. Press F3 to return the screen to "Service Menu"
screen and select "Adjustment" .
in "Service mode".
When "ECMV Automatic Compensation" starts,

15. When "Adjustment" screen is displayed, select the adjustment of each valve is conducted 4 times
"ECMV Automatic Compensation" by using func- automatically and continuously.
tion switches. a During "ECMV Automatic Compensation", "- - -"
a For the selection method, see relevant section is displayed for (c).
in "Service mode". a ECMV adjustment order and screen display (b)
on the machine monitor are as follows.
16. When START is displayed for part (a), press F4 to

start the adjustment.
F3: Returns screen to "Adjustment" screen without
starting adjustment.
F4: Starts adjustment.
F6 and F7: Moves screen to "ECMV Automatic
Compensation (02/02)" screen.
GD535-5 30-145
(01)
ECMV adjustment order and screen display on [15S*MA] and [DXH*KA]. If the valve and
machine monitor conditions are determined to be normal,
Adjust- Screen display (b) on machine monitor repeat the work from step 1.
ment ECMV a The mark * denotes target clutch.
order 1st time 2nd time 3rd time 4th time q When "3: NG (Over Compensation)" is dis-
played:
1 FL FL-1 FL-2 FL-3 FL-4 Perform troubleshooting for failure code
2 FH FH-1 FH-2 FH-3 FH-4 [15S*L1]. If the valve and conditions are
determined to be normal, repeat the work
3 R R-1 R-2 R-3 R-4
from step 1.
4 1st 1-1 1-2 1-3 1-4 a The mark * denotes target clutch.
5 2nd 2-1 2-2 2-3 2-4
6 3rd 3-1 3-2 3-3 3-4
7 4th 4-1 4-2 4-3 4-4
17. For each adjustment work, whether it ends

normally ("OK") or abnormally ("NG") is displayed.
Take actions according to the displayed result.
q Screen display at normal end
When "4-4" (the last ECMV) and "0" (OK) is
displayed for (b) and (c) respectively, all
ECMVs are normal.
q When "0": OK (normal end) is displayed:
18. If the adjustment work ends normally, turn the
Adjustment work ends normally, so go to starting switch to OFF position.
step 18. a The adjusted value is saved in the transmis-
(b): ECMV for which adjustment ends sion controller approximately 3 seconds after
normally the starting switch is turned to OFF position.
(c): Adjustment result a After the adjustment, if it is needed to turn the
starting switch to ON position promptly, wait 10
seconds or more after the starting switch is
turned to OFF position by way of precaution,
and then turn it to ON position,
Adjustment (T/M Initial Learning)

k Be sure to perform the learning work in a place
where an ample traveling area is available
while paying attention to safety in the sur-
rounding area.
Perform this Adjustment item under the following con-
ditions.
q Screen display at abnormal end q Torque converter oil temperature: 70 to 90°C
When other than "0" (OK) is displayed for (c), q Power mode: P mode
the ECMV has an abnormality or the machine q Transmission mode: Manual mode (MANU)
is NG (out of adjustment condition). Abnormal
valve is displayed for (b). 1. Referring to "ECMV Automatic Compensation",
Conditions displayed for (c) and actions to take correct the individual difference in operational
are as follows. feeling of each ECMV.
q When "1: NG (Out Condition)" is displayed: 2. Hold the torque converter oil temperature within
Check the torque converter oil temperature the range of temperature conditions.
and conditions at the adjustment again, k If the adjustment is performed with the oil at
and perform the adjustment work from step a temperature out of the range of tempera-
1. ture conditions, a time lag or gear shift
q When "2:NG (No Fill Signal)" is displayed: shock may occur.
Perform troubleshooting for failure codes
30-146 GD535-5
(01)
a For the method to increase the torque con-

verter oil temperature, see "ECMV Automatic
Compensation".
7. When "Adjustment" screen is displayed, select "T/

M Initial Learning" by using function switches.
a For the selection method, see "Operation
3. Initialize the initial learning data of the transmis- method of service mode" in "Service mode".
sion. For details, see "Adjustment (T/M Initial
Learning Reset)".
4. Set the transmission mode selector switch to the
manual (MANU) mode.
8. When "T/M Initial Learning (01/03)" screen is

displayed, operate the accelerator pedal and gear
shift lever according to the order shown in the
following table.
5. Select P mode by using the power mode selector k Do not use the inching pedal to start and
switch. stop the machine or to make directional
When P mode is selected, the power mode sym- change in this adjustment. If the inching
bol A shown below lights up on the machine moni- pedal is used, the "learning" of each clutch
tor. may not complete successfully.
k Operating the gear shift lever causes the
machine to move. Pay attention to safety in
the surrounding area.
F2: Switches setting for monitoring value between
HOLD and HOLD CANCELED. (If HOLD is
selected, a diagonal appears in HOLD box.)
F3: Returns screen to "Adjustment" screen.
6. Select "Adjustment" on "Service Menu" screen.

in "Service mode".
GD535-5 30-147
(01)
Order 1 2 3 4 5 6 7 8 9 10 11
Directional
N F1 F2 F3 F4 F3 F2 F1 N R1 N
lever
Depress Depress Depress Depress
Accelerator to the to the to the to the Do not Do not Do not Do not Do not Do not Do not
pedal stroke stroke stroke stroke depress. depress. depress. depress. depress. depress. depress.
end. end. end. end.
Holding
5 10 3 3 40 3 3 3 10 3 3
time (at
seconds seconds seconds seconds seconds seconds seconds seconds seconds seconds seconds
minimum)
9. After the machine stops, check the learning status F7: Moves screen to "T/M Initial Learning (03/
of each clutch. 03)" screen.
q If "OFF" is displayed for any clutch, the learn-
ing has not been completed. In this case, do
this adjustment item again starting from step 3.
Initialization of the initial learning data of the
transmission.
q When "ON" is displayed for all clutches and the

learning has completed successfully, display
"T/M Initial Learning (01/03)" screen and press
F3 several times to return to the standard
screen, and then turn the starting switch to
OFF position.
F3: Returns screen to "Adjustment" screen.
F6: Moves screen to "T/M Initial Learning (02/
03)" screen.
30-148 GD535-5
(01)
Adjustment (T/M Initial Learning Reset)

This function is used to initialize the initial learning
data of the transmission through the transmission
controller. Perform this adjustment item if needed
when executing the initial learning of the transmis-
sion.
in "Service mode".
4. When the screen appears, press F4 again to

execute reset.

M Initial Learning Reset" by using function
switches.
in "Service mode".
5. After the execution of reset, check that "1: Learning
Not Done Yet" is displayed for initialization status
(a), and then press F3.
3. When "T/M Initial Learning Reset" screen is

displayed, check initialization status (a).
q When "0: Learning Completed" is displayed,
press F4 to go to step 4. This indicates that the initial learning data of the
q When "1: Learning Not Done Yet" is displayed, transmission has been initialized. Perform the adjust-
go to step 5. ment item "T/M Initial Learning".
GD535-5 30-149
(01)
Adjustment (Inching Pedal 0% Adjustment) q When "0" is displayed for (a)

Use Adjustment menu items to check various settings The machine monitor is waiting for execution
of the machine. of this adjustment. Proceed to the next step.
This function is used to make the transmission con- q When "2" is displayed for (a)
troller recognize the neutral position of the inching The output voltage of the inching pedal sensor
pedal when it is not depressed. Be sure to perform is a value that indicates defective adjustment.
this adjustment item after replacement of the trans- Check the inching pedal for possible causes
mission controller or removal and installation of the such as poor contact of the connector, defec-
inching pedal. tive installation of the inching pedal, etc.
1. Select "Adjustment" on "Service Menu" screen. When "1" is displayed for (a), the transmission
a For the selection method, see relevant section controller recognizes the neutral position of the
in "Service mode". inching pedal.
2. When "Adjustment" screen is displayed, select

"Inching Pedal 0% Adjustment" by using function
switches.
in "Service mode".
3. Check that the gear shift lever is set at P (PARK)

position.
a If the gear shift lever is set at a position other
than P (PARK), this adjustment cannot be
allowed.
5. Display "Inching Pedal 0% Adjustment (02/02)"

screen and check the value of "Inching Pedal
Sensor Volt".
F6 and F7: Moves screen to "Inching Pedal 0%
Adjustment (02/02)" screen.
a Normal output voltage when the inching pedal
is at its neutral position ranges as follows.
q "Inching Pedal Sensor Volt": 1.26 to 1.56 V
q F2: Switches setting for monitoring value
between HOLD and HOLD CANCELED. (If
HOLD is selected, a diagonal appears in
HOLD box.)
4. When "Inching Pedal 0% Adjustment (01/02)"
screen is displayed, enter the setting by using func-
tion switches.
F3: Cancels execution of adjustment and returns
screen to "Adjustment" screen.
F4: Executes adjustment
30-150 GD535-5
(01)
Adjustment (Inching Pedal 100% Adjustment)

of the machine.
This function is used to make the transmission con-
troller recognize the position of the inching pedal
when it is depressed to its stroke end. Be sure to per-
form this adjustment item after replacement of the
transmission controller or removal and installation of
the inching pedal.
in "Service mode".

"Inching Pedal 100% Adjustment" by using func-
tion switches.
in "Service mode".
3. Check that the gear shift lever is set at P (PARK)

position.
a If the gear shift lever is set at a position other
than P (PARK), this adjustment cannot be
allowed.
4. When "Inching Pedal 100% Adjustment (01/02)"

screen is displayed, depress the inching pedal to
its stroke end.
q When "0" is displayed for (a) after the inching
pedal is depressed
The machine monitor is waiting for execution
of this adjustment. Proceed to the next step.
GD535-5 30-151
(01)
q When "2" is displayed for (a) after the inching

pedal is depressed
The output voltage of the inching pedal sensor
is a value that indicates defective adjustment.
Check the inching pedal for possible causes
such as poor contact of the connector, defec-
tive installation of the inching pedal, etc.
a When "1" is displayed for (a), the transmission
controller recognizes the stroke end position of
the inching pedal.
5. Enter the setting by using function switches.

F6 and F7: Moves screen to "Inching Pedal 100%
Adjustment (02/02)" screen.
6. Display "Inching Pedal 100% Adjustment (02/02)"

screen and check the value of "Inching Pedal
Sensor Volt".
a Normal output voltage when the inching pedal
is depressed to its stroke end ranges as fol-
lows.
q "Inching Pedal Sensor Volt": 3.41 to 3.71 V
q F2: Switches setting for monitoring value
between HOLD and HOLD CANCELED. (If
HOLD is selected, a diagonal appears in
HOLD box.)
30-152 GD535-5
(01)
Adjustment (T/C Stall)

of the machine.
This function is used to execute torque converter stall
operation safely with the transmission mode and gear
speed being fixed. Be sure to use this function when
testing the machine under the torque converter stall
condition.
in "Service mode".
4. When the screen with "revised value input box"

screen is displayed, input the number (0 or 1) for
the desired mode and enter it by using function
switches.
q When "0: Normal" is selected:
The machine is in the normal working mode in
which both the transmission mode and gear
speed are not fixed. Select this value to
recover the normal working mode after the
testing is finished.
q When "1: T/C Stall" is selected:
Select this value to test the machine in the
torque converter stall mode.
C Stall" by using function switches.
in "Service mode".
F3: Cancels input.
F4: Enters input.
screen.
3. When "T/C Stall (01/02)" screen is displayed, press

function switches.
q When "0" is displayed for (a)
The machine is currently in the normal working
5. If "T/C Stall (01/02)" screen is displayed, confirma-
mode in which both the transmission mode
tion of the change is requested. In this case, press
and gear speed are not fixed.
F4 to enter the change.
(a): Current setting
The machine is currently set in the torque con-
(b): Revised setting
verter stall mode
Since the gear shift lever is not set at P (PARK)
position, the machine is determined to be out
of the fixing conditions. Move the gear shift
lever to P (PARK) position.
GD535-5 30-153
(01)
Adjustment (Zero Point Adjustment For Art Angle)

of the machine.
This function is used to make the transmission con-
troller recognize the zero point of the articulate angle
sensor. Be sure to perform this adjustment item after
replacement of the transmission controller or removal
and installation of the articulate angle sensor.
1. Set the machine in the straight travel posture, and
insert the articulate lock pin in the locked position.
2. Check that installed length (a) of rod (2) that is
installed to articulate angle sensor (1) is correct.
a Installed length (a) of rod (2): 241 mm
When the change is entered, a number (0 or 1) of

selected mode is displayed for (a).
a If F3 is pressed and the screen is returned to
"Adjustment" screen, the set mode is disabled.
a The gear speed during torque converter stall is
determined depending on the gear shift lever
position as shown in "List of gear shift lever
position and gear speed".

in "Service mode".
List of gear shift lever position and gear speed

Gear shift lever position Gear speed
F8 F8
F1 to F7 N
N N
R1 to R4 N
"Zero Point Adjustment For Art Angle" by using
Since the machine is set in the selected mode, exe-
function switches.
cute normal work or testing under the torque con-
verter stall condition according to the set mode.
in "Service mode".
30-154 GD535-5
(01)
5. When "Zero Point Adjustment For Art Angle" Method for adjusting with adjustment menu (fan
screen is displayed, check output value (b) of the 100% speed adjustment)
articulate angle sensor. This function is used to forcibly set the cooling fan
(a): Current set value recognized by transmission speed to approximately 100 % regardless of the
controller actual oil and coolant temperatures.
(b) Output value of articulate angle sensor a Use this function for testing, adjusting, or trouble-
q When output value (b) of articulate angle sen- shooting as necessary.
sor is within the setting range a Since the cooling fan speed still depends on the
Proceed to the next step. throttle position in this mode, depress the acceler-
q When output value (b) of articulate angle sen- ator pedal when checking the maximum speed.
sor is out of the setting range Adjustment menu is used to check the various set-
The zero point of the articulate angle sensor tings of the machine or to adjust the value.
cannot be set. Check for possible causes such 1. Select “Adjustment” on “Service Menu” screen.
as poor contact of the connector, defective
installation of the rod, etc.
2. After the “Adjustment” screen is displayed, use a

switch on the switch panel to select “Fan 100%
a Setting range of articulate angle sensor: Speed Adjustment”.
2.1 to 2.6 V a Method of selecting is similar to “Service
Menu” screen.
6. Enter execution of the adjustment by using func-
tion switches.
When the output value of the articulate angle sen-
sor is displayed for (a), the transmission controller
recognizes the zero point of the articulate angle
sensor.
GD535-5 30-155
(01)
No Injection
3. When function switch (F4) is pressed, “1” is If the engine is operated after long storage of the
displayed in portion (a) and the fan speed is set to machine, it may be worn or damaged because of
100 %. insufficient lubrication with oil. To prevent this, the
machine has a function to crank the engine without
injecting fuel to lubricate the engine before starting it.
Set No Injection cranking while the engine is stopped.
Even if the operator tries to perform No Injection
cranking while the engine is running, the function is
not enabled.
This function can be selected even when the engine
is running. However, if you execute No Injection
cranking, a message "The engine is operating.
Please turn the key off once." appears on the screen.
4. When function switch (F4) is pressed again, “0”

is displayed in portion (a) and the fan speed goes
back to normal mode.
a When the screen is returned to “Adjustment”
screen by pressing RETURN switch (12), the
fan speed is returned to normal mode, even if it
is set in 100 % mode.
In the following cases, this function cannot be

enabled even if the confirmation screen is displayed
and No Injection cranking is activated. Turn the start-
ing switch to OFF position once, and activate the
function.
q When communication between the machine moni-
tor and engine controller is abnormal
q When engine start operation is performed before
the message "No Injection is possible" is dis-
played.
1. Select "No Injection" on the "Service Menu"

screen.
in "Service mode".
30-156 GD535-5
(01)
2. When "No Injection" screen is displayed, the 4. After the cranking is over, turn the starting switch to
message to ask whether to execute No Injection OFF position.
cranking appears. Select the answer by using You cannot switch the screen described above to
function switches. another screen.
F3: Does not execute. (Returns screen to "Service
Menu" screen.)
F4: Executes.
3. When No Injection cranking (no fuel injection for all

cylinders) is enabled, the message "No injection is
possible. Please turn the key off after no injection
ends." is displayed. Crank the engine by using the
starting motor.
k Do not crank the engine continuously for 20
seconds or longer in order to protect the
starting motor.
a While the screen is changing to the following
screen, the screen of "Getting Ready" is dis-
played.
GD535-5 30-157
(01)
KOMTRAX Settings (Terminal Status)

KOMTRAX Settings screen allows check of setting
status and operating condition of KOMTRAX.
"KOMTRAX Settings (Terminal Status)" is used to
check the setting condition of the KOMTRAX termi-
nal.
1. Select "KOMTRAX Settings" on service menu
screen.
in "Service mode".
2. When "KOMTRAX Settings" screen is displayed,

select "Terminal Status" by using function
switches.
in "Service mode".
3. Following information is displayed on "Terminal

Status" screen.
Terminal Type: Type of KOMTRAX communication
modem
KOMTRAX Communication: State of the imple-
mentation of KOMTRAX Communication opening
GMT Time: Greenwich mean time (9 hours before
Japan time)
F3: Returns screen to "KOMTRAX Settings"
screen.
30-158 GD535-5
(01)
KOMTRAX Settings (GPS & Communication Sta-

tus)
"GPS & Communication Status" is used to check the
positioning and communication conditions of the
KOMTRAX terminal.
screen.
in "Service mode".
KOMTRAX Settings (Modem Status)

"Modem Status" is used to check the phone number
and IMSI of KOMTRAX communication modem.
screen.
in "Service mode".

select "GPS & Communication Status" by using
function switches.
in "Service mode".

select "Modem Status" by using function switches.
in "Service mode".
3. Following information is displayed on "GPS &

Communication Status" screen.
Positioning: Positioning condition of GPS
Communication: Communication environment and
connection status of communication modem
No. of message(s) not yet sent: No. of mail mes-
sages that are stored in the machine monitor and
have not yet been sent.
F1: Moves screen to next page.
F2: Moves screen to previous page.
screen. 3. The phone number and IMSI are displayed
screen.
GD535-5 30-159
(01)
a The messages differ from those sent in the

operator mode for operators.
a Since the messages are only for technicians,
even if a message is received, no message
symbol is displayed unlike in the case of the
operator mode.
q Displaying messages (with reply function)
When the guidance icon is displayed for F4,
pressing F4 displays the message reply
screen.
Service Message
This function allows check of messages only for tech-
nicians from KOMTRAX base station (dealer, etc.).
1. Select "Service Message" on "Service Menu"
screen.
in "Service mode".
1) When the message reply screen is displayed,

input a numeral and enter it by using function
switches. A message "Proceed?" will be
displayed.
F1: Decreases input value by 1.
F2: Increases input value by 1.
F3: Cancels input and return screen to "Ser-
vice Menu" screen.
F4: Enters input value.
2. Display messages.
q Displaying messages (read only)
If there is a message, the contents are displayed.
If there is no message, "No message." is dis-
played.
F1: Moves screen to next page (displays if mes-
sage extends over 2 or more pages).
F2: Moves screen to previous page (displays if
message extends over 2 or more pages).
2) When message "Proceed?" is displayed, if a

numeral is input and entered, the information is
returned to the KOMTRAX base station.
F3: Cancels sending and returns screen to
"Message Reply" screen.
F4: Enters sending.
a The messages differ from those sent in the
operator mode for operators.
a Since the messages are only for techni-
cians, even if a message is received, no
message symbol is displayed unlike in the
case of the operator mode.
30-160 GD535-5
(01)
GD535-5 30-161
(01)
Handling high-voltage circuit of engine controller 30 Testing and adjusting
Handling high-voltage circuit of

engine controller 1
1. Be sure to turn the starting switch to OFF position

and disconnect the battery ground wire before
disconnecting or connecting the connectors
between the engine controller and engine.
2. When you perform troubleshooting, do not start the

engine while a T-adapter is inserted into or
connected to the connector between the engine
controller and engine.
a You may turn the starting switch to OFF or ON
position but must not turn it to START position.
30-162 GD535-5
(01)
30 Testing and adjusting KOMTRAX terminal start-up procedure
KOMTRAX terminal start-up 1. Checking whether machine is subjected to inspec-

procedure 1
tion for KOMTRAX Communication opening
Check whether implementation of inspection for
To use KOMTRAX , observe the following procedures. KOMTRAX Communication opening is needed for
1. KOMTRAX-Keyperson performs "Machine Regis- the machine as follows.
tration" by using KOMTRAX client PC. 1) On the "Service Menu" screen, select
2. Perform "Machine side inspection for KOMTRAX "KOMTRAX Settings" by using switches at the
Communication opening". switch panel section.
q For operating procedures, see "Global a For the selection method, see relevant sec-
KOMTRAX Web Reference Manual (For Key tion in "Service mode".
Person)".
q Operating the KOMTRAX client PC requires
the KOMTRAX operation administrator author-
ity at each distributor. Therefore you must con-
sult the KOMTRAX-Keyperson before using it.
When KOMTRAX terminal is replaced.

O bser ve the following proc edure when using
KOMTRAX after replacement of KOMTRAX terminal.
1. Our technician provides a new terminal, and
records the part number and serial number.
2. Our technician replaces the terminal with a new
one and performs "Machine side inspection for
KOMTRAX Communication opening". Our techni-
cian reports completion of the work and informa- 2) When "KOMTRAX Settings" screen is
tion on the new terminal to KOMTRAX-Keyperson. displayed, select "Terminal Status" by using
3. KOMTRAX-Keyperson performs "Terminal function switches.
Replacement" process by using KOMTRAX client a For the selection method, see relevant sec-
PC. tion in "Service mode".
4. KOMTRAX-Keyperson fills in required items on
"Terminal Replacement Sheet", and sends it by
email to KOMTRAX support center via KOMTRAX
administrator in the subsidiary.
q For operating procedures, see "Global
KOMTRAX Web Reference Manual (For Key
Person)".
q Operating the KOMTRAX client PC requires
the KOMTRAX operation administrator author-
ity at each distributor. Therefore you must con-
sult the KOMTRAX-Keyperson before using it.
Machine side inspection for KOMTRAX Communi-

cation opening
q When operation of the KOMTRAX terminal is 3) When "Terminal Status" screen is displayed,
started or the KOMTRAX terminal is replaced, check the status of KOMTRAX Communication.
inspection for KOMTRAX Communication opening If "Not updated" is displayed for "KOMTRAX
must be done to check that the terminal can per- Communication", perform step 2. If "Already
form normal communication. Open." is displayed, inspection for KOMTRAX
q Implementation of the inspection for KOMTRAX Communication opening is not needed.
Communication opening allows KOMTRAX to
start communication.
q To perform GPS and data communication check at
the inspection for KOMTRAX communication
opening, the machine should be desirably placed
outside under an open sky where radio waves are
not blocked. The KOMTRAX Communication
opening may not be completed when the machine
is placed indoors where radio waves from the sat-
ellite are blocked.
GD535-5 30-163
(01)
KOMTRAX terminal start-up procedure 30 Testing and adjusting
2. Implementation of inspection for KOMTRAX 4) When the message "Are you sure you want to
Communication opening open?" is displayed, use function switches to
Implement KOMTRAX Communication opening implement the opening.
according to the following procedure. F3: Returns screen to "GPS & Communication
1) Select "KOMTRAX Settings" on "Service Status" screen.
Menu" screen. F4: Implements inspection for KOMTRAX
a For the selection method, see relevant sec- Communication opening.
tion in "Service mode".
5) Implementation status of the inspection for

2) When "KOMTRAX Settings" screen is displayed, KOMTRAX Communication opening is
select "GPS & Communication Status." displayed. Check that "OK" is displayed for all
a For the selection method, see relevant sec- items.
tion in "Service mode". "Modem": "OK" appears when it is determined
to be within communication range.
GPS: "OK" appears when it acquires GPS
data.
"Transmission": "OK" appears when it trans-
mits data correctly.
"Inspection Status": "OK" appears when "OK"
is displayed for all of "Modem". "GPS", and
"Transmission".
q It takes 90 seconds to 15 minutes to
approve all items.
3) When "GPS & Communication Status" screen

is displayed, press function switches in the
order of F1, F2, and F3 while keep pressing F8.
30-164 GD535-5
(01)
30 Testing and adjusting KOMTRAX terminal start-up procedure
6) When all items are "OK", "KOMTRAX Commu-

nication Opened." screen is automatically
displayed.
Press the function switch. If "GPS & Communi-
cation Status" screen appears, the machine
side inspection for KOMTRAX Communication
opening is completed.
In other cases than the above, perform step 3.
q Moving to other screens, turning the start-

ing switch to OFF position, or starting the
engine during waiting time for "OK" being
displayed for all items does not matter.
If there is nothing abnormal, the inspection
for KOMTRAX Communication opening fin-
ishes automatically. Select screens in the
order of "Service Menu", "KOMTRAX Set-
tings", and "Terminal Status", and check 3. Troubleshooting when inspection for KOMTRAX
that "Already Open." is indicated for the Communication opening resulted in abnormal end
item "KOMTRAX Communication" on "Ter- q If any of sub steps 1) to 5) in step 2. cannot be
minal Status" screen. performed normally, perform the steps again
q The opening may not be completed when from step 2.-1).
the machine is placed indoors where radio q If step 2.-6) cannot be completed normally,
waves from the satellite are blocked. possible causes are as follows.
Troubleshooting when inspection for KOMTRAX Communication opening resulted in abnormal end
Symptom Cause Remedy
Something on the cab prevents monitoring of GPS
Remove the obstacle on the cab.
"OK" is not satellite.
displayed for GPS. GPS antenna cable is not connected to the Check the connection and connect it surely if it is
machine monitor or loosely connected. loose.
Use a mobile phone in hand to check whether the
machine is within communication range. If the
Mobile phone is out of communication range. machine is outside communication range, move it
to a region within communication range to
"OK" is not
implement the inspection.
displayed for
Modem. Communication antenna cable is not connected to Check the connection and connect it surely if it is
KOMTRAX terminal or loosely connected. loose.
KOMTRAX terminal is not connected to the wiring Check the connection and connect it surely if it is
harness on machine side or loosely connected. loose.
4. After the troubleshooting, perform the steps again

from step 2.-1).
GD535-5 30-165
(01)
KOMTRAX terminal start-up procedure 30 Testing and adjusting
If the problem cannot be solved, contact the local support center.
30-166 GD535-5
(01)
30 Testing and adjusting Adjusting rearview camera angle
Adjusting rearview camera angle 1
k Be sure to adjust the camera before starting

work. If it is not adjusted properly, you cannot
secure the visibility and a serious personal
injury or death may result.
k When adjusting the angle of the camera, pre-
pare a scaffold first in order to provide a safe
working platform.
If you try to work standing on the ripper, there
is a danger of serious injury or death due to
falling off from the machine.
k Install only the Komatsu genuine camera.
Method for adjusting rear view camera angle 1. Remove bolts (1) (3 places) and remove cover (2).
Adjust the angle of the rear view camera so that peo-
ple within 1 m away from the machine's rear part (W)
is displayed in the monitor at the operator's seat.
2. Loosen mounting bolts (3) (3 places) and adjust

angle (A).
a Adjust it so that a part of the machine body can
be viewed on the monitor screen.
3. After adjusting, tighten bolts (3) (3 places).
4. Install cover (2) and tighten bolts (1) (3 places).
a If the image on the monitor is not aligned correctly,

adjust mounting angle (A) of the rear view camera.
a Angle (A) can be adjusted within the range from
35 to 50 °.
GD535-5 30-167
(01)
Adjusting rearview camera angle 30 Testing and adjusting
30-168 GD535-5
(01)
30 Testing and adjusting Handle battery disconnect switch
Handle battery disconnect switch 1 q System operating lamp (2) may sometimes
light up while the starting switch is turned to
(O): OFF position OFF position because KOMTRAX terminal
(I): ON position may maintain its communication under this
q Battery disconnect switch (1) is usually used in the
condition.
following cases in the same purpose of discon- q Even if system operating lamp (2) is not lit, it
necting the cable from the negative terminal of the may seem to be lit slightly because of a very lit-
battery. tle leakage current inside the controller. This
q When storing the machine for a long period (1
phenomenon does not indicate abnormality.
month or longer) q The KOMTRAX terminal performs communica-
q When servicing or repairing the electrical sys-
tion periodically even if the starting switch is
tem kept in OFF position, thus it repeats starting
q When performing electric welding
and stopping.
q When battery disconnect switch (1) is at OFF posi-
q The start and stop cycle (sleep cycle) of
tion, all the continuous power supplies for the KOMTRAX terminal varies depending on the
components including the starting switch B termi- factors including the communication state and
nal and controllers are all cut out. It is the same machine stop time. It may be lit for a maximum
state as the time when the battery is not con- of approximately 1 hour.
nected, and all the electrical system of the q When you want to open the battery circuit for
machine are out of operation.
k It is extremely dangerous if battery disconnect
maintenance but system operating lamp (2) is
lit, turn the starting switch to ON position once,
switch (1) is turned to ON position by unau- turn it to OFF position, and then the lamp goes
thorized person. out in 6 minutes. After system operating lamp
(2) goes out, turn battery disconnect switch (1)
to OFF position immediately.
a Key must be removed when turning the battery

disconnect switch (1) to OFF position.
q The operating condition of each controller can
be checked with the system operating lamp (2)
to prevent the abnormal end of the disconnec-
tion of the battery power supply circuit while
the controllers are in operation.
q Before shutting off the battery power supply
circuit, turn the starting switch to OFF position,
and check that system operating lamp (2) goes
out, then turn the battery disconnect switch (1)
to OFF position.
q If the battery disconnect switch (1) is turned to
OFF position (battery power supply circuit is
OFF) while the system operating lamp (2) is lit,
data loss error of controller may occur. Never
operate the battery disconnect switch (1) while
the system operating lamp (2) is lit.
q The system operating lamp (2) goes out in
maximum 6 minutes after the starting switch is
turned to OFF position.
GD535-5 30-169
(01)
Preparatory work for troubleshooting of electrical system failure 30 Testing and adjusting
Preparatory work for 2. Engine controller

troubleshooting of electrical a The engine controller is installed to the engine
on the right side of the machine.
system failure 1
1) Open R.H. side cover (4).
a When performing troubleshooting of electric circuits

of machine monitor, engine controller, and trans-
mission controller, expose the applicable connector
part according to the following procedure.
1. Machine monitor
1) Remove mounting bolts (1) and (2), and pull out
machine monitor (3) toward the operator's seat.
2) Connect or insert T-adapters for trouble-

shooting to connectors ECM and EC2 of engine
controller (5).
a Since connectors ECM and EC2 are
secured with screws, loosen the screws
before disconnecting them.
a When returning the connectors to the origi-
nal state, tighten the screws to the speci-
fied torque to fix them.
2) Insert or connect T-adapters for trouble- 3 Screw:

shooting into or to FP1 connector of the 2.55 to 3.1 Nm {0.26 to 0.32 kgm}
machine monitor.
30-170 GD535-5
(01)
30 Testing and adjusting Preparatory work for troubleshooting of electrical system failure
a The transmission controller is installed in the
rear section of operator's compartment (6).
1) Insert or connect T-adapters for trouble-

shooting into or to connectors TM39, TM40,
and TM41 of transmission controller (7).
a Since the connectors are secured with
screws, loosen the screws before discon-
necting them.
a When returning the connectors to the origi-
nal state, tighten the screws to the speci-
fied torque to fix them.
3 Screw: 2.82 Nm {0.288 kgm}
GD535-5 30-171
(01)
Pm Clinic 30 Testing and adjusting
Pm Clinic 1
Pm Clinic 1
30-172 GD535-5
(01)
30 Testing and adjusting Pm Clinic
Pm Clinic measurement location (1/3)
Reference item (page) for measurement procedure

*1 Engine speed: Testing engine speed (30-16 page)
*2 Blowby pressure: Testing blowby pressure (30-29 page)
*3 Engine oil pressure: Testing engine oil pressure (30-30 page)
*4 Boost pressure: Testing boost pressure (30-18 page)
*5 Exhaust gas temperature: Testing exhaust gas temperature (30-20 page)
GD535-5 30-173
(01)

*6 Power train oil pressure: Testing power train oil pressure (30-54 page)
30-174 GD535-5
(01)

*7 Steering oil pressure: Testing and adjusting steering oil pressure (30-80 page)
*8 Brake oil pressure: Testing and adjusting brake oil pressure (30-84 page)
*9 Work equipment oil pressure: Testing work equipment oil pressure (30-95 page)
GD535-5 30-175
(01)
Pm Clinic check sheet (1/6)

GD535-5
Machine serial number
#
SAA6D107E - 1
Engine serial No.
#
Hours check
Work instruction Date of inspection Service meter reading Inspector

Year Month Day h
a Check after starting the engine. Keep torque converter oil temperature at 90°C or below during torque con-
verter stall.
No good
Standard Repair limit Meas
Good
Item Condition Unit value for new Standard uring
machine value Result
q Coolant temperature:
Low idle 750 to 850 750 to 850
80 to 90°C
q Hydraulic oil temper-
ature: 45 to 55°C E mode 1825 to 1925 1825 to 1925
q Torque converter oil
Engine temperature: High idle
rpm
speed 60 to 80°C P mode 2100 to 2200 2100 to 2200
q Select torque con-
verter stall mode
(when testing engine Torque converter
speed at torque con- stall 1790 ± 1990 1790 ± 1990
verter stall).
Blowby q Hydraulic oil temperature: 45 to 55°C kPa Max. 1.17 Max. 1.96
pressure q Torque converter oil temperature: 60 to 80°C {mmH2O} {Max. 120} {Max. 200}
Engine
q Coolant temperature:
Min. 0.29 Min. 0.25
60 to 100°C High idle
{Min. 3.0} {Min. 2.5}
q Engine Oil (*1)
Engine oil MPa {kg/
EO10W30-LA
pressure cm2}
EO15W40-LA
Min. 0.10 Min. 0.07
EOS5W30-LA Low idle
{Min. 1.0} {Min. 0.7}
EOS5W40-LA

Boost kPa Min. 127 Min. 100
pressure {mmHg} {Min. 950} {Min. 750}
q At aftercooler outlet
Exhaust gas
temperature
(turbocharger °C Max. 650 Max. 700
q Whole speed range
inlet
q Ambient temperature: 20°C
temperature)
q At turbocharger inlet
*1: KES diesel engine oil
30-176 GD535-5
(01)
No good
Standard Repair limit
Good
Test
Item Condition Unit value for new Standard
results
machine value
2.35 to 2.75 2.35 to 2.75
Low idle
{24.0 to 28.0} {24.0 to 28.0}
Main relief pressure q Torque converter oil
of power train Rated
temperature: 2.53 to 2.93 2.53 to 2.93
speed
60 to 80°C (2,000 rpm) {25.9 to 29.9} {25.9 to 29.9}
q Transmission oil tem-
perature: 60 to 80°C Rated
Torque converter Max. 0.9 Max. 0.9
q With engine running at speed
inlet pressure {Max. 9.2} {Max. 9.2}
Low idle, or at rated (2,000 rpm)
speed (2,000 rpm)
Rated
Torque converter q While running wheels 0.48 to 0.68 0.48 to 0.68
idle off ground with speed
outlet pressure {4.9 to 6.9} {4.9 to 6.9}
gear shift lever at P or (2,000 rpm)
Power train oil pressure
Torque converter each gear Rated

1.56 to 1.96 1.56 to 1.96
lockup clutch speed
{16.0 to 20.0} {16.0 to 20.0}
pressure (2,000 rpm)
MPa
{kg/cm2} 1.96 to 2.45 1.96 to 2.45
FL
{20.0 to 25.0} {20.0 to 25.0}
1.96 to 2.45 1.96 to 2.45
FH
{20.0 to 25.0} {20.0 to 25.0}
q Torque converter oil 1.96 to 2.45 1.96 to 2.45

R
temperature: {20.0 to 25.0} {20.0 to 25.0}
Transmission 60 to 80°C
1.96 to 2.45 1.96 to 2.45
control valve set q Transmission oil tem- 1st
{20.0 to 25.0} {20.0 to 25.0}
pressure perature: 60 to 80°C
q Rated speed (2,000 1.96 to 2.45 1.96 to 2.45
rpm) 2nd
{20.0 to 25.0} {20.0 to 25.0}
1.96 to 2.45 1.96 to 2.45
3rd
{20.0 to 25.0} {20.0 to 25.0}
1.96 to 2.45 1.96 to 2.45
4th
{20.0 to 25.0} {20.0 to 25.0}
No good
Standard Repair limit Good
Test
Item Condition Unit value for new Standard
results
machine value
Cut-in 8.86 to 9.36 8.56 to 9.36
q Hydraulic oil tempera- pressure {90.4 to 95.5} {87.3 to 95.5}
Brake accumulator ture: 45 to 55°C
charge pressure q With engine running at 13.3 to 13.8 13.3 to 13.8
Cut-out
High idle {135.7 to {135.7 to
pressure MPa
140.8} 140.8}
{kg/cm2}
Hydraulic oil temperature: 45 to 55°C
Brake
q
Wheel brake q With engine stopped (after charging 4.0 to 4.8 4.0 to 4.8
operating pressure accumulator) {40.9 to 49.1} {40.9 to 49.1}
q When brake pedal is depressed
Wheel brake q With engine running at High idle
m Max. 15.8 Max. 15.8
braking distance q Braking distance when traveling at
35 km/h
GD535-5 30-177
(01)

Standard
No good
Repair limit
Good
value for Test
Item Condition Unit Standard
new results
value
machine
Steering MPa 16.6 to 18.2 16.6 to 18.2
q With engine at high idle
Steering
pressure {kg/cm2} {169 to 190} {169 to 190}

q With steering cylinder in relief condition
Play of steering q With engine at low idle
mm 0 to 25 0 to 25
wheel q Front wheels raised off the ground
Standard
No good
Repair limit
Good
value for Test
new results
value
machine
Work equipment oil pressure
Surface
temperature of q With engine stopped °C - -
hydraulic tank

Work equipment q With engine at high idle MPa 19.1 to 19.6 18.6 to 19.6
oil pressure q Work equipment circuit relief pressure: {kg/cm2} {195 to 200} {190 to 200}
with leaning cylinder in relief condition
30-178 GD535-5
(01)

Standard
No good
Repair limit
Good
value for Test
new results
value
machine
RAISE 1.7 to 2.3 Max. 4.0
Blade lift speed
LOWER 2.6 to 3.4 Max. 5.0
Left
6.9 to 9.5 Max. 10.0
Blade side shift shifting
speed Right
4.5 to 6.1 Max. 7.0
shifting
Left
1.9 to 2.7 Max. 4.0
Drawbar side shift q Hydraulic oil temperature: 45 shifting
speed to 55°C
Right
q With engine at high idle 2.8 to 3.8 Max. 5.0
shifting
q Blade lift: Move cylinder be-
tween stroke ends and oper- Left
6.8 to 9.4 Max. 10.0
Blade rotation ate both cylinders rotation
speed independently.
q Drawbar side shift: Move cyl- Right
6.8 to 9.4 Max. 10.0
rotation
Work equipment speed
inder between stroke ends.

q Blade side shift: Move cylin- In large
der between stroke ends. cutting
q Blade rotation: Move blade 1.7 to 2.3 Max. 3.0
angle Sec.
between rotation start and 90 direction
Power tilt speed deg. rotation positions.
q Power tilt: Move cylinder be- In small
tween stroke ends. cutting
1.4 to 2.0 Max. 3.0
q Articulate: Move cylinder be- angle
tween stroke ends. direction
q Leaning: Move cylinder be- Left turn 3.6 to 4.8 Max. 6.0
tween stroke ends.
Articulate speed q Ripper lift: Move cylinder be- Right
3.5 to 4.9 Max. 6.0
tween stroke ends. turn
q Scarifier lift: Move cylinder be-
Leaning
tween stroke ends. 0.6 to 0.8 Max. 2.0
to left
Leaning speed
Leaning
0.9 to 1.1 Max. 2.0
to right
Ripper speed
Scarifier lift speed
a Set the blade in the specified posture and stop the engine.
Standard
No good
Good
value for Test

Item Condition Unit Repair limit
new results
machine
Hydraulic drift
Natural drift of
blade (while mm/10
q With cylinder at LOWER stroke end Max. 20 Max. 35
raising machine min.
q Measure retraction amount of cylinder.
off ground)
GD535-5 30-179
(01)
No good
Good
Standard value Test
for new machine results
q Power mode: P mode

q Fan 100% speed ad-
Maximum fan speed of justment mode
rpm 1,250 to 1,350 1,250 to 1,350
cooling fan q Accelerator pedal: De-
press to stroke end
(High idle)
q Engine coolant temper-
ature: Max. 80 °C
Cooling fan
q Hydraulic oil tempera-

Minimum fan speed of ture: Max. 70 °C
rpm 650 to 750 650 to 750
cooling fan q Torque converter oil tem-
perature: Max. 85 °C
q Accelerator pedal: Not
depressed (Low idle)
q Fan 100% speed ad-
justment mode
Cooling fan drive MPa 13.5 to 15.5 13.5 to 15.5
q Accelerator pedal: De-
pressure {kg/cm2} {137.7 to 158.1} {137.7 to 158.1}
press to stroke end
(High idle)
a Replace the plug with a spare plug.
No good
Good
Standard value Test
Final drive
Visual check of final drive Metal powder should not be

q With engine stopped -
drain plug noticeable.
No good
Good
Standard value Test
Front wheel, left

Front wheel, right
Rear wheel, left
front 13.00 - 24 - 12PR:
kPa {kg/ 240 to 280 {2.4 to 2.8}
Tire
Tire inflation pressure Rear wheel, left

rear cm2} 14.00 - 24 - 12PR:
240 to 280 {2.4 to 2.8}
Rear wheel, right
front
Rear wheel, right
rear
30-180 GD535-5
(01)

Note: Write down the phenomena and information which draws your attention during today's checkup.
GD535-5 30-181
(01)
30-182 GD535-5
(01)
40 Troubleshooting
GD535-5 40-1
(01)
Contents 40 Troubleshooting
Contents 1
Acronyms - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-8
Information related to troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-13
Points to remember when troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-13
How to proceed in troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-14
Checks before troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-15
Inspection procedure before troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-17
Troubleshooting procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-32
Failure code list - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-34
Symptoms and troubleshooting numbers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-42
Information described in troubleshooting table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-45
Diagnosis of open harness in pressure sensor system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-47
Connector list and layout - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-49
Connector pin layout - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-63
T-box and T-adapter list - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-99
Locations of fuses - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-104
Troubleshooting by failure code (display of code) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-107
Failure code [1500L0] Double Engagement of T/M Clutches - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-107
Failure code [15G0MW] Failure of R-Clutch System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-108
Failure code [15H0MW] Failure of Clutch System (FH) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-109
Failure code [15J0MW] Failure of Clutch System (FL)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-110
Failure code [15K0MW] Failure of Clutch System (1st) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-111
Failure code [15L0MW] Failure of Clutch System (2nd) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-112
Failure code [15M0MW] Failure of Clutch System (3rd)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-113
Failure code [15N0MW] Failure of Clutch System (4th) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-114
Failure code [15SBL1] Release Trouble of ECMV (R) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-115
Failure code [15SBMA] Malfunction of ECMV (R) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-117
Failure code [15SCL1] Release Trouble of ECMV (FH) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-119
Failure code [15SCMA] Malfunction of ECMV (FH) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-121
Failure code [15SDL1] Release Trouble of ECMV (FL) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-123
Failure code [15SDMA] Malfunction of ECMV (FL) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-125
Failure code [15SEL1] Release Trouble of ECMV (1st) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-127
Failure code [15SEMA] Malfunction of ECMV (1st) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-129
Failure code [15SFL1] Release Trouble of ECMV (2nd) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-131
Failure code [15SFMA] Malfunction of ECMV (2nd) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-133
Failure code [15SGL1] Release Trouble of ECMV (3rd) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-135
Failure code [15SGMA] Malfunction of ECMV (3rd) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-137
Failure code [15SHL1] Release Trouble of ECMV (4th)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-139
Failure code [15SHMA] Malfunction of ECMV (4th)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-141
Failure code [15SJMA] Malfunction of ECMV (L/U) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-143
Failure code [15U0NT] Overload of Inching Clutch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-144
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-145
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-147
Failure code [989L00] Engine Controller Lock Caution 1 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-149
Failure code [989M00] Engine Controller Lock Caution 2 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-150
Failure code [989N00] Engine Controller Lock Caution 3- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-151
Failure code [AB00KE] Charge Voltage Low - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-152
Failure code [AB00KY] Hot Short of Alternator R Terminal- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-153
Failure code [B@BAZG] Derating in speed due to engine oil pressure drop - - - - - - - - - - - - - - - - - - - - 40-154
Failure code [B@BCNS] Engine Overheat - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-155
Failure code [B@CENS] T/C Oil Temp. Overheat - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-156
Failure code [B@CKNS] DIFF Oil Temp. Overheat - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-157
Failure code [B@HANS] HYD Oil Temp. Overheat - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-159
Failure code [CA111] Engine NE, controller internal error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-161
40-2 GD535-5
(01)
40 Troubleshooting Contents
Failure code [CA115] Engine NE, Bkup speed sensor error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-162
Failure code [CA122] Charge pressure sensor high error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-163
Failure code [CA123] Charge pressure sensor low error- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-165
Failure code [CA131] Throttle sensor high error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-167
Failure code [CA132] Throttle sensor low error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-169
Failure code [CA144] Coolant sensor high error- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-172
Failure code [CA145] Coolant sensor low error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-174
Failure code [CA153] Charge temperature sensor high error- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-176
Failure code [CA154] Charge temperature sensor low error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-178
Failure code [CA155] Speed derating error by high charge temperature- - - - - - - - - - - - - - - - - - - - - - - 40-180
Failure code [CA187] Sensor power supply 2 low error- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-181
Failure code [CA221] Atmospheric pressure sensor high error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-183
Failure code [CA222] Atmospheric pressure sensor low error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-185
Failure code [CA227] Sensor power supply 2 high error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-187
Failure code [CA234] Engine overspeed - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-188
Failure code [CA238] Ne speed sensor power supply error- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-189
Failure code [CA271] IMV short-circuit error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-190
Failure code [CA272] IMV open circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-192
Failure code [CA322] Injector #1 (L/B #1) open/short - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-194
Failure code [CA342] Data compatibility error in engine controller - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-206
Failure code [CA351] Injector drive circuit error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-207
Failure code [CA352] Sensor power supply 1 low error- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-208
Failure code [CA386] Sensor power supply 1 high error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-210
Failure code [CA428] Water-in-fuel sensor high error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-211
Failure code [CA429] Water-in-fuel sensor low error- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-213
Failure code [CA431] Idle validation switch error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-215
Failure code [CA432] Idle validation action error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-219
Failure code [CA435] Engine oil pressure switch error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-222
Failure code [CA441] Power supply voltage low error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-223
Failure code [CA442] Power supply voltage high error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-225
Failure code [CA449] Common rail pressure high error 2 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-226
Failure code [CA451] Common rail pressure sensor high error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-227
Failure code [CA452] Common rail pressure sensor low error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-229
Failure code [CA488] Torque derating error by high charge temperature - - - - - - - - - - - - - - - - - - - - - - 40-231
Failure code [CA553] Common rail pressure high error 1 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-232
Failure code [CA559] Supply pump pressure low error 1 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-233
Failure code [CA689] Engine Ne speed sensor error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-235
Failure code [CA731] Engine Bkup speed sensor phase error- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-237
Failure code [CA757] All continuous data lost error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-239
Failure code [CA778] Engine Bkup speed sensor error- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-240
Failure code [CA1633] KOMNET (CAN communication) error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-244
Failure code [CA2185] Throttle sensor power supply high error- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-248
Failure code [CA2186] Throttle sensor power supply low error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-250
Failure code [CA2249] Supply pump pressure low error 2- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-252
Failure code [CA2311] Abnormality in IMV (IMA) solenoid - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-253
Failure code [CA2555] Intake heater relay open circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-254
Failure code [CA2556] Intake heater relay short circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-256
Failure code [D160KA] Disconnection of Backup Light Relay - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-258
Failure code [D160KB] Ground Fault of Backup Light Relay - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-260
GD535-5 40-3
(01)
Failure code [D160KY] Hot Short of Back Lamp Relay Output - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-262
Failure code [D19JKZ] Personal Code Relay Abnormality - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-264
Failure code [D19KKZ] Failure of Diff Control Relay - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-266
Failure code [D1EHKA] Disconnection of Engine Start Relay - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-268
Failure code [D1EHKB] Ground Fault of Engine Start Relay - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-269
Failure code [D1EHKY] Hot Short of Engine Start Relay - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-270
Failure code [D1FBKB] Ground Fault of Sol. Self-Holding Relay - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-271
Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-273
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-274
Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) - - - - - - - - - - - - - - - - - - - - - - - - - - 40-276
Failure code [DAF0MB] Monitor ROM Abnormality - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-277
Failure code [DAF0MC] Monitor Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-278
Failure code [DAF3KK] Controller Power Source Low (MON) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-279
Failure code [DAFLKA] Op Lamp Open Cir (Mon)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-281
Failure code [DAFLKB] Op Lamp Shrt Cir (Mon)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-283
Failure code [DAQ0KK] Controller Power Source Low (T/M) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-285
Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M) - - - - - - - - - - - - - - - - - - - - - - - - - - 40-287
Failure code [DAQ0MC] T/M Con Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-288
Failure code [DAQ1KA] Disconnection of Key SW ACC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-289
Failure code [DAQ2KK] Solenoid Power Source Low (T/M) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-291
Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M) - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-293
Failure code [DAQLKA] Op Lamp Open Cir (T/M Cont) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-294
Failure code [DAQLKB] Op Lamp Shrt Cir (T/M Cont) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-296
Failure code [DAQQKR] CAN2 Discon (Transmission Con) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-298
Failure code [DAQRMA] Inconsistency of Option Selection (T/M)- - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-299
Failure code [DB2QKR] CAN2 Discon (Engine Con) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-300
Failure code [DD1PKB] Abnormality of RPM Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-304
Failure code [DD1QKB] Abnormality of RPM Set Mode Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-306
Failure code [DDB6L4] Parking brake signal error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-308
Failure code [DDTHKA] Disconnection of Fill Switch (FH) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-310
Failure code [DDTJKA] Disconnection of Fill Switch (FL)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-311
Failure code [DDTKKA] Disconnection of Fill Switch (1st) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-312
Failure code [DDTLKA] Disconnection of Fill Switch (2nd) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-313
Failure code [DDTMKA] Disconnection of Fill Switch (3rd)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-314
Failure code [DDTNKA] Disconnection of Fill Switch (R) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-315
Failure code [DDTPKA] Disconnection of Fill Switch (4th) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-316
Failure code [DF10KA] Disconnection of Shift Lever Input - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-317
Failure code [DF10L4] Gear Speed/Travel Direction Signal Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-321
Failure code [DGF1KX] Out of Range of T/M Oil Temp. Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-324
Failure code [DGH2KB] Ground Fault of Hydraulic Oil Temp. S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-326
Failure code [DGT1KX] Out of Range of T/C Oil Temp. Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-328
Failure code [DGT7KB] Ground Fault of Diff Oil Temp. S.(C) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-330
Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor - - - - - - - - - - - - - - - - - - - - - - - - - 40-331
Failure code [DHT5L6] Failure of T/C Oil Press Sensor- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-333
Failure code [DJF1KA] Disconnection of Fuel Level Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-335
Failure code [DK70KX] Out of Range of Inching Potentio. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-337
Failure code [DKD0KX] Out of Range of Articulated Angle Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-339
Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-341
Failure code [DLF1LC] Failure of T/M Input Speed Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-343
Failure code [DLF2KA] Disconnection of T/M Inter. Speed Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-345
Failure code [DLF2LC] Failure of T/M Intermediate Speed Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-347
Failure code [DLM3KA] Rad Fan Spd Sen Opn/Shrt Cir - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-349
Failure code [DLM3LC] Rad Fan Spd Sen Sig Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-351
Failure code [DLM3MB] Rad Fan Spd Sen Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-352
40-4 GD535-5
(01)
Failure code [DLT3KA] Disconnection of T/M output Speed Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - 40-353

Failure code [DW4BKA] Disconnection of Parking Brake Valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-355
Failure code [DW4BKB] Ground Fault of Parking Brake Valve- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-357
Failure code [DW4BKY] Hot Short of Parking Brake Solenoid - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-359
Failure code [DW7BKA] Rad Fan R Sol Opn Cir - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-361
Failure code [DW7BKB] Rad Fan R Sol Gnd Flt- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-363
Failure code [DW7BKY] Rad Fan R Sol Shrt Cir - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-365
Failure code [DX16KA] Rad Fan Pump EPC Sol Opn Cir - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-367
Failure code [DX16KB] Rad Fan Pump EPC Sol Gnd Flt - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-369
Failure code [DX16KY] Rad Fan Pmp EPC Sol Shrt Cir - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-371
Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup)- - - - - - - - - - - - - - - - - - - - - - - - - - 40-373
Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup) - - - - - - - - - - - - - - - - - - - - - - - - - - 40-375
Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-377
Failure code [DXH2KA] Disconnection of ECMV Solenoid (High) - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-379
Failure code [DXH2KB] Ground Fault of ECMV Solenoid (High) - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-381
Failure code [DXH2KY] Hot Short of ECMV Solenoid (High) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-383
Failure code [DXH3KA] Disconnection of ECMV Solenoid (Low) - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-385
Failure code [DXH3KB] Ground Fault of ECMV Solenoid (Low)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-387
Failure code [DXH3KY] Hot Short of ECMV Solenoid (Low) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-389
Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-391
Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-393
Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-395
Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd) - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-397
Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-399
Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-401
Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd) - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-403
Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-405
Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-407
Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse) - - - - - - - - - - - - - - - - - - - - - - - - - 40-409
Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse) - - - - - - - - - - - - - - - - - - - - - - - - - 40-411
Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse) - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-413
Failure code [DXHHKA] Disconnection of ECMV Solenoid (4th) - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-415
Failure code [DXHHKB] Ground Fault of ECMV Solenoid (4th) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-417
Failure code [DXHHKY] Hot Short of ECMV Solenoid (4th)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-419
Troubleshooting of electrical system (E-mode) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-421
E-1 Engine does not start (Starting motor does not rotate). - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-421
E-2 Manual preheating system does not work - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-425
E-3 When starting switch is turned ON, machine monitor displays nothing. - - - - - - - - - - - - - - - - - - - - 40-431
E-4 LCD panel backlight of machine monitor fails (goes out or flickers). - - - - - - - - - - - - - - - - - - - - - - - 40-434
E-5 LCD display failure of machine monitor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-435
E-6 The switch of machine monitor switch panel does not work. - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-436
E-7 Two-switch operation of switch panel on machine monitor does not function. - - - - - - - - - - - - - - - - 40-437
E-8 Machine monitor buzzer does not sound. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-438
E-9 Some gauges or caution lamps of machine monitor do not work normally. - - - - - - - - - - - - - - - - - - 40-439
E-10 Rearview monitor does not light up or backlight flickers. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-440
E-11 Rearview monitor images are not displayed clearly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-442
E-12 Rearview monitor brightness cannot be adjusted - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-444
E-13 Night lighting lamp of rearview monitor is abnormal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-447
E-14 Speedometer or engine speed display is abnormal. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-449
E-15 Engine coolant temperature is displayed abnormally. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-450
E-16 Articulated meter display is abnormal.- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-452
E-17 Torque converter oil temperature is displayed abnormally. - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-454
E-18 Fuel gauge is displayed abnormally. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-456
E-19 Centralized warning lamps do not light or do not go out. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-458
GD535-5 40-5
(01)
E-20 Alarm buzzer does not sound or does not stop sounding. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-459
E-21 Transmission mode cannot be switched. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-461
E-22 Engine mode cannot be switched. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-463
E-23 Differential gear lock function does not operate or is not canceled (for differential gear lock model). - - - 40-465
E-24 Cannot be locked or canceled by the lifter lock pin. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-467
E-25 Horn does not sound or does not stop sounding. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-469
E-26 Backup alarm does not sound or does not stop sounding. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-471
E-27 Headlamps, clearance lamps, and tail lamps do not light up or go out. - - - - - - - - - - - - - - - - - - - - 40-474
E-28 Working lamps do not light up or go out. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-482
E-29 Turn indicator light or emergency flashing light does not flash. - - - - - - - - - - - - - - - - - - - - - - - - - - 40-487
E-30 Stop lamp does not light up or does not go out. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-496
E-31 Backup lamp does not light up or does not go out- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-498
E-32 All wipers do not operate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-500
E-33 Front wiper does not operate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-502
E-34 Rear wiper does not operate- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-506
E-35 Left and right door wiper does not operate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-509
E-36 Left door wiper does not operate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-512
E-37 Right door wiper does not operate- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-514
E-38 Front or door washer does not operate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-516
E-39 Rear washer does not operate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-518
E-40 KOMTRAX system does not operate normally. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-520
Troubleshooting of hydraulic and mechanical system (H-mode) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-522
How to use troubleshooting table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-522
H-1 Engine speed drops significantly or engine stalls - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-528
H-2 Machine does not move off. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-529
H-3 Gear speed does not shift. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-530
H-4 Travel speed or power is low. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-531
H-5 Torque converter lockup does not operate or is not canceled. - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-534
H-6 Machine starts or gear speed shifts with long time lag. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-535
H-7 Torque converter oil temperature is high. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-538
H-8 Differential gear lock function does not operate or is not canceled.- - - - - - - - - - - - - - - - - - - - - - - - 40-541
H-9 Steering speed or power is insufficient. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-542
H-10 Steering wheel does not move - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-543
H-11 Wheel brakes do not work or are weak - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-544
H-12 Wheel brakes are not released or drag - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-545
H-13 Parking brake does not work or it is weak - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-546
H-14 Parking brake (including emergency release system) is not released or drags - - - - - - - - - - - - - - 40-547
H-15 All work equipment operates slowly or lacks power- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-548
H-16 Work equipment does not operate. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-549
H-17 Unusual noise is heard from around hydraulic pump - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-550
H-18 Blade lift speed or power is low. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-551
H-19 Hydraulic drift of lifted blade is large. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-552
H-20 Drawbar side shift speed or power is low - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-553
H-21 Blade side shift speed or power is low. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-554
H-22 Power tilt speed or power is low. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-555
H-23 Articulate speed or power is low. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-556
H-24 Leaning speed or power is insufficient. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-557
H-25 Hydraulic drift (tilting) of leaning is large. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-558
H-26 Blade does not rotate. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-559
H-27 Lifter lock pin is not locked or is not canceled. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-560
H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats) - - - - - - 40-561
Troubleshooting of engine (S-mode) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-563
How to read matrix - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-563
S-1 Engine startability is poor.- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-566
40-6 GD535-5
(01)
S-2 Engine does not start. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-567

S-3 Engine does not pick-up smoothly. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-570
S-4 Engine stops during operation. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-571
S-5 Engine runs rough or is unstable. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-572
S-6 Engine lacks power. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-573
S-7 Exhaust smoke is black (Incomplete combustion) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-574
S-8 Large oil consumption (or blue exhaust gas) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-575
S-9 Oil becomes contaminated early. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-576
S-10 Fuel consumption is excessive. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-577
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)- - - - - - - - - - - - - - - - - - - - - - 40-578
S-12 Oil pressure drops. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-579
S-13 Oil amount increases (due to water or fuel mixing). - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-580
S-14 Coolant temperature rises too high (overheating). - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-581
S-15 Unusual noise is heard. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-582
S-16 Vibration is excessive. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-583
GD535-5 40-7
(01)
Acronyms 40 Troubleshooting
Acronyms 1
System
Advanced Joystick
ARAC
braking force.
Automatic Retarder
Automatic Spin
Brake Cooling oil
Regulator
used independently.
Closed-center Load
Sensing System
injection timing.
ECU)
40-8 GD535-5
(01)
40 Troubleshooting Acronyms
Electronic Control
Modulation Valve

ECM)
Exhaust Gas
Recirculation
Equipment
Monitoring System
Electromagnetic
Forward-Neutral-
Reverse
Global Positioning
System
Plus) earth

Global Navigation
Satellite System

HSS
Hydro Static
control
Unit
motions.
GD535-5 40-9
(01)
KOMATSU Closed
KCSF Engine
KOMATSU Diesel
Oxidation Catalyst
muffler.
Particulate Filter
KOMATSU Traction
LIN
load.
LVDS
sensor.
Service
NC Normally Closed
NO Normally Open
PC Hydraulic system
40-10 GD535-5
(01)
40 Troubleshooting Acronyms
PCCS
Pre-stroke Control
Valve
Control
hydraulic pressure.
Hydraulic system
PTP

Structure
Selective Catalytic
Reduction
VGT Engine

D: Bulldozer
HD: Dump truck
WA: Wheel loader
GD535-5 40-11
(01)

A/C Air Conditioner
A/M Air Mix damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
ENG Engine
F.G. Frame Ground
GND Ground
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/M Transmission
40-12 GD535-5
(01)
40 Troubleshooting Points to remember when troubleshooting
Information related to troubleshooting 1
Points to remember when troubleshooting 1
k Stop the machine on a level place and make sure than the lock pin, chocks, parking brake, etc. are
applied normally.
k When performing the operation with 2 or more service technicians, keep strictly to the agreed signals,
and do not allow any unauthorized person to come near.
k If you remove the radiator cap when the engine is still hot, the hot water gushes out and you will burn.
Remove the cap only when engine is cool.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the cable from the negative (-) terminal of the battery
first.
k When removing the plug or cap from a location which is under pressure of oil, always release the
internal pressure first. When installing measuring equipment, be sure to connect it properly.
Troubleshooting denotes to locate the primary cause, repair the failure without delay and prevent its recurrence.
Despite the importance of understanding the structure and operation of the target system in troubleshooting, you
should be aware how interviewing with the operator concerned can facilitate in roughly identifying the cause of the
given undesirable symptom.
1. When performing troubleshooting, do not hurry to 4. Checking failure

disassemble the components. Check the extent of the failure yourself, and judge
If components are disassembled immediately after whether it is a real failure or a problem of the
any failure occurs, method of operation, etc.
q parts that have no connection with the failure a When operating the machine to reenact the
or other unnecessary parts are disassembled. failure symptoms, do not perform any investi-
q It will become impossible to find the cause of gation or measurement that may make the
the failure. problem worse.
It will also cause a waste of manhours, parts, or oil
or grease, and at the same time, will also lose the 5. Troubleshooting
confidence of the user or operator. Use the results of the investigation and inspection
For this reason, when performing troubleshooting, in Items 2 to 4 to narrow down the probable
it is necessary to perform thorough prior investiga- causes of the failure, then use the troubleshooting
tion and to perform troubleshooting corresponding flow chart (matrix) to locate the failure exactly.
to the fixed procedure. a The basic procedure for troubleshooting is as
follows.
2. Points to ask the user or operator 1] Start from the simple points.
1) Have any other problems occurred apart from 2] Start from the most likely points.
the problem that has been reported? 3] Investigate other related parts or informa-
2) Is there anything strange about the machine tion.
before the failure occurred?
3) Did the failure occur suddenly, or were there 6. Fundamental measures for determining failure
problems with the machine condition before cause
this? Even if the failure is repaired in hand, if the root
4) Under what conditions did the failure occur? cause of the failure is not repaired, the same fail-
5) Had any repairs been performed before the ure will occur again. To that end, you must locate
failure? When were these repairs performed? and eliminate the primary cause behind the given
failure.
6) Has the same kind of failure occurred before?
3. Checks before troubleshooting

1) Is there abnormal symptoms in the machine?
2) Check the work inspection points.
3) Check the other inspection points.
4) Check other maintenance matters which can
be checked externally and are considered to be
necessary.
GD535-5 40-13
(01)
How to proceed in troubleshooting 40 Troubleshooting
How to proceed in troubleshooting 1
40-14 GD535-5
(01)
40 Troubleshooting Checks before troubleshooting
Checks before troubleshooting 1
No. Item Criteria Remedy
1 Check for unusual noise and smell - Repair
2 Check of engine for dirt - Remove
3 Check of engine for water leakage - Repair
4 Check of engine for oil leakage - Repair

a. Engine, lubricating oil, and coolant
5 Check of fuel line for leakage - Repair
6 Check of radiator for clogging - Remove
7 Check of fuel level and type - Refilling with fuel
8 Check of foreign material in fuel - Clean and drain
9 Check of fuel prefilter - Replace
10 Check of fuel filter - Replace
11 Check of engine oil level (in oil pan) and type Between H and L Refilling with oil
Refilling with
12 Check of coolant level (in sub tank) Between H and L
coolant
Machine monitor
13 Check of air cleaner for clogging does not indicate Clean or replace
clogging.
1 Check for unusual noise and smell - Repair

b. Hydraulic and mechanical equipment
2 Check for oil leakage - Repair
3 Check of hydraulic oil Between H and L Refilling with oil
4 Check of hydraulic oil strainer - Clean and drain
5 Check of hydraulic oil filter - Replace
6 Check of transmission case oil level Between H and L Refilling with oil
7 Check of power train pump strainer - Clean and drain
8 Replacement of transmission oil filter - Replace
9 Check of final drive case oil level Between H and L Refilling with oil
10 Bleeding air - Air bleeding
GD535-5 40-15
(01)
Checks before troubleshooting 40 Troubleshooting
Retighten or
1 Check of battery terminal for looseness and corrosion -
replace
Retighten or
2 Check of alternator terminal for looseness and corrosion -
replace
Retighten or
3 Check of starting motor terminal for looseness and corrosion -
replace
4 Check of battery voltage (with engine stopped) 20 to 30 V Charge or replace
5 Check of battery electrolyte level Between H and L Add or replace
Check of wiring harness for discoloration, burnt areas and cover

6 - Repair or replace
peeling
Check for coming off of wiring harness clamp and sagging of wiring
7 - Repair
c. Electrical equipment
harness
8 Check of grounding - Repair
9 Check for loose connector and damaged lock - Repair or replace
10 Check of connector pin for corrosion, bends and deformation - Repair or replace
Dry, clean or
11 Check of connector for water and foreign material -
replace
12 Check of wiring harness for open or short circuit - Repair or replace
13 Check of fuse for blowout and corrosion - Replace
14 Slow-blow fuse - Replace
27.5 to 29.5 V after

15 Check of alternator voltage (when engine speed is medium or higher) few minutes Replace
operation
Check of battery relay operation sound (when starting switch is turned

16 - Replace
to ON or OFF position)
17 Check and clean rear-view camera - Clean or repair
1 Check of tires - Repair

d. Exterior
2 Check of handrails and steps - Repair
3 Check of mirrors - Clean or repair

e. Interior
1 Check of gauges and monitors - Clean or replace
2 Check of seat belt - Repair
40-16 GD535-5
(01)
40 Troubleshooting Inspection procedure before troubleshooting
Inspection procedure before troubleshooting 1
Walk-around check
Before starting the engine, look around and under the machine to check for any loose nuts or bolts, leakages of
oil, fuel, or coolant, and check the condition of the work equipment and hydraulic system.
Check the connectors for looseness, wiring harnesses for play, and accumulation of dust in places that reach high
temperatures.
k Any accumulation of flammable materials, or leakage of fuel or oil, around the battery, engine itself,
muffler, turbocharger, or other high temperature engine parts can cause the machine to catch fire.
Check them carefully, and repair them if abnormal.
a1. and b1. Check for unusual sound and smell c1. Check around batteries and dirt removal
Check for unusual sound or smell. Check for any accumulated dirt and combustibles
If the machine is operated with the unusual sound (dead leaves, twigs, etc.) around the batteries. If
or smell, the underlying cause may damage the any, remove them.
machine, so stop the operation immediately once
you recognize it. d1. Check of tires for abnormality, wear, and loose
bolts
a2. Check around engine and dirt removal If any abnormality is found, repair it.
Check if there is any accumulated dirt around the
engine, and combustibles (dead leaves, twigs, d2. Check of handrails and steps for abnormality
etc.) on engine itself, turbocharger, or the other and looseness of bolts
surroundings of engine parts that reach high tem- If any abnormality is found, repair it and tighten
perature. If any, remove them. any loose bolts.
a3. Check for water leakage around engine d3. Check and clean rearview mirrors (if equipped)
a4. Check for oil leakage around engine Check rearview mirror for abnormality. If any,
Check for oil leakage from engine and coolant repair it.
leakage from cooling system. If any abnormality is Clean the mirror surface and adjust the mirror
found, repair it. angle so that the rear of the machine can be seen
from the operator's seat.
a5. Check for leakage from fuel line
Check for fuel leakage, check hoses and pipes for e1. Check of gauges and monitors for abnormality
damage. If any abnormality is found, repair it. Check gauges and monitors in the operator's cab
for abnormality. If any abnormality is found,
a6. Check for radiator and dirt removal replace it with a new one.
Check if there is any accumulated dirt and any Clean up the surfaces.
combustibles (dead leaves, twigs, etc.) around the
radiator. If any, remove them. e2. Check of seat belt and mounting hardware
For removal of dirt from the radiator, see the Oper- Check the hook, the lock, and hook mounting part
ation and Maintenance Manual, "Cleaning and for damage. If any abnormality is found, replace it
testing of radiator fins, oil cooler fins, aftercooler with a new one.
fins, and air conditioner condenser fins (machine
with the air conditioner)".
Testing according to testing procedure
a. Engine, lubricating oil, and coolant
b2. Check of work equipment, cylinders, linkage
and hoses for breakage, wear and clearance
a7. Check of fuel level and type
k Fuel is highly flammable and dangerous.
Check the work equipment, cylinders, linkage, and
hoses for breakage, wear, and clearance. If any
Never bring open flames near fuel.
k When adding fuel, never spill it or let it over-
abnormality is found, repair it.
flow.
k Wipe off any spilled fuel. If fuel spills over soil
b3. Check of hydraulic equipment, hydraulic tank,
hoses, and joints for oil leakage
or sand, remove all the fuel and soil or sand
Check for oil leaks. If any abnormality is found,
together.
repair it.
GD535-5 40-17
(01)
Inspection procedure before troubleshooting 40 Troubleshooting
1. Turn the starting switch to ON position, and check

the fuel level with fuel level gauge (G) on the
monitor panel.
After checking, turn the switch back to OFF posi-
tion.
a9. Check of fuel prefilter (water separator)

k Immediately after the engine is stopped, its
parts and oil are still very hot, and may cause
burn injury. Accordingly, wait until all parts
have cooled down before starting the work.
k High pressure is generated inside the engine
2. If fuel level is low, open fuel filler cap (F) of fuel fuel piping system when the engine is running.
tank, and add fuel through filler port to the level Stop the engine and wait at least 30 seconds
enough for checking. until the inner pressure is released and then
q If breather hole (1) in the oil filler cap is
replace the filter.
clogged, the pressure in the tank decreases
k Never bring open flames near fuel.
and fuel may not be supplied. To prevent this,
clean the breather hole. a A special filter with high-efficiency filtering proper-
ties is adopted for Komatsu genuine fuel prefilter
cartridges. Be sure to use Komatsu genuine parts
when replacing.
a The common rail fuel injection system used on this

machine consists of more precise parts than those
in the conventional injection pump and nozzles. If
any cartridge other than a Komatsu genuine fuel
filter cartridge is used, foreign material may enter,
and it may cause problems in the injection system.
Do no use substitute parts.
a During testing or maintenance of the fuel system,
take extreme care not to allow any foreign material
to enter the fuel system. If any dust or other mate-
rial sticks to any part, wash the part thoroughly
with clean fuel.
q Prepare an oil reserver.
q Prepare a filter wrench.
a8. Check of foreign material in fuel

Open drain valve (1) under the fuel tank, and drain
the water mixed in the fuel and sediments.
40-18 GD535-5
(01)
1. Open the engine side cover on the left side of the 12. Remove filter cartridge cap (A), and install it to the
machine. filter holder.
2. Disconnect connector (1), and remove clamp (2). 13. When installing the cartridge, tighten it until the
a Cover the terminals of disconnected connector packing surface contacts the sealing surface of the
with a plastic bag and tapes so that the termi- filter holder, then tighten it 3/4 of a turn.
nals are not contaminated. a If the filter cartridge is overly tightened, the
3. Place an oil reservoir under filter cartridge (3). packing will be damaged and this leads to
leakage of fuel. If the filter cartridge is too
loose, fuel will also leak from the packing.
Therefore, be sure to observe the fastening
angle.
14. Connect all connector (1), clamp (2) and hose (6)
that you have disconnected before.
4. Disconnect hose (6) from drain plug (5).

5. Turn filter cartridge (3) counterclockwise by using
the filter wrench, and remove it.
6. The water separator is mounted at the bottom of
the cartridge you have just removed. Rotate cup
(4) of the water separator counterclockwise and
remove it. 15. Then, proceed to Step "a10. Check of fuel filter".
If it is damaged, replace it with a new one.
a10. Check of fuel filter
7. Install currently removed cup (4) to the bottom of
the new fuel prefilter cartridge. At this time, be sure
to replace the O-ring with a new one.
3 Tightening torque of cup (4):
k High pressure is generated inside the engine
10 Nm {1.0 kgm}
a When replacing seal ring, apply clean oil on its
fuel piping system when the engine is running.
surface.
Stop the engine and wait at least 30 seconds
8. Check that drain plug (5) on the bottom of fuel until the inner pressure is released and then
prefilter cap (4) is tightened securely.
3 Tightening torque:
replace the filter.
k Never bring open flames near fuel.

0.2 to 0.45 Nm {0.02 to 0.046 kgm}
9. Clean the filter holder. a A special filter with high-efficiency filtering proper-
ties is adopted for Komatsu genuine fuel filter car-
tridges. Be sure to use Komatsu genuine parts
when replacing.
a The common rail fuel injection system used on this

machine consists of more precise parts than those
in the conventional injection pump and nozzles. If
any cartridge other than a Komatsu genuine fuel
filter cartridge is used, foreign material may enter,
and it may cause problems in the injection system.
Do no use substitute parts.
a During testing or maintenance of the fuel system,

10. Fill the filter cartridge with clean fuel, using 8 small take extreme care not to allow any foreign material
holes (B) of the new filter cartridge. to enter the fuel system. If any dust or other mate-
11. Thinly coat the packing surface of filter cartridge rial sticks to any part, wash the part thoroughly
with clean oil. with clean fuel.
GD535-5 40-19
(01)
q Prepare an oil reserver. 3. Remove dipstick (G) and wipe off oil on it with a
q Prepare a filter wrench. cloth.
1. Open the engine right side cover. 4. Insert dipstick (G) fully and pull it out.
2. Place an oil pan under the filter cartridge.
3. Turn filter cartridge (1) counterclockwise by using
the filter wrench, and remove it.
4. Clean the filter holder.
5. If the oil level is between H mark and L mark on

dipstick (G), it is appropriate.
If the oil level is below L mark, add oil through oil
filler port (F).
5. Thinly coat the packing surface of filter cartridge
with oil.
6. Remove filter cartridge cap (A), and install it to the
filter holder.
7. When installing the cartridge, tighten it until the
packing surface contacts the sealing surface of the
filter holder, then tighten it 3/4 of a turn.
a If the filter cartridge is overly tightened, the
packing will be damaged and this leads to
leakage of fuel. If the filter cartridge is too
loose, fuel will also leak from the packing.
Therefore, be sure to observe the fastening
angle.
6. When the oil is above FULL level,
1) Place oil reservoir (P) under drain plug (P) at
the right rear position.
2) Drain oil by opening drain plug (P).
3) Tighten drain plug (P).
3 Drain plug tightening torque:
118 to 162 Nm {12 to 16.5 kgm}
a11. Check of engine oil level (in oil pan) and type
a When checking the oil level after the engine has
been operated, wait at least 15 minutes after stop-
ping the engine. 7. If the oil is at the correct level, tighten the oil filler
a If the machine is at an angle, make it level before cap securely and close the engine hood.
checking.
1. Stop the engine.
2. Open the engine right side cover.
40-20 GD535-5
(01)
a12. Check of coolant level (in reservoir tank)

k There is no need to open the radiator cap at
the usual checks. When checking the coolant
level, check it in reservoir tank when the
engine is cooled down.
k Immediately after the engine is stopped, the
coolant is still very hot and the pressure is
accumulated in the radiator. If the cap is
removed under these conditions, you may be
scalded. If you need to remove the radiator
cap, wait until the temperature drops before
you do. Then turn the cap slowly to release the
pressure and remove it with care.
1. Check that coolant level is between FULL and
LOW marks of reservoir tank (1). If the coolant is
insufficient, remove the cap and add the Super
Coolant (AF-NAC) between FULL and LOW
marks.
2. After refilling with coolant, tighten the cap securely.
3. If the reservoir tank is empty, coolant may be
leaking. If any abnormality is found after the check,
repair it immediately. If normal, remove bolts (2),
and remove cover (3). Remove the cap, add Super
Coolant (AF-NAC) (contained in the radiator)
through coolant filler port (4), and add it to the a13. Check of air cleaner for clogging
reservoir tank. k When using compressed air for cleaning, put
on personal protective items such as protec-
tive eyeglasses, gloves, dust mask, etc. to pro-
tect yourself from dirt that will fly out.
k When removing the outer element from the air
cleaner body, do not forcibly pull it out, other-
wise it can be dangerous. Be careful not to fall
from a high location on unsafe scaffolding as a
reaction when pulling out the outer element.
k If performing testing, cleaning, or maintenance
while the engine running, dust may enter into
the engine and engine may be damaged. Stop
the engine before performing the works.
Testing
1. Open the engine right side cover.
2. If yellow indicator panel (2), mounted in the trans-
parent part of dust indicator (1), has reached red
line (3), clean the air cleaner element.
GD535-5 40-21
(01)
a If the element is cleaned frequently before the yel-

low indicator panel of dust indicator (1) reaches
the red line, the air cleaner will not deliver the opti-
mum performance, and the cleaning effect will
decrease.
Cleaning or replacement of outer element

a Do not leave the air cleaner element in the the
direct sunlight before and after cleaning of the ele-
ment.
a When the outer element is cleaned 6 times or
used for 1 year, replace it. When replacing it,
replace the inner element at the same time. 3. Blow dry compressed air (Max. 0.20 MPa {2 kg/
a Even when the number of cleanings of the outer cm2}) from the inside of the element along the
element is less than 6 times, the inner and outer pleats. Then blow it from outside along the pleats,
elements must be replaced if the yellow indicator and finally blow it from the inside again.
panel of the dust indicator reaches the center of 4. After clearing the element, throw light on its inside
the scale (5 kPa). by using a light bulb to check it. If it has a small hole
1. Open the engine right side cover, remove clips (4), or thin part, replace it.
and remove dust cup (5). a Do not tap or hit the element against any other
object when cleaning it.
a Do not use the element if its folds or gasket or
seal is damaged.
a Install the element by pushing it straight. Do
not force to mount it, or clips and air cleaner
body may be damaged.
a Do not start the engine when the inner element
is removed. If so, the engine may be damaged.
2. Remove outer element (6), and clean both the

inside of air cleaner body and dust cup (5).
a Never remove inner element (7). If it is
removed, dirt will enter and can lead to engine
trouble.
a Do not remove evacuator valve (8) when
cleaning the dust cup.
40-22 GD535-5
(01)
b. Hydraulic and mechanical equipment
b3. Check of hydraulic oil level

k When removing the oil filler cap, the oil may
spurt out. Turn it slowly to release the internal
pressure, then remove it.
1. When you check the hydraulic oil, place the
machine as follows:
q Return the leaning of front tires to the upright
5. Set the cleaned outer element, install dust cup (5), position to allow straight driving.
and secure it using clips (4).
k After you have replaced the inner or outer ele-
q Straighten the front frame and rear frame (zero
articulation angle), and mount the articulation
ment, be sure to replace O-ring (9) with a new lock pins.
one. q Return the blade side shift control lever to its
6. Press the button of dust indicator (1) to return the center position, tilt the blade in a right angle to
yellow indicator panel to its original position. the chassis, and lightly ground the blade.
7. Close the engine right side cover. q If the machine has the blade accumulator, turn
the blade accumulator switch ON in order to
drain oil from the accumulator, and lift the
blade to the highest position. Then, turn the
accumulator switch OFF, and ground the
blade.
2. Start the engine, and run it at low idle state.
3. Check the oil level using sight gauge (G). It is
normal if the oil is at sight gauge (G) level.
a Be careful not to add oil any higher than sight
gauge (G) level since it can damage the
hydraulic circuit or allow the spurting of oil.
a If oil level is excessively high, stop the engine
and wait for the oil temperature to cool down.
Then, drain excessive oil from the drain plug.
4. If the oil is below the sight gauge (G) level, refill

with oil through oil filler port (F).
5. If the oil is above sight gauge (G), drain the exces-
sive oil from the drain plug and check the oil level
again.
6. If the oil is at the correct level, tighten oil filler cap
(F) securely.
GD535-5 40-23
(01)
b4. Check of hydraulic oil strainer 8. Insert strainer (5) in projected portion (6) of the
k Immediately after the engine is stopped, its tank to install.
parts and oil are still very hot, and may cause 9. Install the bolts (1) while pressing down spring (3)
burn injury. Accordingly, wait until all parts with the projection at the bottom of cover (2).
k When you remove the oil filler cap, oil may
spurt out. Be careful to rotate it slowly, and
release inner pressure gradually.
1. Slowly open oil filler cap (F), and release the air
completely from the hydraulic tank.
10. Tighten drain plug (P).
b.5 Check of hydraulic oil filter

2. Stop the engine, and return the oil from accumu- have cooled down before starting the work.
lator to the tank by pressing the brake pedal k When you remove the oil filler (F) cap, oil may
approximately 20 times. If the machine has the spurt out. Be careful to rotate it slowly, and
blade accumulator, turn the blade accumulator release inner pressure gradually.
switch ON, stop the engine, and release the pres-
sure by operating the blade lift lever. 1. Remove bolts (1), and remove cover (2).
3. Place an oil reservoir under drain plug (P).
4. Remove drain valve (P) with care not to get
splashed with drained oil, and drain oil.
a Loosen drain plug (P) carefully so that the oil
does not spurt out.
2. Remove the element, clean the removed parts and

inside of filter case, and install a new element.
3. Install cover (2) and tighten bolts (1).
5. When drained, remove 6 clamping bolts (1), and

remove cover (2).
a When removing bolts (1), keep pressing down
cover (2) since it may jump out by spring (3)
action.
6. Pull out the top of rod (4) upward, and remove
spring (3) and strainer (5).
7. Remove any dirt stuck to strainer (5), then wash it
in flushing oil. If strainer (5) is damaged, replace it
with a new one.
40-24 GD535-5
(01)
b6. Check of transmission case oil level

k Before this check, shift the gear shift lever to
the "P" (Parking) position so that the machine
does not move. Also, make sure that each
lever is at neutral position.
q You cannot measure the exact oil level until 12
hours elapses after the engine is stopped
because the oil remains in various parts.
1. Stop the engine.
2. Remove the cap of oil filler port (F).
3. Remove dipstick (G), clean it with a cloth, fully
insert the dipstick and remove it.
4. The oil level should be between the H and L marks
on dipstick (G).
q If the oil level is below L mark, add oil through
oil filler port (F).
b7. Transmission
1. Place an oil reservoir under the transmission case.
2. Remove drain plug (1).
q Loosen drain plug (2) carefully so that the oil
does not spurt out.
3. When drained, tighten drain plug (2) and install
drain plug (1).
3 Drain plug (1): 59 to 78.5 Nm {6 to 8 kgm}
3 Drain plug (2): 49 to 78.5 Nm {5 to 8 kgm}
5. If the oil is above H mark, remove drain plug (1), 3 Drain plug (3): 9.8 to 12.7 Nm {1.0 to 1.3
and loosen drain plug (2) slowly. Then, drain the kgm}
excessive oil, and check the oil level again. 4. Remove drain plug (3) to drain the hydraulic oil.
5. Remove bolts (4), remove cover (5), and remove
and clean oil strainer (7).
6. If the oil level is correct, insert dipstick (G) fully into

the dipstick pipe, and close the cap of oil filler port.
q Dipstick (G) has some marks. "A" shows the oil 6. Remove any dirt stuck to strainer (7), then wash
level when engine is stopped (ENG STOP), with clean light oil or flushing oil. If the strainer is
and "B" shows oil level when engine idles damaged, replace it with a new one.
(ENG IDLING) on either side of dipstick. Use 7. After cleaning, install oil strainer (7), and install
"A" shows the oil level when engine is stopped new O-ring (6) on the cover. Install cover (5), and
(ENG STOP). tighten bolts (4).
GD535-5 40-25
(01)
b9. Check of final drive case oil level

k Since the oil may spurt out due to internal
pressure, rotate the plug gradually from its
side to release the internal pressure and then
remove it carefully.
1. Stop the engine, and leave it more than 5 minutes
to cool it down.
2. Remove the oil filler cap, pull out oil level gauge
(G), and clean it with a cloth. Fully insert the
dipstick and remove it.
3. The oil level should be between the H and L marks
on dipstick (G).
q If the oil level is below L mark, add oil through
8. Add specified amount of oil through oil filler port
oil filler port (F).
(F).
9. After refilling it with oil, confirm that oil is refilled to
the specified level according to "Check of oil level
of transmission case".
b8. Replacement of transmission oil filter and car-

tridge
q Prepare a filter wrench.
1. Place an oil reservoir under the filter cartridge.
2. Turn filter cartridge (1) counterclockwise and 4. If the oil is above H mark, drain the excessive oil
remove it by using the filter wrench. from drain plug (P) and check the oil level again.
3. Clean the filter holder, coat the seal surface of the 5. If the oil level is correct, insert dipstick (G) fully into
new filter cartridge with clean engine oil, and install the dipstick pipe, and close the cap of oil filler port.
it.
3 Tightening torque:
54 to 64 Nm {5 to 6 kgm}
40-26 GD535-5
(01)
b10. Air bleeding

q For the bleeding air from the fuel system, see
Testing and adjusting, "Bleeding air from fuel cir-
cuit".
q For air bleeding from the hydraulic system, see
Testing and adjusting, "Bleeding air from work
equipment circuit".
c. Electrical equipment
c1. Check of battery terminal for looseness and
corrosion
The battery is mounted at the left rear side of opera-
tor's cab. Check the terminals of battery (1) for loose-
ness and corrosion. c4. Check of battery voltage (with engine stopped)
Check the battery voltage by using the battery tester
while the engine is stopped.
c5. Check of battery electrolyte level

Check before operating the machine.
k Do not use the battery if the battery electrolyte
level is below LOWER LEVEL line. If it is used
under that condition, its inside deteriorates, its
service life is shortened, and it may lead to an
explosion.
k Since the battery produces combustible gas
that can explode, do not bring any open flame
near it.
c2. Check of alternator terminal for looseness and k Battery electrolyte is dangerous. Take care
corrosion that it does not come in contact with your eyes
Open the engine hood, and check cables at terminals or skin. If it does, wash it away with water and
B and R of alternator for open circuit, looseness and contact your doctor.
corrosion. a Do not add the battery fluid above the UPPER
LEVEL line. If the electrolyte level is too high, it
may leak and cause damage to the paint surface
or corrode other parts.
a To avoid freezing, add purified water (such as a
commercial battery fluid) before starting work the
next day.
q When checking the electrolyte level through the
side face of the battery
1. Wipe and clean the battery surface, especially
around the battery level lines with a wet cloth, and
check to see that the battery fluid is between the
UPPER LEVEL (U.L.) and LOWER LEVEL (L.L.)
lines.
c3. Check of starting motor terminal for looseness a Do not clean the battery with a dry cloth since
and corrosion static electricity may cause an explosion.
Open the engine hood, and check cables at terminals
B and C of starting motor for open circuit, looseness
and corrosion.
GD535-5 40-27
(01)
2. If the electrolyte level is below the center between a If the fluid exceeds the UPPER LEVEL,
the UPPER LEVEL (U.L.) and LOWER LEVEL remove the fluid using a dropping pipette or
(L.L.) lines, remove cap (2) and add purified water others until the fluid drops to the UPPER
(example: commercially available battery fluid) to LEVEL. Neutralize the removed fluid with bak-
the UPPER LEVEL (U.L.) line immediately. ing soda (sodium bicarbonate), then flush it
3. After adding the purified water, tighten cap (1) away with a large amount of water.
securely.
c6. Check of wiring harness for discoloration,
burn and cover peeling
q Check the wiring harness and cables for discolor-
ation and burn.
a If discolored or burnt, the circuit may be shorted or
grounded.
q Check the wiring harnesses and cables for dam-
age and peeling of the covers.
q If any abnormality is found, repair or replace the
wiring harness or cables.
c7. Check for coming off of wiring harness clamp

and sagging of wiring harness
a If the fluid exceeds the UPPER LEVEL, q Check wiring harness for sagging and looseness
remove the fluid using a dropping pipette or due to coming off of harness clamp
others until the fluid drops to the UPPER a In particular, carefully check around the hot and
LEVEL. Neutralize the removed fluid with bak- movable parts.
ing soda (sodium bicarbonate), then flush it q If removed from the clamp, secure it with the
away with a large amount of water. clamp.
q When electrolyte level cannot be checked through
the side face of the battery
1. Remove cap (1) on the top of battery. (described
previously)
2. Check the fluid level by watching fluid opening (2).
If the fluid level is below sleeve (3), always add the
purified water (such as a commercial battery fluid)
until it reaches the bottom of sleeve (the UPPER
LEVEL).
q (A) Correct level: Since the electrolyte level
reaches to the sleeve bottom, the shape of the
electrode plates will appear distorted due to
the surface tension.
q (B) Low: Electrolyte level does not reach the
c8. Check of grounding
bottom of sleeve, so pole plates appear
Check the connection of each ground terminal.
straight and not bent.
q Check the mounting bolts and nuts for looseness.
3. After adding fluid, tighten cap (1).
q Check ground terminal (1) and the contact surface
of machine body for rusting and adhering of insu-
lation materials including foreign material.
This figure gives an example of battery grounding.
q For each grounding position, see the "Connector
list and layout".
40-28 GD535-5
(01)
c9. Check for loose connector and damaged lock c10. Check connector pins for corrosion, bending
q Check the connection of male and female connec-
and deformation.
tors by pulling them by hand. q Disconnect the connectors, and check their pins
q If the connection is loose, secure it.
for corrosion, bending, sinking than other pins,
and extension of female pins.
q If pins are defective, repair or replace them.
a If the pins are not shiny, apply contact restorer to
them and connect and disconnect the connectors
several times to shine them. (If the pins do not
become shiny, connect and disconnect the con-
nector 10 times.)
c11. Check of connector for water and foreign

material insertion
q Disconnect connectors, and check them for enter-
ing of water or foreign material inside the connec-
tor.
q Check the connectors for unlocking, and check

the lock and connector housing for cracking.
a If there is entering of water or foreign material

inside connector, the seals may be damaged.
Check the seals for damage.
2. Check lock screws (L) of the transmission a If the seal is defective, repair or replace it.
controller for looseness. a Dry the inside of the connector with a dryer.
a Use a hexagonal wrench with 4 mm width
across flats.
GD535-5 40-29
(01)
3) Face the connector (at the plug side) straight to

receptacle (since the seal is protruding), and
slightly insert the connector. During this time,
take care not to peel the seal.
4) Tighten the hexagonal bolt (at the center of
connector) for 2 or 3 turns.
5) Fully insert the connector at the plug side, and
adjust the connector at the plug side so that
clearance between the engaged receptacle
and the connector at plug side is even in all
directions.
6) Tighten the lock bolt with the specified torque.
3 Hexagonal bolts:
2.8 ± 0.3 Nm {0.28 ± 0.03 kgm}
q Wipe and remove any foreign material inside con- a If tightening it too strong, the lock bolt may
nector with a cloth or others, and blow the air to break. So be careful.
clean the connector.
c12. Check of wiring harness for open or short

Cautions circuit
1. Unplugging connector R1 q Check the connection (crimped part) between
Slowly pull out the connector, and check it for connector pins and wiring harness.
damage or peeling of seal. Also check the adhe- q If the line is open as shown in (A), repair or
sion of foreign materials. replace the wiring harness or cables.
a If the seal is damaged, replace it.
q Visually check wiring harnesses for peeling of har-

2. Plugging connector R1 ness covers and the pins for contact with adjacent
1) Check to see that seal is attached to the plug pins due to defective crimping.
correctly.
2) Make sure that key engages with the groove of
receptacle (in normal direction).
40-30 GD535-5
(01)
c13. Check of fuse for blow and corrosion

a Make sure to turn off the power supply (starting
switch is OFF) before replacing the fuse.
q The fuse holder is located at the rear left of opera-
tor's seat.
q If a fuse is corroded and coated with white pow-
der, or there is any play between the fuse and fuse
holder, replace the fuse.
q Replace each fuse with the one of the same
capacity.
c15. Check of alternator voltage (when engine

speed is medium or higher)
1. Open the engine hood.
2. Apply the positive (+) probe of multimeter to
terminal (B) of alternator, and apply the negative (-
) probe to the chassis ground.
3. Start the engine, warm it up, and measure the
voltage while running the engine at a medium or a
higher speed.
q If the voltage is abnormal, repair or replace the
c14. Slow-blow fuse alternator.
q If an overcurrent flows, the electric circuit is cut off
by the slow-blow fuse, and electrical equipment
and wirings are protected from damage.
q When you turn the starting switch to ON position
but the power is not supplied, the slow-blow fuse
may be blown. Check the fuse and replace it if
necessary.
(1)60A: Slow-blow fuse for secondary power supply

(2)30A: Slow-blow fuse for continuous power supply
(3)120A: Slow-blow fuse for heater relay (intake air
heater)
(4)120A: Slow-blow fuse for alternator
c16. Check of battery relay operation sound
1. Open the battery cover.
2. Turn the starting switch to the ON and OFF posi-
tions, and check whether the battery relay opera-
tion sound is heard or not.
q If the operation sound is not heard, check the
related circuits, by referring to the description
of troubleshooting for E-1 described in the E-
mode troubleshooting.
q If the relating circuit is normal, replace the bat-
tery relay.
GD535-5 40-31
(01)
Troubleshooting procedure 40 Troubleshooting
Troubleshooting procedure 1
Classification of troubleshooting 3) Press the [F4] function key to enter, and go to

the "Abnormality Record" screen.
Mode Content
Code display Troubleshooting by failure code
E-mode Troubleshooting of electrical system
Troubleshooting of hydraulic and
H-mode
mechanical systems
S-mode Troubleshooting of engine
1. Check to see that both an action level and failure

code are displayed on the machine monitor.
a If multiple failure codes are displayed simulta-
neously, all the codes are displayed repeatedly
in order. Note down all the codes. 4) Press the [F4] function key to enter, and go to
If action level and failure code are displayed on the "Mechanical System Abnormality Record"
the standard screen of the machine monitor, screen.
perform the troubleshooting for the corre- 5) Press the [F1] function key, check if the next
sponding "Display of code" corresponding to failure code is displayed, and note down all of
the displayed failure code. the failure codes.
2. Check a mechanical system failure code and an a A failure code of the mechanical system
electrical system failure code with the abnormality cannot be deleted.
record function of the machine monitor. 6) Press the [F3] function key to return to the
1) Hold down the [F8] function key on the standard "Abnormality Diagnosis Record" screen.
screen, and press the [F1], [F2] and [F3] keys
sequentially.
7) On the Service Menu screen, press the [F1]

function key twice and select "03 Abnormality
2) On the Service Menu screen, press the [F1] Record".
function key twice and select "03 Abnormality
Record".
40-32 GD535-5
(01)
40 Troubleshooting Troubleshooting procedure
8) Press the [F4] function key to enter, and go to

the "Abnormality Record" screen. q In this case, check a symptom which is
assumed to be a cause of failure again
and select the same phenomenon from
the table of "Symptom and trouble-
shooting numbers", and then perform
troubleshooting corresponding to that
phenomenon in the "E mode", "H mode"
or "S mode".
3. After repairing, clear all the failure codes from the
Electrical System Abnormality Record.
1) Hold down the [F8] function key, and press the
[F1], [F2] and [F3] keys sequentially to enter the
"Clear mode".
2) Press the [F8] function key.
9) Press the [F4] function key to enter, and go to
the "Electrical Systems Abnormality Record" 3) Press the [F4] function key to clear all failure
screen. codes.
10)Press the [F1] function key, check if the next 4) Press the [F3] function key to return to the
failure code is displayed, and note down all of "Electrical System Abnormality Record"
the failure codes. screen. See if any failure code is still displayed
and note down the displayed ones.
5) Press the [F3] function key to return to the
"Abnormality Record" screen.
6) Note down information of all columns.
a Similar to the Electrical System Failure
Record, character "E" on the left of a failure
code indicates that the failure code is
"active" (the failure remains or restoration
to normal has not been checked).
7) Press the [F8] function key to clear all failure
codes. Check if the failure is still displayed or
not, and write it down.
8) Press the [F3] function key to return to the
a Character "E" on the left of a failure code "Abnormality Record" screen.
indicates that the failure code is "active"
(the failure remains or restoration to normal
has not been checked). If "E" is not dis-
played, the failure code is "inactive" and the
code is cleared in the subsequent clearing
step. Be sure to record this failure code on
a paper.
q If the failure code is found in the Abnormal-
ity Record:
Perform troubleshooting for the displayed
"Failure code".
a If an electrical system failure code is dis-
played, delete all the codes once and re-
produce them, and then see if the failure
is still detected.
a A failure code of the mechanical system
cannot be deleted.
q If the failure code is not found in the Abnor-
mality Record
q A failure that the machine cannot find
out by itself may have occurred in the
electrical system or hydraulic and
mechanical system.
GD535-5 40-33
(01)
Failure code list 40 Troubleshooting
Failure code list 1
Failure Applicable History

Failure (displayed on screen) Action level
code equipment category
Mechanical
1500L0 Failure code [1500L0] Double Engagement of T/M Clutches TM L04
system
Electrical
15G0MW Failure code [15G0MW] Failure of Clutch System (R) TM L03
system
Electrical
15H0MW Failure code [15H0MW] Failure of Clutch System (FH) TM L03
system
Electrical
15J0MW Failure code [15J0MW] Failure of Clutch System (FL) TM L03
system
Electrical
15K0MW Failure code [15K0MW] Failure of Clutch System (1st) TM L03
system
Electrical
15L0MW Failure code [15L0MW] Failure of Clutch System (2nd) TM L03
system
Electrical
15M0MW Failure code [15M0MW] Failure of Clutch System (3rd) TM L03
system
Electrical
15N0MW Failure code [15N0MW] Failure of Clutch System (4th) TM L03
system
Electrical
15SBL1 Failure code [15SBL1] Release Trouble of ECMV (R) TM L01
system
Electrical
15SBMA Failure code [15SBMA] Malfunction of ECMV (R) TM L03
system
Electrical
15SCL1 Failure code [15SCL1] Release Trouble of ECMV (FH) TM L01
system
Electrical
15SCMA Failure code [15SCMA] Malfunction of ECMV (FH) TM L03
system
Electrical
15SDL1 Failure code [15SDL1] Release Trouble of ECMV (FL) TM L01
system
Electrical
15SDMA Failure code [15SDMA] Malfunction of ECMV (FL) TM L03
system
Electrical
15SEL1 Failure code [15SEL1] Release Trouble of ECMV (1st) TM L01
system
Electrical
15SEMA Failure code [15SEMA] Malfunction of ECMV (1st) TM L03
system
Electrical
15SFL1 Failure code [15SFL1] Release Trouble of ECMV (2nd) TM L01
system
Electrical
15SFMA Failure code [15SFMA] Malfunction of ECMV (2nd) TM L03
system
Electrical
15SGL1 Failure code [15SGL1] Release Trouble of ECMV (3rd) TM L01
system
Electrical
15SGMA Failure code [15SGMA] Malfunction of ECMV (3rd) TM L03
system
Electrical
15SHL1 Failure code [15SHL1] Release Trouble of ECMV (4th) TM L01
system
Electrical
15SHMA Failure code [15SHMA] Malfunction of ECMV (4th) TM L03
system
Electrical
15SJMA Failure code [15SJMA] Malfunction of ECMV (L/U) TM L03
system
40-34 GD535-5
(01)
40 Troubleshooting Failure code list

Mechanical
15U0NT Failure code [15U0NT] Overload of Inching Clutch TM L02
system
Mechanical
2G42ZG Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) MON L03
system
Mechanical
2G43ZG Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) MON L03
system
Electrical
989L00 Failure code [989L00] Engine Controller Lock Caution1 MON -
system
Electrical
989M00 Failure code [989M00] Engine Controller Lock Caution2 MON -
system
Electrical
989N00 Failure code [989N00] Engine Controller Lock Caution3 MON -
system
Electrical
AB00KE Failure code [AB00KE] Charge Voltage Low MON L03
system
Electrical
AB00KY Failure code [AB00KY] Hot Short of Alternator R TerminalTerminal TM L03
system
Failure code [B@BAZG] Derating in speed due to engine oil pressure Electrical
B@BAZG ENG L03
drop system
Mechanical
B@BCNS Failure code [B@BCNS] Engine Overheat ENG L02
system
Mechanical
B@CENS Failure code [B@CENS] T/C Oil Temp. Overheat MON L02
system
Mechanical
B@CKNS Failure code [B@CKNS] DIFF Oil Temp. Overheat MON L02
system
Mechanical
B@HANS Failure code [B@HANS] HYD Oil Temp. Overheat MON L02
system
Electrical
CA111 Failure code [CA111] Engine controller internal error ENG L03
system
Electrical
CA115 Failure code [CA115] Engine Ne, Bkup speed sensor error ENG L03
system
Electrical
CA122 Failure code [CA122] Charge pressure sensor high error ENG L03
system
Electrical
CA123 Failure code [CA123] Charge pressure sensor low error ENG L03
system
Electrical
CA131 Failure code [CA131] Throttle sensor high error ENG L03
system
Electrical
CA132 Failure code [CA132] Throttle sensor low error ENG L03
system
Electrical
CA144 Failure code [CA144] Coolant sensor high error ENG L01
system
Electrical
CA145 Failure code [CA145] Coolant sensor low error ENG L01
system
Electrical
CA153 Failure code [CA153] Charge temperature sensor high error ENG L01
system
Electrical
CA154 Failure code [CA154] Charge temperature sensor low error ENG L01
system
GD535-5 40-35
(01)

Failure code [CA155] Speed derating error by high charge Electrical
CA155 ENG L03
temperature system
Electrical
CA187 Failure code [CA187] Sensor power supply 2 low error ENG L03
system
Electrical
CA221 Failure code [CA221] Atmospheric pressure sensor high error ENG L01
system
Electrical
CA222 Failure code [CA222] Atmospheric pressure sensor low error ENG L01
system
Electrical
CA227 Failure code [CA227] Sensor power supply 2 high error ENG L03
system
Mechanical
CA234 Failure code [CA234] Engine overspeed ENG L02
system
Electrical
CA238 Failure code [CA238] Ne speed sensor power supply error ENG L03
system
Electrical
CA271 Failure code [CA271] IMV/IMA: Short circuit ENG L03
system
Electrical
CA272 Failure code [CA272] IMV/IMA open circuit ENG L03
system
Electrical
CA322 Failure code [CA322] Injector #1 (L#1) open/short ENG L03
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
CA342 Failure code [CA342] Data compatibility error in engine controller ENG L03
system
Electrical
CA351 Failure code [CA351] Injector drive circuit error ENG L03
system
Electrical
CA352 Failure code [CA352] Sensor power supply 1 low error ENG L03
system
Electrical
CA386 Failure code [CA386] Sensor power supply 1 high error ENG L03
system
Electrical
CA428 Failure code [CA428] Water-in-fuel sensor high error ENG L01
system
Electrical
CA429 Failure code [CA429] Water-in-fuel sensor low error ENG L01
system
Electrical
CA431 Failure code [CA431] Idle validation switch error ENG L01
system
Electrical
CA432 Failure code [CA432] Idle validation action error ENG L03
system
40-36 GD535-5
(01)

Electrical
CA435 Failure code [CA435] Engine oil pressure switch error ENG L01
system
Electrical
CA441 Failure code [CA441] Power supply voltage low error ENG L03
system
Electrical
CA442 Failure code [CA442] Power supply voltage high error ENG L03
system
Electrical
CA449 Failure code [CA449] Common rail pressure high error 2 ENG L03
system
Electrical
CA451 Failure code [CA451] Common rail pressure sensor high error ENG L03
system
Electrical
CA452 Failure code [CA452] Common rail pressure sensor low error ENG L03
system
Failure code [CA488] Torque derating error by high charge Electrical
CA488 ENG L03
temperature system
Electrical
CA553 Failure code [CA553] Common rail pressure high error 1 ENG L03
system
Electrical
CA559 Failure code [CA559] Supply pump pressure low error 1 ENG L03
system
Electrical
CA689 Failure code [CA689] Engine Ne speed sensor error ENG L03
system
Electrical
CA731 Failure code [CA731] Engine Bkup speed sensor phase error ENG L03
system
Electrical
CA757 Failure code [CA757] All continuous data lost error ENG L03
system
Electrical
CA778 Failure code [CA778] Engine Bkup speed sensor error ENG L03
system
Electrical
CA1633 Failure code [CA1633] KOMNET (CAN communication) error ENG L03
system
Electrical
CA2185 Failure code [CA2185] Throttle sensor power supply high error ENG L03
system
Electrical
CA2186 Failure code [CA2186] Throttle sensor power supply low error ENG L03
system
Electrical
CA2249 Failure code [CA2249] Supply pump pressure low error 2 ENG L03
system
Electrical
CA2311 Failure code [CA2311] Abnormality in IMV (IMA) solenoid ENG L03
system
Electrical
CA2555 Failure code [CA2555] Intake heater relay open circuit ENG L01
system
Electrical
CA2556 Failure code [CA2556] Intake heater relay short circuit ENG L01
system
Electrical
D160KA Failure code [D160KA] Disconnection of Backup Light Relay TM L01
system
Electrical
D160KB Failure code [D160KB] Ground Fault of Backup Light Relay TM L01
system
Electrical
D160KY Failure code [D160KY] Hot Short of Backup Lamp Relay Output TM L01
system
GD535-5 40-37
(01)

Electrical
D19JKZ Failure code [D19JKZ] Personal Code Relay Abnormality MON L03
system
Electrical
D19KKZ Failure code [D19KKZ] Failure of Diff Control Relay TM L01
system
Electrical
D1EHKA Failure code [D1EHKA] Disconnection of Engine Start Relay TM L03
system
Electrical
D1EHKB Failure code [D1EHKB] Ground Fault of Engine Start Relay TM L03
system
Electrical
D1EHKY Failure code [D1EHKY] Hot Short of Engine Start Relay TM L03
system
Electrical
D1FBKB Failure code [D1FBKB] Ground Fault of Sol. Self-Holding Relay TM L03
system
Electrical
D8AQK4 Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 MON L03
system
Electrical
D8AQKR Failure code [D8AQKR] CAN2 Discon (KOMTRAX) MON -
system
Electrical
DAF0KT Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) MON L03
system
Electrical
DAF0MB Failure code [DAF0MB] Monitor ROM Abnormality MON -
system
Electrical
DAF0MC Failure code [DAF0MC] Monitor Error MON -
system
Electrical
DAF3KK Failure code [DAF3KK] Controller Power Source Low (MON) MON -
system
Electrical
DAFLKA Failure code [DAFLKA] Op Lamp Open Cir (Mon) MON -
system
Electrical
DAFLKB Failure code [DAFLKB] Op Lamp Shrt Cir (Mon) MON -
system
Electrical
DAQ0KK Failure code [DAQ0KK] Controller Power Source Low (T/M) TM L03
system
Electrical
DAQ0KT Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M) TM L01
system
Electrical
DAQ0MC Failure code [DAQ0MC] T/M Con Error TM -
system
Electrical
DAQ1KA Failure code [DAQ1KA] Disconnection of Key SW ACC TM L03
system
Electrical
DAQ2KK Failure code [DAQ2KK] Solenoid Power Source Low (T/M) TM L03
system
Electrical
DAQ9KQ Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M) TM L03
system
Electrical
DAQLKA Failure code [DAQLKA] Op Lamp Open Cir (T/M Cont) TM L03
system
Electrical
DAQLKB Failure code [DAQLKB] Op Lamp Shrt Cir (T/M Cont) TM L03
system
Electrical
DAQQKR Failure code [DAQQKR] CAN2 Discon (Transmission Con) MON L03
system
40-38 GD535-5
(01)

Electrical
DAQRMA Failure code [DAQRMA] Inconsistency of Option Selection (T/M) TM L03
system
Electrical
DB2QKR Failure code [DB2QKR] CAN2 Discon (Engine Con) MON L03
system
Electrical
DD1PKB Failure code [DD1PKB] Abnormality of RPM Switch TM L03
system
Electrical
DD1QKB Failure code [DD1QKB] Abnormality of RPM Set Mode Switch TM L03
system
Electrical
DDB6L4 Failure code [DDB6L4] Parking brake signal error TM L03
system
Electrical
DDTHKA Failure code [DDTHKA] Disconnection of Fill Switch (FH) TM L01
system
Electrical
DDTJKA Failure code [DDTJKA] Disconnection of Fill Switch (FL) TM L01
system
Electrical
DDTKKA Failure code [DDTKKA] Disconnection of Fill Switch (1st) TM L01
system
Electrical
DDTLKA Failure code [DDTLKA] Disconnection of Fill Switch (2nd) TM L01
system
Electrical
DDTMKA Failure code [DDTMKA] Disconnection of Fill Switch (3rd) TM L01
system
Electrical
DDTNKA Failure code [DDTNKA] Disconnection of Fill Switch (R) TM L01
system
Electrical
DDTPKA Failure code [DDTPKA] Disconnection of Fill Switch (4th) TM L01
system
Electrical
DF10KA Failure code [DF10KA] Disconnection of Shift Lever Input TM L03
system
Electrical
DF10L4 Failure code [DF10L4] Gear speed/travel direction signal error TM L03
system
Electrical
DGF1KX Failure code [DGF1KX] Out of Range of T/M Oil Temp. Sensor TM L03
system
Electrical
DGH2KB Failure code [DGH2KB] Ground Fault of Hydraulic Oil Temp. S TM L01
system
Electrical
DGT1KX Failure code [DGT1KX] Out of Range of T/C Oil Temp. Sensor TM L01
system
Electrical
DGT7KB Failure code [DGT7KB] Ground Fault of Diff Oil Temp. S.(C) TM L01
system
Electrical
DHT5KX Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor TM L01
system
Electrical
DHT5L6 Failure code [DHT5L6] Failure of T/C Oil Press Sensor TM L01
system
Electrical
DJF1KA Failure code [DJF1KA] Disconnection of Fuel Level Sensor MON L01
system
Electrical
DK70KX Failure code [DK70KX] Out of Range of Inching Potentio. TM L03
system
Electrical
DKD0KX Failure code [DKD0KX] Out of Range of Articulate Angle Sensor TM L01
system
GD535-5 40-39
(01)

Electrical
DLF1KA Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor TM L03
system
Electrical
DLF1LC Failure code [DLF1LC] Failure of T/M Input Speed Sensor TM L03
system
Electrical
DLF2KA Failure code [DLF2KA] Disconnection of T/M Inter. Speed Sensor TM L03
system
Electrical
DLF2LC Failure code [DLF2LC] Failure of T/M Intermediate Speed Sensor TM L03
system
Electrical
DLM3KA Failure code [DLM3KA] Rad Fan Spd Sen Opn/Shrt Cir TM L01
system
Electrical
DLM3LC Failure code [DLM3LC] Rad Fan Spd Sen Sig Error TM L03
system
Electrical
DLM3MB Failure code [DLM3MB] Rad Fan Spd Sen Error TM L01
system
Electrical
DLT3KA Failure code [DLT3KA] Disconnection of T/M output Speed Sensor TM L03
system
Electrical
DW4BKA Failure code [DW4BKA] Disconnection of Parking Brake Valve TM L03
system
Electrical
DW4BKB Failure code [DW4BKB] Ground Fault of Parking Brake Valve TM L03
system
Electrical
DW4BKY Failure code [DW4BKY] Hot Short of Parking Brake Solenoid TM L03
system
Electrical
DW7BKA Failure code [DW7BKA] Rad Fan R Sol Opn Cir TM L01
system
Electrical
DW7BKB Failure code [DW7BKB] Rad Fan R Sol Gnd Flt TM L01
system
Electrical
DW7BKY Failure code [DW7BKY] Rad Fan R Sol Shrt Cir TM L01
system
Electrical
DX16KA Failure code [DX16KA] Rad Fan Pump EPC Sol Opn Cir TM L01
system
Electrical
DX16KB Failure code [DX16KB] Rad Fan Pump EPC Sol Gnd Flt TM L01
system
Electrical
DX16KY Failure code [DX16KY] Rad Fan Pmp EPC Sol Shrt Cir TM L01
system
Electrical
DXH1KA Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup) TM L03
system
Electrical
DXH1KB Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup) TM L03
system
Electrical
DXH1KY Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup) TM L03
system
Electrical
DXH2KA Failure code [DXH2KA] Disconnection of ECMV Solenoid (High) TM L03
system
Electrical
DXH2KB Failure code [DXH2KB] Ground Fault of ECMV Solenoid (High) TM L03
system
Electrical
DXH2KY Failure code [DXH2KY] Hot Short of ECMV Solenoid (High) TM L03
system
40-40 GD535-5
(01)

Electrical
DXH3KA Failure code [DXH3KA] Disconnection of ECMV Solenoid (Low) TM L03
system
Electrical
DXH3KB Failure code [DXH3KB] Ground Fault of ECMV Solenoid (Low) TM L03
system
Electrical
DXH3KY Failure code [DXH3KY] Hot Short of ECMV Solenoid (Low) TM L03
system
Electrical
DXH4KA Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st) TM L03
system
Electrical
DXH4KB Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st) TM L03
system
Electrical
DXH4KY Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st) TM L03
system
Electrical
DXH5KA Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd) TM L03
system
Electrical
DXH5KB Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd) TM L03
system
Electrical
DXH5KY Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd) TM L03
system
Electrical
DXH6KA Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd) TM L03
system
Electrical
DXH6KB Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd) TM L03
system
Electrical
DXH6KY Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd) TM L03
system
Electrical
DXH7KA Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse) TM L03
system
Electrical
DXH7KB Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse) TM L03
system
Electrical
DXH7KY Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse) TM L03
system
Electrical
DXHHKA Failure code [DXHHKA] Disconnection of ECMV Solenoid (4th) TM L03
system
Electrical
DXHHKB Failure code [DXHHKB] Ground Fault of ECMV Solenoid (4th) TM L03
system
Electrical
DXHHKY Failure code [DXHHKY] Hot Short of ECMV Solenoid (4th) TM L03
system
a This table lists failure codes in alphabetical order.

a Applicable equipment is the controller or machine monitor which checks the system.
MON: Machine monitor
ENG: Engine controller
TM: Transmission controller
a The failure codes that do not have numbers in Action Level columns are not displayed on the standard screen
even when a failure related to them occurs. They are simply recorded in the abnormality record (electrical sys-
tem or mechanical system) of the service menu.
a History category means the classification of either electrical system or mechanical system which is used for
storage in the Failure History of the service menu.
GD535-5 40-41
(01)
Symptoms and troubleshooting numbers 40 Troubleshooting
Symptoms and troubleshooting numbers 1
Troubleshooting
No. Symptom of failure
Index Described page
Action code and failure code
1 The action code and failure code are displayed on the machine monitor.
The abnormality record is checked and the failure code is displayed in the
2 Perform troubleshooting for failure
Mechanical System Abnormality Record.
code
The abnormality record is checked and the failure code is displayed in the
3
Electrical System Abnormality Record.
Troubleshooting
Symptom related to engine
4 Engine startability is poor. S-1 40-566
5 Engine does not start. E-1, S-2 40-421, 40-567
6 Engine does not pick-up smoothly. S-3 40-570
7 Engine stops during operation. S-4, H-1 40-571, 40-528
8 Engine runs rough or is unstable. S-5 40-572
9 Engine lacks power. S-6 40-573
10 Exhaust smoke is black (Incomplete combustion) S-7 40-574
11 Large oil consumption (or blue exhaust gas) S-8 40-575
12 Oil becomes contaminated early. S-9 40-576
13 Fuel consumption is excessive. S-10 40-577
14 Oil is in coolant (or coolant spurts back or coolant level goes down). S-11 40-578
15 Oil pressure drops. S-12 40-579
16 Oil amount increases (due to water or fuel insertion). S-13 40-580
17 Coolant temperature rises too high (overheating). S-14 40-581
18 Unusual noise is heard. S-15 40-582
19 Vibration is excessive S-16 40-583
20 Preheating system does not work. E-2 40-425
Symptom related to power train
21 Machine does not move off. H-2 40-529
22 Gear speed does not shift. H-3 40-530
23 Travel speed or power is low. H-4 40-531
24 Torque converter lockup does not operate or is not canceled. H-5 40-534
25 Machine starts or gear speed shifts with long time lag. H-6 40-535
26 Torque converter oil temperature is high. H-7 40-538
27 Differential gear lock function does not operate or is not canceled. H-8, E-23 40-541, 40-465
Symptoms related to steering
28 Steering speed or power is insufficient. H-9 40-542
40-42 GD535-5
(01)
40 Troubleshooting Symptoms and troubleshooting numbers
Troubleshooting
29 Steering wheel does not move. H-10 40-543
Symptoms related to brake
30 Wheel brakes do not work or are weak. H-11 40-544
31 Wheel brakes are not released or drag. H-12 40-545
32 Parking brake does not work or its performance is low. H-13 40-546
33 Parking brake (including emergency release system) is not released or drags. H-14 40-547
Symptoms related to work equipment
34 All work equipment operates slowly or lacks power. H-15 40-548
35 All work equipment do not operate. H-16 40-549
36 Unusual noise is heard from around hydraulic pump. H-17 40-550
37 Blade lift speed or power is low. H-18 40-551
38 Hydraulic drift of lifted blade is large. H-19 40-552
39 Drawbar side shift speed or power is low. H-20 40-553
40 Blade cross slide speed or power is low. H-21 40-554
41 Power tilt speed or power is low. H-22 40-555
42 Articulate speed or power is low. H-23 40-556
43 Leaning speed or power is insufficient. H-24 40-557
44 Hydraulic drift (tilting) of leaning is large. H-25 40-558
45 Blade does not rotate. H-26 40-559
46 Lifter lock pin is not locked or is not canceled. H-27, E-20 40-560, 40-459
Symptom related to fan
Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine
47 H-28 40-561
overheats)
Symptom related to machine monitor
When starting switch is turned to ON position, machine monitor displays
48 E-3 40-431
nothing.
49 The LCD panel backlight of machine monitor fails (goes out or flickers). E-4 40-434
50 LCD display failure of machine monitor E-5 40-435
51 The switch of machine monitor switch panel does not work. E-6 40-436
52 2 switches operation of switch panel on machine monitor does not function E-7 40-437
53 The machine monitor buzzer does not sound. E-8 40-438
54 Some gauge or caution lamps of machine monitor do not work normally. E-9 40-439
55 Rearview monitor does not light up or backlight flickers E-10 40-440
56 Rearview monitor images are not displayed clearly E-11 40-442
57 Rearview monitor brightness cannot be adjusted E-12 40-444
58 Night lighting lamp of rearview monitor is abnormal E-13 40-447
59 Speedometer or engine speed display is abnormal. E-14 40-449
60 Engine coolant temperature is displayed abnormally. E-15 40-450
61 Articulated meter display is abnormal. E-16 40-452
GD535-5 40-43
(01)
Symptoms and troubleshooting numbers 40 Troubleshooting
Troubleshooting
62 Torque converter oil temperature is displayed abnormally. E-17 40-454
63 Fuel gauge is displayed abnormally. E-18 40-456
64 Centralized warning lamps do not light up or go out. E-19 40-458
65 Alarm buzzer does not sound or does not stop sounding. E-20 40-459
Others
See section 80,
"Explanation of
Air conditioner does not work normally. (Including failure codes for air procedure for
66 80-24
conditioner) testing and
troubleshooting of
air conditioner".
67 Transmission mode cannot be switched. E-21 40-461
68 Engine mode cannot be switched. E-22 40-463
Differential gear lock function does not operate or is not canceled (for
69 E-23 40-465
differential gear lock model).
70 Cannot be locked or canceled by the lifter lock pin. E-24 40-467
71 Horn does not sound or does not stop sounding. E-25 40-469
72 Backup alarm does not sound or does not stop sounding E-26 40-471
73 Headlamps, clearance lamps, and tail lamps do not light up or go out. E-27 40-474
74 Working lamps do not light up or go out. E-28 40-482
75 Turn indicator light or emergency flashing light does not flash. E-29 40-487
76 Stop lamp does not light up or does not go out E-30 40-496
77 Backup lamp does not light up or does not go out E-31 40-498
78 All wipers do not operate E-32 40-500
79 Front wiper does not operate E-33 40-502
80 Rear wiper does not operate E-34 40-506
81 Left and right door wiper does not operate E-35 40-509
82 Left door wiper does not operate E-36 40-512
84 Right door wiper does not operate E-37 40-514
85 Front or door washer does not operate E-38 40-516
86 Rear washer does not operate E-39 40-518
87 KOMTRAX system does not operate normally. E-40 40-520
40-44 GD535-5
(01)
40 Troubleshooting Information described in troubleshooting table
Information described in troubleshooting table 1
(Rev. 2010/02)
a The following information is summarized in the troubleshooting table. Before performing troubleshooting, un-
derstand that information fully.
Action code Failure code

Display on Display on Failure name displayed on Abnormality Record screen of the machine
Failure
machine machine monitor
monitor monitor
Detail of
Description of the failure detected by the machine monitor or controller
failure
Response by
the machine An action that is performed to protect the system and devices when a failure is detected by the machine
monitor or monitor or controller
controller
Problem on A problem that appears as a failure on the machine as a result of an action (shown above) that is performed
machine by the machine monitor or controller.
Related
Information on occurred failure or troubleshooting
information
No. Cause Procedure, measuring location, criteria, and remarks

<Description>
q Procedure
1 Defective --- q Measurement location
a "Between A and B" denotes measuring values such as voltage and resis-
tance between A and B.
q Criteria to judge probable causes (during normal)
q Remarks for determination of probable cause
Open or short circuit in <How to use troubleshooting sheet>
2 q Perform troubleshooting procedures in following order.
wiring harness
q If the check result does not meet the criteria, the probable cause described on the left col-
umn is the actual cause of the failure.
Open circuit in wiring q If the check result meet the criteria and there is no specific instruction, proceed to the next
harness step (cause).
3 (Wire breakage or q If a defect is found and repaired, check that the defect has been corrected.
defective contact of <Failures in wiring harness>
connector) q Open circuit
Connection of connector is defective or wiring harness is broken.
q Ground fault
Ground fault in wiring
A wiring harness not to be connected to the ground (earth) circuit comes into contact with
harness
4 the ground (earth) circuit or chassis accidentally.
(Contact with ground
q Hot short circuit
circuit) A wiring harness not to be connected to the power (24 V) circuit comes into contact with
the power (24 V) circuit accidentally.
q Short circuit
Hot short circuit An independent wire in the harness abnormally comes into contact with another wire.
5 (Contact with ground (Defective insulation in connector or others)
circuit) <Precautions for troubleshooting>
(1) Connector number indication method and handling of T-adapter
For troubleshooting, insert or connect T-adapters as follows unless otherwise specified.
q When "Male" or "Female" is not indicated with a connector number, discon-
Short circuit in wiring nect the connector, and insert T-adapter between the male and female con-
6
harness nectors.
q When "Male" or "Female" is indicated with a connector number, disconnect the
connector, and connect T-adapter to the indicated side of connector.
(2) Pin number description sequence and tester lead handling
For troubleshooting, connect the positive (+) and negative (-) leads as shown below unless
7 Defective controller otherwise specified.
q Connect the positive (+) lead to pin or wiring harness indicated first.
q Connect the negative (-) lead to a pin or wiring harness indicated second.
GD535-5 40-45
(01)
Information described in troubleshooting table 40 Troubleshooting
Related circuit diagram
This is the excerpted circuit diagram related to troubleshooting

q The circuit diagram contains the connector No., pin No., and con-
nector color related to the failure.
q The circuit diagram contains the destination or source of the
branch line in a wiring harness.
q Arrow (io): Approximate installation portion on the machine.
q NO: Normally Open
q NC: Normally Closed
40-46 GD535-5
(01)
40 Troubleshooting Diagnosis of open harness in pressure sensor system
Diagnosis of open harness in pressure sensor system 1
The pressure sensor consists of not only resistors but electronic devices such as amps. As their characteristics
and polarity may vary, they must be measured carefully.
Applicable failure codes
q CA123: Charge air pressure sensor low error
q CA451: Common rail pressure sensor high error
Procedure
1. Measure the resistance of pressure sensor alone, and write it down.
1) Unplug connector (1) of the pressure sensor, and plug the connector into socket (2) at sensor side.
2) Measure resistance R1 and R2 between each pin.
q If you touch the multimeter probes in reverse polarity, the measurement value may change. Apply probes
in the correct polarity in Steps 1 and 2, and measure the resistance.
q If the measured value is infinite, reverse the polarity and use the value that you can measure.
q As the measured value may vary, measure the resistance several times.
This may be caused by electrical charge in the sensor. Measure the resistance several times in a similar
way to Steps 1 and 2. In Step 3, consider this variation and check the wiring harness for an open.
2. Connect the engine controller harness to the pressure sensor, measure the resistance of pressure sensor, and
write it down.
1) As the 5 V power of the pressure sensor is also supplied to other sensors, unplug the other sensor connec-
tors. (*)
2) Keeping the pressure sensor you wish to measure connected, unplug connector (3) from the engine
controller, and connect T-adapter (4) to the wiring harness.
3) Connect T-box (5) to T-adapter (4), and measure resistance R1' and R2' between each pin.
3. Determining of disconnection
If there is an apparent difference between resistance R1 and R2 measured in Step 1 and resistance R1' and
R2' measured in Step 2, you may ascertain that "the wiring harness is open-circuited".
GD535-5 40-47
(01)
Diagnosis of open harness in pressure sensor system 40 Troubleshooting
Measurement points of pressure sensor, and reference value list
Measured resistance
Sensor Sensor pins measured inside of sensor Remarks
(Reference value)
R2: Between pins (2) and
Approx. 100 z
(4) Sensors are common to engines 107 and
Charge pressure sensor
R1: Between pins (1) and 114
Approx. 200 z
(4)
R2: Between pins (3) and
Approx. 23 kz
(1)
Common rail pressure
R1: Between pins (1) Infinite resistance if polarity is reversed
sensor
(Positive) and (2) Approx. 10 Mz
(Negative)
* Unplug the following sensor connectors during R2' measurement. (See the related circuit diagrams of each code.)
q When measuring the R2' resistance of charge pressure sensor (CA123):
Connectors of atmospheric pressure sensor, CAM sensor, and crankcase pressure sensor
q When measuring the R2' resistance of common rail pressure sensor (CA451):
Because the 5V power is used exclusively, this power supply has no connector to be unplugged.
Measurement note (See the related circuit diagrams of each code for the measurement point.)
Sensor alone Sensor + Wiring harness

Measured Measured
Sensor (Measurement point at sensor (Measurement point at harness side of
value value
pin side) engine controller)
R2: Between pins (2) and (4) R2': Between pins (78) and (54) (*)
Charge pressure sensor
R1: Between pins (1) and (4) R1': Between pins (45) and (54)
R2: Between pins (3) and (1) R2': Between pins (78) and (54) (*)
sensor R1: Between pins (1) (Positive) R1': Between pins (58) (Positive) and
and (2) (Negative) (42) (Negative)
40-48 GD535-5
(01)
40 Troubleshooting Connector list and layout
Connector list and layout 1
Number
Connector No. Connector type Installation location Layout address
of pins
A.PRESS.SEN. FRAMATOME 3 Ambient pressure sensor AK-3
AC1 YAZAKI 12 Air conditioner unit W-2
AC3 YAZAKI 14 Intermediate connector AD-3
AC4 YAZAKI 6 Intermediate connector AD-2
AC5 AMP 20 Air conditioner control panel AA-9
AC6 AMP 16 Air conditioner control panel AA-9
B.PRESS.TEMP.SEN. SUMITOMO 4 Boost pressure and boost temperature sensor AM-5
B11 DT 3 Articulation sensor V-1
B13 DT 2 Brake lamp switch R-1
B15 KES1 2 Window washer (door) U-1
B16 YAZAKI 2 Window washer (front) T-1
B17 YAZAKI 2 Window washer (rear) T-1
B19 DT 2 Power connector W-2
B20 DT 2 Diode V-1
B21 DT 2 Diode U-1
B22 DT 2 Diode U-1
B25 DT 2 Diode U-9
BZ DT 2 Backup alarm K-9,AV-7
BZ1 DT 2 Intermediate connector T-1
BZ2 Relay 5 Differential lock buzzer relay R-9
BZ3 DT 2 Differential lock alarm buzzer Q-8
C.RAIL.PRESS.SEN. BOSCH 3 Common rail pressure sensor AP-4
C1 DT 12 Intermediate connector AD-2
C2 DT 12 Intermediate connector AD-2
C3 DT 2 Room lamp Y-8
C5 YAZAKI 9 RADIO Z-9
C6 DT 2 Speaker (R.H.) AB-9
C7 DT 2 Speaker (L.H.) AD-8
C11 M 4 Door wiper motor (L.H.) AB-1
C12 Relay 6 Front wiper relay (Lo) W-8
C13 M 4 Door wiper motor (R.H.) Y-3
C14 Relay 6 Front wiper relay (Hi) W-8
C15 DT 6 Front wiper motor Z-1
C16 M 4 Rear wiper motor W-8
C20 SWP 6 Yellow revolving warning lamp switch AD-5
C21 SWP 6 Working lamp switch AD-4
C22 Relay 4 Working lamp relay W-7
C23 DT 2 Working lamp (if equipped) Y-4
GD535-5 40-49
(01)
Connector list and layout 40 Troubleshooting
Number
of pins
C27 M 3 Turn signal (Right) (If equipped) Y-5
C28 M 3 Turn signal (Left) (If equipped) Y-5
C29 DT 2 Intermediate connector Y-6
C30 DT 2 Yellow revolving warning lamp Y-7
C31 Relay 6 Yellow revolving warning lamp relay W-7
C32 DT 2 Buzzer AC-9
C33 SWP 6 Brightness adjustment switch AD-6
C38 DT 2 Diode Y-2
C39 DT 2 Interlock solenoid Y-2
C40 M 1 Door switch (R.H.) Y-7
C41 M 1 Door switch (L.H.) Z-1
C42 Relay 5 Interlock solenoid relay Y-2
C43 DT 12 Intermediate connector AC-2
C46 DT 12 Intermediate connector AC-1
C51 Relay 6 Rear wiper intermittent relay W-7
C53 YAZAKI 11 Rear wiper timer R-1
C54 YAZAKI 11 Door wiper timer O-2
CAM1 DT 4 Intermediate connector L-6
CAM2 DT 4 Intermediate connector S-1
CAN DT 12 KOMNET service connector W-5
CAN DT 3 CAN AL-2
CAN1 DT 3 CAN terminating resistor AN-1
CON DT 6 12V converter W-4
CT41 Terminal 1 Ground J-3
CT42 Terminal 1 Ground Z-9
E01 DT 2 Safety relay AK-7
E02 Terminal 1 Alternator terminal R AO-8
E07 Terminal 1 Grid heater AM-5
E19 Terminal 1 Safety relay AK-8
E20 Terminal 1 Safety relay AK-7
E21 Terminal 1 Starting motor terminal C AM-5
E29 Terminal 1 Alternator terminal B AO-9
E30 Terminal 1 Starting motor terminal B AL-5
E31 Terminal 1 Slow-blow fuse AN-5
E32 Terminal 1 Slow-blow fuse AO-7
E33 Terminal 1 Slow-blow fuse AO-7
EC2 DRC 50 Engine controller AL-2
40-50 GD535-5
(01)
Number
of pins
EC3 DTP 4 Engine controller AM-1
ECM DRC 60 Engine controller AM-1
ENG.PRESS.SW. FRAMATOME 1 Engine oil pressure switch (low pressure) AP-2
ENG.W.TEMP.SW. PACKARD 2 Engine coolant temperature sensor AK-4
ER1 DT 12 Intermediate connector AO-6
ET39 DT 2 Fuel level sensor L-5,AV-5
ET40A Terminal 1 Battery disconnect switch L-7
ET40B Terminal 1 Ground J-3,AU-4
ET41A Terminal 1 Battery L-2,AV-2
ET41B Terminal 1 Battery disconnect switch K-4
ET42 Terminal 1 Battery L-2,AV-2
ET43 Terminal 1 Battery L-3,AV-3
ET44 Terminal 1 Battery K-3,AU-3
ET45 Terminal 1 Battery relay J-3,AT-3
ET47 Terminal 1 Slow-blow fuse K-3,AU-3
ET48 Terminal 1 Slow-blow fuse L-3,AV-3
ET54 Terminal 1 Heater relay AM-5
ET77 Terminal 1 Ground I-3,AT-3
ET82 Terminal 1 Heater relay AN-5
ET88 DT 2 Air conditioner compressor (if equipped) AO-1
ET89 Terminal 1 Ground H-2,AR-2
ET103A Terminal 1 Ground AO-2
ET103B Terminal 1 Ground AP-2
ET104 DT 2 Alternator terminal R AK-6
FB1 ― 15 Fuse box W-7
FL1 DT 3 Headlamp (R.H.) A-3,AK-3
FL2 DT 3 Headlamp (L.H.) A-1,AK-1
FL3 DT 3 Front combination lamp (R.H.) A-3
FL4 DT 3 Front combination lamp (L.H.) B-1
GD535-5 40-51
(01)
Number
of pins
FL6 DT 3 Intermediate connector I-9,AS-9
FL6 DT 3 Inching pedal Q-1
FL7 X 2 Horn AK-3
FL8 X 2 Horn A-1,AK-1
FL9 DT 2 Working lamp (R.H.) D-8,AN-8
FL10 DT 2 Working lamp (L.H.) F-9,AP-9
FL17 DT 12 Intermediate connector E-8
FLG2 Terminal 1 Ground (ROPS frame) E-8,AO-8
FP1 AMP070 12 Machine monitor N-5
FP3 DT 12 Monitor panel N-6
FP4 M 2 Alarm buzzer N-3
FP7 DT 6 Dimmer switch N-4
FP8 DT 3 Turn signal switch N-5
FP9 DT 2 Horn switch N-5
FP12 SWP 6 Differential lock switch N-6
FT11 Terminal 1 Ground V-1
FT12 Terminal 1 Ground G-1,AQ-1
FT13 Terminal 1 Ground I-3,AS-3
FT14 Terminal 1 Ground V-1
G SEN. FRAMATOME 3 G sensor AL-1
H10 YAZAKI 1 Rear window glass heating wire AB-9
H11 YAZAKI 1 Rear window glass heating wire AD-6
H12 SWP 6 Electrically heated rear window glass switch AD-5
H13 DT 2 Rearview mirror heater (if equipped) Y-4
H14 SWP 6 Heated rearview mirror switch AD-5
H15 Relay 6 Rear line heater relay W-7
H17 AMP 8 Rear window glass heater timer W-3
IMA BOSCH 2 IMA fuel pump actuator AP-3
ING. #1,2 DTP 4 Injector #1, 2 AL-4
ING. #3,4 DTP 4 Injector #3, 4 AN-5
ING. #5,6 DTP 4 Injector #5, 6 AO-5
L21 S 10 Wiper switch N-5
L48 DT 6 Front wiper timer W-2
L80A 070 18 KOMTRAX controller W-6
L80B 070 12 KOMTRAX controller W-6
NE.SEN. FRAMATOME 3 NE sensor AM-1
OPT2 DT 2 Power connector (ACC power supply) V-2
R1 DRC 70 Intermediate connector U-1
R4 DT 2 Intermediate connector S-1
R5 DTHD 1 Intermediate connector S-1
40-52 GD535-5
(01)
Number
of pins
R6 DTHD 1 Intermediate connector S-1
R7 DTP/DT 2 Intermediate connector S-1
R8 DT 2 Differential temperature sensor J-3,AU-4
R9 DT 2 Differential lock solenoid K-4,AU-4
R10 DT 2 Lifter solenoid H-9,AR-9
R11 DT 2 Parking brake solenoid G-9,AQ-9
R12 DT 2 Differential lock pressure switch K-4
R15 DT 2 Accumulator oil pressure switch J-1,AT-1
R16 DT 2 Accumulator oil pressure switch J-1,AT-1
R17 DT 2 Hydraulic oil temperature sensor AG-9
R18 DT 2 Diode J-3,AT-3
R19 DT 2 Diode K-3,AU-3
R23 DT 2 System operating lamp K-4
R28 DT 2 Diode AL-5
R29 DT 2 Diode AL-5
R31 DT 2 Diode AK-5
R48 DT 6 Intermediate connector L-5,AV-5
RL1 DT 12 Intermediate connector L-7,AV-6
RL2 DT 6 Combination lamp (R.H.) J-9,AS-9
RL3 DT 6 Combination lamp (L.H.) K-9,AU-9
RL4 DT 2 Rear work equipment lamp (if equipped) I-9,AT-9
RL5 DT 2 Rear work equipment lamp (if equipped) L-8,AV-8
RL9 DT 2 Intermediate connector J-9,AT-9
RL10 DT 2 License lamp (if equipped) I-9
RL11 DT 4 Rear view camera (if equipped) J-9
RT6 DT 2 Fan reverse solenoid K-9
RT7 DT 2 Fan motor EPC solenoid L-8
RT8 DT 2 Fan speed sensor L-8
RT9 DT 6 Intermediate connector L-6
RVM1 AMP 12 Rear view monitor Y-2
RVM2 AMP 8 Rear view monitor Y-2
RVS2 SWP 5 Rear view monitor brightness selection switch AD-6
Rearview monitor reverse travel interlock selector
RVS3 SWP 6 AD-6
switch
SCT1 YAZAKI 2 12V power supply R-9
SCT2 YAZAKI 2 12V power supply R-9
SP11 Relay 5 Dimmer relay W-8
SP12 Relay 5 Small lamp relay V-9
SP13 Relay 6 Headlamp relay V-9
SP14 Relay 6 Front working lamp relay U-9
GD535-5 40-53
(01)
Number
of pins
SP15 Relay 5 Rear working lamp relay V-9
SP16 Relay 5 Lamp relay W-9
SP17 Relay 5 Safety relay U-9
SP18 Relay 6 Hazard lamp relay 1 T-9
SP19 Relay 5 Hazard lamp relay 2 T-9
SP21 SWP 6 Accumulator switch (if equipped) P-8
SP22 SWP 6 Head lamp switch Q-8
SP23 SWP 6 Front working lamp switch Q-8
SP24 SWP 6 Rear working lamp switch Q-8
SP25 SWP 6 Hazard lamp switch P-7
SP26 Relay 4 Turn signal lamp relay S-9
SP27 Relay 6 Horn relay W-7
VC2 (CARLING
SP28 10 Lifter lock switch R-9
TECHNOGIES)
SP29 YAZAKI 2 24V cigarette lighter W-3
SP30 Relay 6 Cut-off relay 1 S-9
SP31 Relay 6 Accumulator relay (if equipped) T-9
SP32 Relay 5 Personal lock relay U-9
SP35 DT 2 Diode V-9
SP36 DT 2 Diode U-9
SP37 DT 2 Diode S-9
SP38 DT 2 Diode T-9
SP40 Relay 5 Automatic preheater relay V-9
SP41 SWP 6 Parking lamp switch (if equipped) R-9
SP42 Relay 5 Parking lamp relay V-9
SP43 Relay 6 Self-holding relay S-9
SP46 DT 2 Diode S-9
ST1 Terminal 1 Horn switch N-4
ST6 Terminal 1 Starting switch B N-6
ST7 Terminal 1 Starting switch BR P-7
ST8 Terminal 1 Starting switch C O-7
ST9 Terminal 1 Starting switch ACC O-7
ST10 Terminal 1 Starting switch R1 N-2
T9A DT 6 Accelerator pedal Q-1
T9B DT 2 Accelerator pedal R-1
T20 DT 12 Intermediate connector AJ-7
TEL DT/SWP 12 Intermediate connector W-5
TG1 Terminal 1 Ground AJ-2
40-54 GD535-5
(01)
Number
of pins
TM1 DT 2 FH clutch oil pressure switch AE-7
TM2 DT 2 FH solenoid AE-6
TM3 DT 2 FL clutch oil pressure switch AE-6
TM4 DT 2 FL solenoid AE-5
TM5 DT 2 2nd clutch oil pressure switch AE-4
TM6 DT 2 2nd speed solenoid AE-2
TM7 DT 2 3rd clutch oil pressure switch AF-1
TM8 DT 2 3rd speed solenoid AH-1
TM10 DT 2 1st clutch oil pressure switch AE-8
TM11 DT 2 1st speed solenoid AF-9
TM12 DT 2 R clutch oil pressure switch AG-9
TM13 DT 2 R solenoid AH-9
TM14 DT 2 4th clutch oil pressure switch AI-9
TM15 DT 2 4th speed solenoid AI-8
TM16 DT 2 L/U solenoid AJ-8
TM17 DT 2 Torque converter oil temperature sensor AJ-5
TM18 TYCO AMP 3 Torque converter oil pressure sensor AJ-6
TM19 DT 2 Transmission oil temperature sensor AG-1
TM20 DT 2 Transmission input shaft speed sensor AH-9
TM21 DT 2 Intermediate shaft speed sensor AE-3
TM22 DT 2 Transmission output shaft speed sensor AF-2
TM30 SWP 6 Transmission mode switch P-8
TM36 HD30 21 Gear shift lever O-1
TM37 SWP 6 RPM set mode switch N-6
VC2 (CARLING
TM38 10 RPM set/resume switch O-7
TECHNOGIES)
TM39 DRC 24 Transmission controller W-4
TM42 Relay 5 Backup lamp relay T-9
TM43 Relay 5 Differential lock relay (if equipped) W-8
TM45 SWP 6 Engine mode switch Q-8
WIF1 DT 2 Water-in-fuel sensor AP-4
WIF2 DT 2 Intermediate connector AO-1
GD535-5 40-55
(01)
Layout of connectors (1/7)
40-56 GD535-5
(01)
(2/7)
GD535-5 40-57
(01)
(3/7)
40-58 GD535-5
(01)
(4/7)
GD535-5 40-59
(01)
(5/7)
40-60 GD535-5
(01)
(6/7)
GD535-5 40-61
(01)
(7/7)
40-62 GD535-5
(01)
40 Troubleshooting Connector pin layout
Connector pin layout 1
a The "male" and "female" pins, and the convex and concave fittings (housing) are shown.
GD535-5 40-63
(01)
Connector pin layout 40 Troubleshooting
40-64 GD535-5
(01)
GD535-5 40-65
(01)
40-66 GD535-5
(01)
GD535-5 40-67
(01)
40-68 GD535-5
(01)
GD535-5 40-69
(01)
40-70 GD535-5
(01)
GD535-5 40-71
(01)
40-72 GD535-5
(01)
GD535-5 40-73
(01)
40-74 GD535-5
(01)
GD535-5 40-75
(01)
40-76 GD535-5
(01)
GD535-5 40-77
(01)
40-78 GD535-5
(01)
GD535-5 40-79
(01)
40-80 GD535-5
(01)
GD535-5 40-81
(01)
40-82 GD535-5
(01)
GD535-5 40-83
(01)
40-84 GD535-5
(01)
GD535-5 40-85
(01)
40-86 GD535-5
(01)
GD535-5 40-87
(01)
40-88 GD535-5
(01)
GD535-5 40-89
(01)
40-90 GD535-5
(01)
GD535-5 40-91
(01)
40-92 GD535-5
(01)
GD535-5 40-93
(01)
40-94 GD535-5
(01)
GD535-5 40-95
(01)
40-96 GD535-5
(01)
GD535-5 40-97
(01)
40-98 GD535-5
(01)
40 Troubleshooting T-box and T-adapter list
T-box and T-adapter list 1
(Rev. 2009.3)
a The part numbers of the T-boxes and T-adapters are listed in the vertical column, and the part numbers of har-
ness checker assemblies are listed in the horizontal line.
T-adapter kit
Number of pins
Non-kit part
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
ID
Part No. Part name
marking
799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37 q
799-601-3200 T-box (for MS) 37 q
799-601-3380 Plate for MS (14 pins) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
799-601-2750 Adapter for ECONO 2 EANO 2P q q
EANO
799-601-2790 Adapter for ECONO 12 q q
12P
799-601-2810 Adapter for DLI 8 DLI-8P q q
EANO
799-601-2840 Extension cable (ECONO type) 12 q q q
12P
799-601-2850 Case q
799-601-4350 T-box (DRC60 or ECONO) 60 q
GD535-5 40-99
(01)
T-box and T-adapter list 40 Troubleshooting
T-adapter kit
Number of pins
Non-kit part
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
ID
Part No. Part name
marking
799-601-4360 Case q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7050 Adapter for SWP 6 SW6P q q q
799-601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 - q q
799-601-7090 Adapter for M 2 M2P q q q q
799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for S 8 S8P q q q q
799-601-7150 Adapter for S (white) 10 S10P q q q q
799-601-7160 Adapter for S (blue) 12 S12P q q q
799-601-7170 Adapter for S (blue) 16 S16P q q q q
799-601-7330 Adapter for S (white) 16 S16PW q
799-601-7350 Adapter for S (white) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short socket adapter for X 2 - q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
40-100 GD535-5
(01)
T-adapter kit
Number of pins
Non-kit part
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
ID
Part No. Part name
marking
799-601-7370 Adapter for relay 6 REL-6P q

799-601-7380 Adapter for JFC 2 - q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q q q
799-601-9030 Adapter for DT 3 DT3 q q
799-601-9040 Adapter for DT 4 DT4 q q q q
799-601-9050 Adapter for DT 6 DT6 q q
799-601-9060 Adapter for DT (gray) 8 DT8GR q q
799-601-9070 Adapter for DT (black) 8 DT8B q q
799-601-9080 Adapter for DT (green) 8 DT8G q q
799-601-9090 Adapter for DT (brown) 8 DT8BR q q
799-601-9110 Adapter for DT (gray) 12 DT12GR q q
799-601-9120 Adapter for DT (black) 12 DT12B q q
799-601-9130 Adapter for DT (green) 12 DT12G q q
799-601-9140 Adapter for DT (brown) 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9310 Plate for HD30 (24 pins) q q q
799-601-9320 T-box (for ECONO) 24 q q q
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
Adapter PFUEL for engine
799-601-9420 3 A3 q q
(CRI-T3)
Oil pressure sensor
GD535-5 40-101
(01)
T-box and T-adapter list 40 Troubleshooting
T-adapter kit
Number of pins
Non-kit part
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
ID
Part No. Part name
marking
Socket for engine (CRI-T2)

799-601-9430* Socket PCV for engine (CRI- 2 P q q
T3)
799-601-9440* Socket for engine (CRI-T2) 3 1, 2, 3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540* Socket TIM for engine (CRI- 2 A q q
T3)
795-799-5460 Cable for engine (HPI-T2) 3 - q
Adapter PIM for engine (140-
799-601-4110 4 ITT3N q q
T3)
Adapters NE and CAM for
799-601-4130 3 FCIN q q
engine (CRI-T3)
799-601-4140 3 FCIG q q
Ambient pressure
Adapter POIL for engine (CRI-
799-601-4150 3 FCIB q q
T3)
799-601-4160 2 4160 q q
Oil pressure switch
Adapter PEVA for engine
799-601-4180 3 4180 q q
(CRI-T3)
799-601-4190* 3 1, 2, 3L q q
Socket for engine (CRI-T3) 1, 2, 3,
799-601-4230* 4 q q
Intake pressure/temperature 4C
Socket PAMB for engine (CRI-
799-601-4240* 3 1, 2, 3A q q
T3)
Socket PIM for engine (CRI-
799-601-4250* 3 1, 2, 3B q q
T3)
799-601-4330* Socket G for engine (CRI-T3) 3 1, 2, 3, G q q
799-601-4340* 2 2, PA q q
Pump actuator
1, 2, 3,
799-601-4380* (95) 4 q
4T
Intake pressure/temperature
799-601-4260 Adapter for controller (ENG) 4 DTP4 q q
799-601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
40-102 GD535-5
(01)
T-adapter kit
Number of pins
Non-kit part
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
ID
Part No. Part name
marking
799-601-4390* Socket for controller (95ENG) 60 - q

799-601-4280* Box for controller (PUMP) 121 - q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
Multi-adapter for DT 2 to 4, 2,
799-601-9890 - q
DTM 2 pins 3, 4
*: These are not T-adapters but sockets.
GD535-5 40-103
(01)
Locations of fuses 40 Troubleshooting
Locations of fuses 1
Connection table of fuse box

a This connection table shows the fuse box and the devices which receive power from the fuse box (A switched
power supply is the power which is supplied while the starting switch is in ON position and an unswitched power
supply is the power which is supplied while the starting switch is in OFF and ON positions).
a When performing troubleshooting related to the electrical system, you should check the fuse box to see if the
power is supplied normally.
Fuse box 1 (FB1)
Type of power supply Fuse No. Fuse capacity Destination of power

1 10A Machine monitor
Slow-blow fuse for 2 15A Key switch (B)
continuous power
supply (30A) 3 10A Continuous power supply for transmission controller
4 10A Emergency flashing lights
5 - -
6 10A Turn signal lamp
7 15A Solenoid
8 - -
Slow-blow fuse for 9 15A Rear working lamp
switch power supply
(60A) 10 15A Front working lamp
11 10A Transmission controller
12 15A Headlamp
13 10A Brake lamp, backup lamp
14 10A Horn
Switch power start-up
15 5A Engine controller, accessory
Switch ACC
40-104 GD535-5
(01)
40 Troubleshooting Locations of fuses
Fuse box 2 (Fuse box FB2)

1 20A Air conditioner blower
Slow-blow fuse for 2 10A Continuous power supply for operator's cab
continuous power
supply (30A) 3 10A Room lamp
4 30A Continuous power supply for engine controller
5 - -
6 10A 12V converter
7 5A Radio
8 5A Air conditioner compressor
9 10A Illumination
Slow-blow fuse for
switch power supply 10 10A Spare
(60A)
11 5A Air conditioner control
12 15A Cab mount working lamp
13 10A Yellow rotation lamp
14 20A Door wiper
15 20A Front wiper, rear wiper
Fuse box 3 (Fuse box FB3)

- 1 - -
- 2 - -
- 3 - -
- 4 - -
- 5 - -
- 6 - -
- 7 - -
- 8 - -
- 9 - -
- 10 - -
- 11 - -
Slow-blow fuse for
switch power supply 12 15A Rear heating glass
(60A)
- 13 - -
- 14 - -
- 15 - -
Locations of fuse boxes and fuse No.
GD535-5 40-105
(01)
Locations of fuses 40 Troubleshooting
40-106 GD535-5
(01)
40 Troubleshooting Failure code [1500L0] Double Engagement of T/M Clutches
Troubleshooting by failure code (display of code) 1
Failure code [1500L0] Double Engagement of T/M Clutches 1
Action
Failure code Double Engagement of T/M clutches
code Failure
(Transmission controller system)
L04 1500L0
Detail of failure Two Clutch Fill signals in erroneous combination were entered.
q Flashes the centralized warning lamp and sounds the alarm buzzer.
Action of q Holds the gear in neutral position.
controller q Even if cause of failure disappears, machine does not become normal until starting switch is turned to
OFF position.
Problem on
The machine stops if traveling, or it cannot start if stopped.
machine
q Input condition (ON/OFF) from ECMV fill switch of each clutch can be checked with monitoring function.
(Code: 02216, 02217)
Related
q After the repair has completed, follow the procedure below and check to see that no failure code is dis-
information
played.
Procedure: Start engine. + Shift the lever (at all gear shift positions).

Failure of clutch ECMV
1 If other failure codes are also displayed, perform troubleshooting for them.
system
Failure of transmission If another failure code is not displayed at the same time, the controller may have failed.
2
controller (Since this is an internal failure, troubleshooting cannot be performed.)
GD535-5 40-107
(01)
Failure code [15G0MW] Failure of R-Clutch System 40 Troubleshooting
Failure code [15G0MW] Failure of R-Clutch System 1
Action
Failure code Failure of R-clutch system
code Failure
L03 15G0MW
During output to R-clutch ECMV solenoid, the value calculated either from the engine speed, transmission
Detail of failure input shaft speed sensor signal, transmission intermediate shaft speed sensor signal, or transmission
output shaft speed sensor signal is abnormal.
Action of
q Even if cause of failure disappears, machine does not become normal until starting switch is turned to
controller
OFF position.
Problem on
None in particular
machine
q The output current command value to the R-clutch ECMV solenoid can be checked with monitoring func-
tion.
Related (Code: 31606)
information q After the repair has completed, follow the procedure below and check to see that no failure code is dis-
played.
Procedure: Start engine. + Shift the lever (any of R1 to R4 positions).

Failure of R-clutch oil 1. Check the transmission oil filter for clogging and other failure.
1 pressure or mechanical 2. See the Testing and adjusting, "Testing power train oil pressure", and make sure that
system clutch oil pressure is normal.
Failure of R-clutch ECMV
2 Perform troubleshooting for failure code [DXH7KA], [DXH7KB] or [DXH7KY].
solenoid system
40-108 GD535-5
(01)
40 Troubleshooting Failure code [15H0MW] Failure of Clutch System (FH)
Failure code [15H0MW] Failure of Clutch System (FH) 1
Action
Failure code Failure of clutch system (FH)
code Failure
L03 15H0MW
During output to FH-clutch ECMV solenoid, the value calculated either from the engine speed, transmission
Action of
controller
OFF position.
Problem on
The creep function does not work.
machine
q The output current command value to the FH-clutch ECMV solenoid can be checked with monitoring
function. (Code: 31608)
Related
information
played.
Procedure: Start engine. + Shift the lever (any of F2, F4, F6 or F8 position).

Failure of FH-clutch oil 1. Check the transmission oil filter for clogging and other failure.
Failure of FH-clutch
ECMV solenoid system
GD535-5 40-109
(01)
Failure code [15J0MW] Failure of Clutch System (FL) 40 Troubleshooting
Failure code [15J0MW] Failure of Clutch System (FL) 1
Action
Failure code Failure of clutch system (FL)
code Failure
L03 15J0MW
During output to FL-clutch ECMV solenoid, the value calculated either from the engine speed, transmission
Action of
controller
OFF position.
Problem on
machine
q The output current command value to the FL-clutch ECMV solenoid can be checked with monitoring func-
tion. (Code: 31607)
Related
information
played.

Failure of FL-clutch oil 1. Check the transmission oil filter for clogging and other failure.
Failure of FL-clutch
2 3. Perform troubleshooting for failure code [DXH3KA], [DXH3KB] or [DXH3KY].
40-110 GD535-5
(01)
40 Troubleshooting Failure code [15K0MW] Failure of Clutch System (1st)
Failure code [15K0MW] Failure of Clutch System (1st) 1
Action
Failure code Failure of 1st clutch system
code Failure
L03 15K0MW
During output to 1st clutch ECMV solenoid, the value calculated either from the engine speed, transmission
Action of
controller
OFF position.
Problem on
machine
q The output current command value to the 1st clutch ECMV solenoid can be checked with monitoring
Related
information
played.
Procedure: Start engine. + Shift the lever (any of F1, F2 or R1 position).

Failure of 1st clutch oil 1. Check the transmission oil filter for clogging and other failure.
Failure of 1st clutch
1. Turn the starting switch to OFF position.
Grounding of 2. Disconnect connectors TM40 and TM22, and connect T-adapter to either female side.
3 transmission output shaft
speed sensor circuit Between TM40 (female) (30) or TM22 (female) (1) and
Resistance Min. 1 Mz
ground
Hot short of transmission 2. Disconnect connector TM22, and connect T-adapter to female side.
4 output shaft speed 3. Turn starting switch to ON position.
sensor circuit
Between TM22 (female) (1) and (2) Voltage 3 to 4V
Circuit diagram related to transmission output shaft speed sensor
GD535-5 40-111
(01)
Failure code [15L0MW] Failure of Clutch System (2nd) 40 Troubleshooting
Failure code [15L0MW] Failure of Clutch System (2nd) 1
Action
Failure code Failure of 2nd clutch system
code Failure
L03 15L0MW
During output to 2nd clutch ECMV solenoid, the value calculated either from the engine speed, transmission
Action of
controller
OFF position.
Problem on
None in particular
machine
q The output current command value to the 2nd clutch ECMV solenoid can be checked with monitoring
Related
information
played.
Procedure: Start engine. + Shift the lever (any of F3, F4, or R2 position).

Failure of 2nd clutch oil 1. Check the transmission oil filter for clogging and other failure.
Failure of 2nd clutch
ground
sensor circuit
Between TM22 (female) (1) and (2) Voltage 3 to 4 V
40-112 GD535-5
(01)
40 Troubleshooting Failure code [15M0MW] Failure of Clutch System (3rd)
Failure code [15M0MW] Failure of Clutch System (3rd) 1
Action
Failure code Failure of 3rd clutch system
code Failure
L03 15M0MW
During output to 3rd clutch ECMV solenoid, the value calculated either from the engine speed, transmission
Action of
controller
OFF position.
Problem on
None in particular
machine
q The output current command value to the 3rd clutch ECMV solenoid can be checked with monitoring
Related
information
played.

Failure of 3rd clutch oil 1. Check the transmission oil filter for clogging and other failure.
Failure of 3rd clutch
ground
sensor circuit
GD535-5 40-113
(01)
Failure code [15N0MW] Failure of Clutch System (4th) 40 Troubleshooting
Failure code [15N0MW] Failure of Clutch System (4th) 1
Action
Failure code Failure of 4th clutch system
code Failure
L03 15N0MW
During output to 4th clutch ECMV solenoid, the value calculated either from the engine speed, transmission
Action of
controller
OFF position.
Problem on
None in particular
machine
q The output current command value to the 4th clutch ECMV solenoid can be checked with monitoring
Related
information
played.
Procedure: Start engine. + Shift the lever (any of F7, F8, or R4 position).

Failure of 4th clutch oil 1. Check the transmission oil filter for clogging and other failure.
Failure of 4th clutch
2 Perform troubleshooting for failure code [DXHHKA], [DXHHKB] or [DXHHKY].
ground
sensor circuit
40-114 GD535-5
(01)
40 Troubleshooting Failure code [15SBL1] Release Trouble of ECMV (R)
Failure code [15SBL1] Release Trouble of ECMV (R) 1
Action
Failure code Release trouble of ECMV (R)
code Failure
L01 15SBL1
Even if the output to the R-clutch ECMV solenoid is turned OFF, the signal from Fill switch is kept ON and
Detail of failure
the clutch is not released.
q Particular action is not taken. (If double engagement is detected simultaneously, the gear speed is set to
Action of
neutral.)
controller
q If cause of failure disappears, machine becomes normal by itself.
Problem on
Machine can move backward only.
machine
tion. (Code: 31606)
q Input condition (ON/OFF) from ECMV fill switch of R-clutch can be checked with monitoring function.
Related
(Code: 02216, 02217)
information
played.
Procedure: Start engine.

Failure of R-clutch ECMV 2. Disconnect connector TM12, and connect T-adapter to male side.
2
fill switch Between TM12 (female) (1) and ground
(Fill switch OFF)
2. Disconnect connector TM12.
Harness grounding or 3. Start engine.
3 transmission controller
failure If failure code [15SBL1] still continues, the wiring harness is grounded or the transmission
controller has failed.
(If failure code [15SBL1] is cleared, the R-clutch fill switch has failed.)
If no failure is found by check on Cause 3, this check is not required.
Ground fault in wiring 2. Disconnect connectors TM40 and TM12, and connect T-adapter to either female side.
4
harness
Between TM40 (female) (27) or TM12 (female) (1) and
ground
If "Failure during check of cause 3" and "Normal during check of cause 4" occur, the
transmission controller has failed.
Reference: The following shows the criteria during normal.
2. Lift the machine so that the drive wheels idle.
3. Insert T-adapter into connector TM12.
Failure of transmission 4. Start engine.
5
controller Hold the shift lever to N position.
Between TM40 (27) and ground Voltage 7 to 11V
Steps 1 to 4 are the same as above.
5. Shift the lever (at travel speed) and diagnose it (while drive wheels are idling).
Between TM40 (27) and ground R1 Voltage Max. 1 V
GD535-5 40-115
(01)
Failure code [15SBL1] Release Trouble of ECMV (R) 40 Troubleshooting
Circuit diagram related to reverse clutch ECMV solenoid
40-116 GD535-5
(01)
40 Troubleshooting Failure code [15SBMA] Malfunction of ECMV (R)
Failure code [15SBMA] Malfunction of ECMV (R) 1
Action
Failure code Malfunction of ECMV (R)
code Failure
L03 15SBMA
q Even if signal is output to the R clutch ECMV solenoid, the clutch is not engaged when the signal from
fill switch is OFF.
Detail of failure q During output to R-clutch ECMV solenoid, a clutch slipping is detected from either engine speed signal,
transmission input shaft speed sensor signal, transmission intermediate shaft speed sensor signal, or
transmission output shaft speed sensor signal.
Action of q Keeps to turn OFF the output to R-clutch ECMV solenoid.
OFF position.
Problem on
Machine can move forward only.
machine
tion. (Code: 31606)
Related
(Code: 02216, 02217)
information
played.

2. Disconnect connector TM12, and connect T-adapter to male side.
3. Start engine.
Hold the shift lever to N position.
Failure of R-clutch ECMV Between TM12 (male) (1) and ground Resistance Min. 1 Mz
2
fill switch 1. Steps 1 to 2 are the same as above.
3. Start engine.
Between TM12 (male) (1) and ground R1 Resistance Max. 1 z
Open circuit in wiring 2. Disconnect connectors TM40 and TM12, and connect T-adapter to each female side.
3
harness
Between TM40 (female) (27) and TM12 (female) (1) Resistance Max. 1 z
3. Start engine.
Failure of transmission Between TM40 (27) and ground Voltage 7 to 11 V

4
controller 1. Steps 1 to 2 are the same as above.
3. Start engine.
Between TM40 (27) and ground R1 Voltage Max. 1 V
GD535-5 40-117
(01)
Failure code [15SBMA] Malfunction of ECMV (R) 40 Troubleshooting
Circuit diagram related to reverse clutch ECMV solenoid
40-118 GD535-5
(01)
40 Troubleshooting Failure code [15SCL1] Release Trouble of ECMV (FH)
Failure code [15SCL1] Release Trouble of ECMV (FH) 1
Action
Failure code Release trouble of ECMV (FH)
code Failure
L01 15SCL1
Even if the output to the FH-clutch ECMV solenoid is turned OFF, the clutch is not released if signal from Fill
Detail of failure
switch is kept ON.
Action of
neutral.)
controller
Problem on
Machine can travel with F2, F4, F6 or F8 shift position.
machine
q Input condition (ON/OFF) from ECMV fill switch of FH-clutch can be checked with monitoring function.
Related
(Code: 02216, 02217)
information
played.

Failure of FH-clutch 2. Disconnect connector TM1, and connect T-adapter to male side.
2
ECMV fill switch Between TM1 (male) (1) and ground
(Fill switch OFF)
failure If failure code [15SCL1] still continues, the wiring harness is grounded or the transmission
(If failure code [15SCL1] is cleared, the FH-clutch fill switch has failed.)
Ground fault in wiring 1. Turn the starting switch to OFF position.
4 2. Disconnect connectors TM40 and TM1, and connect T-adapter to either female side.
harness
Between TM40 (female) (7) or TM1 (female) (1) and ground Resistance Min. 1 Mz
Reference
5
Between TM40 (7) and ground Voltage 7 to 11 V
Between TM40 (7) and ground F2 Voltage Max. 1 V
GD535-5 40-119
(01)
Failure code [15SCL1] Release Trouble of ECMV (FH) 40 Troubleshooting
Circuit diagram related to FH-clutch ECMV solenoid
40-120 GD535-5
(01)
40 Troubleshooting Failure code [15SCMA] Malfunction of ECMV (FH)
Failure code [15SCMA] Malfunction of ECMV (FH) 1
Action
Failure code Malfunction of ECMV (FH)
code Failure
L03 15SCMA
q Even if signal is output to the FH-clutch ECMV solenoid, the clutch is not engaged when the signal from
fill switch is OFF.
Detail of failure q During output to FH-clutch ECMV solenoid, a clutch slipping is detected from either engine speed signal,
Action of q Keeps to turn OFF the output to FH-clutch ECMV solenoid.
OFF position.
Problem on
Machine can travel at F1, F3, F5, F7, R1, R2, R3 or R4 gear position only.
machine
Related
(Code: 02216, 02217)
information
played.

3. Start engine.
Failure of FH-clutch Between TM1 (male) (1) and ground Resistance Min. 1 Mz
2
ECMV fill switch Steps 1 to 2 are the same as above.
4. Start engine.
Between TM1 (male) (1) and ground F2 Resistance Min. 1 Mz
3
harness
3. Start engine.

4
controller Steps 1 to 2 are the same as above.
4. Start engine.
GD535-5 40-121
(01)
Failure code [15SCMA] Malfunction of ECMV (FH) 40 Troubleshooting
40-122 GD535-5
(01)
40 Troubleshooting Failure code [15SDL1] Release Trouble of ECMV (FL)
Failure code [15SDL1] Release Trouble of ECMV (FL) 1
Action
Failure code Release trouble of ECMV (FL)
code Failure
L01 15SDL1
Even if the output to the FL-clutch ECMV solenoid is turned OFF, the clutch is not released when signal
Detail of failure
from Fill switch is kept ON.
Action of
neutral.)
controller
Problem on
Machine can travel with F1, F3, F5 or F7 shift position.
machine
tion. (Code: 31607)
q Input condition (ON/OFF) from ECMV fill switch of FL-clutch can be checked with monitoring function.
Related
(Code: 02216, 02217)
information
played.

Failure of FL-clutch 2. Disconnect connector TM3, and connect T-adapter to male side.
2
ECMV fill switch Between TM3 (male) (1) and ground
(Fill switch OFF)
failure If failure code [15SDL1] still continues, the wiring harness is grounded or the transmission
(If failure code [15SDL1] is cleared, the FL-clutch fill switch has failed.)
4
harness
ground
Reference
5
GD535-5 40-123
(01)
Failure code [15SDL1] Release Trouble of ECMV (FL) 40 Troubleshooting
Circuit diagram related to FL-clutch ECMV solenoid
40-124 GD535-5
(01)
40 Troubleshooting Failure code [15SDMA] Malfunction of ECMV (FL)
Failure code [15SDMA] Malfunction of ECMV (FL) 1
Action
Failure code Malfunction of ECMV (FL)
code Failure
L03 15SDMA
q Even if signal is output to the FL-clutch ECMV solenoid, the clutch is not engaged when the signal from
fill switch is OFF.
Detail of failure q During output to FL-clutch ECMV solenoid, a clutch slipping is detected from either engine speed signal,
Action of q Keeps to turn OFF the output to FL-clutch ECMV solenoid.
OFF position.
Problem on
Machine can travel at F2, F4, F6, F8, R1, R2, R3 or R4 gear position only.
machine
tion. (Code: 31607)
Related
(Code: 02216, 02217)
information
played.

3. Start engine.
Failure of FL-clutch Between TM3 (male) (1) and ground Resistance Min. 1 Mz
2
4. Start engine.
Between TM3 (male) (1) and ground F1 Resistance Max. 1 z
3
harness
4. Start engine.
Failure of transmission Hold the shift lever to N position.
4
controller Between TM40 (17) and ground Voltage 7 to 11 V
GD535-5 40-125
(01)
Failure code [15SDMA] Malfunction of ECMV (FL) 40 Troubleshooting
40-126 GD535-5
(01)
40 Troubleshooting Failure code [15SEL1] Release Trouble of ECMV (1st)
Failure code [15SEL1] Release Trouble of ECMV (1st) 1
Action
Failure code Release trouble of ECMV (1st)
code Failure
L01 15SEL1
Even if the output to the 1st clutch ECMV solenoid is turned OFF, the clutch is not released when signal
Detail of failure
Action of
neutral.)
controller
Problem on
Machine can travel in F1, F2 or R1 gear position only.
machine
q Input condition (ON/OFF) from ECMV fill switch of 1st clutch can be checked with monitoring function.
Related
(Code: 02216, 02217)
information
played.

Failure of 1st clutch 2. Disconnect connector TM10, and connect T-adapter to male side.
2
ECMV fill switch a Normal criteria when fill switch is OFF
Between TM10 (male) (1) and ground Resistance Min. 1 Mz
failure If failure code [15SEL1] still continues, the wiring harness is grounded or the transmission
(If failure code [15SEL1] is cleared, the 1st clutch fill switch has failed.)
4
harness
ground
5
Between TM40 (13) and ground F1/R1 Voltage Max. 1 V
GD535-5 40-127
(01)
Failure code [15SEL1] Release Trouble of ECMV (1st) 40 Troubleshooting
Circuit diagram related to 1st clutch ECMV solenoid
40-128 GD535-5
(01)
40 Troubleshooting Failure code [15SEMA] Malfunction of ECMV (1st)
Failure code [15SEMA] Malfunction of ECMV (1st) 1
Action
Failure code Malfunction of 1st clutch ECMV solenoid
code Failure
L03 15SEMA
q Even if signal is output to the 1st clutch ECMV solenoid, the clutch is not engaged when the signal from
fill switch is OFF.
Detail of failure q During output to 1st clutch ECMV solenoid, a clutch slipping is detected from either engine speed signal,
Action of q Keeps to turn OFF the output to 1st clutch ECMV solenoid.
OFF position.
Problem on
Machine can travel in F3 to F8, or R2 to R4 positions only.
machine
Related
(Code: 02216, 02217)
information
played.

3. Start engine.
Failure of 1st clutch Between TM10 (male) (1) and ground Resistance Min. 1 Mz
2
4. Start engine.
Between TM10 (male) (1) and ground F1/R1 Resistance Max. 1 z
3
harness
3. Start engine.

4
4. Start engine.
Between TM40 (13) and ground F1/R1 Voltage Max. 1 V
GD535-5 40-129
(01)
Failure code [15SEMA] Malfunction of ECMV (1st) 40 Troubleshooting
40-130 GD535-5
(01)
40 Troubleshooting Failure code [15SFL1] Release Trouble of ECMV (2nd)
Failure code [15SFL1] Release Trouble of ECMV (2nd) 1
Action
Failure code Release trouble of ECMV (2nd)
code Failure
L01 15SFL1
Even if the output to the 2nd clutch ECMV solenoid is turned OFF, the clutch is not released when signal
Detail of failure
Action of
neutral.)
controller
Problem on
machine
q Input condition (ON/OFF) from ECMV fill switch of 2nd clutch can be checked with monitoring function.
Related
(Code: 02216, 02217)
information
played.

Failure of 2nd clutch 2. Disconnect connector TM5, and connect T-adapter to male side.
2
failure If failure code [15SFL1] still continues, the wiring harness is grounded or the transmission
(If failure code [15SFL1] is cleared, the 2nd clutch fill switch has failed.)
harness
5
GD535-5 40-131
(01)
Failure code [15SFL1] Release Trouble of ECMV (2nd) 40 Troubleshooting
Circuit diagram related to 2nd clutch ECMV solenoid
40-132 GD535-5
(01)
40 Troubleshooting Failure code [15SFMA] Malfunction of ECMV (2nd)
Failure code [15SFMA] Malfunction of ECMV (2nd) 1
Action
Failure code Malfunction of 2nd clutch ECMV solenoid
code Failure
L03 15SFMA
q Even if signal is output to the 2nd clutch ECMV solenoid, the clutch is not engaged when the signal from
fill switch is OFF.
Detail of failure q During output to 2nd clutch ECMV solenoid, a clutch slipping is detected from either engine speed signal,
Action of q Keeps to turn OFF the output to 2nd clutch ECMV solenoid.
OFF position.
Problem on
Machine can travel in F1, F2, F5 to F8, R1, R3, or R4 gear position only.
machine
Related
(Code: 02216, 02217)
information
played.

3. Start engine.
Failure of 2nd clutch Between TM5 (male) (1) and ground Resistance Min. 1 Mz
2
4. Start engine.
3
harness
3. Start engine.

4
4. Start engine.
GD535-5 40-133
(01)
Failure code [15SFMA] Malfunction of ECMV (2nd) 40 Troubleshooting
Circuit diagram related to 2nd clutch ECMV solenoid
40-134 GD535-5
(01)
40 Troubleshooting Failure code [15SGL1] Release Trouble of ECMV (3rd)
Failure code [15SGL1] Release Trouble of ECMV (3rd) 1
Action
Failure code Release trouble of ECMV (3rd)
code Failure
L01 15SGL1
Even if the output to the 3rd clutch ECMV solenoid is turned OFF, the clutch is not released when signal
Detail of failure
Action of
neutral.)
controller
Problem on
machine
q Input condition (ON/OFF) from ECMV fill switch of 3rd clutch can be checked with monitoring function.
Related
(Code: 02216, 02217)
information
played.

Failure of 3rd clutch 2. Disconnect connector TM7, and connect T-adapter to male side.
2
failure If failure code [15SGL1] still continues, the wiring harness is grounded or the transmission
(If failure code [15SGL1] is cleared, the 3rd clutch fill switch has failed.)
harness
Reference
5
GD535-5 40-135
(01)
Failure code [15SGL1] Release Trouble of ECMV (3rd) 40 Troubleshooting
Circuit diagram related to 3rd clutch ECMV solenoid
40-136 GD535-5
(01)
40 Troubleshooting Failure code [15SGMA] Malfunction of ECMV (3rd)
Failure code [15SGMA] Malfunction of ECMV (3rd) 1
Action
Failure code Malfunction of ECMV (3rd)
code Failure
L03 15SGMA
q Even if signal is output to the 3rd clutch ECMV solenoid, the clutch is not engaged when the signal from
fill switch is OFF.
Detail of failure q During output to 3rd clutch ECMV solenoid, a clutch slipping is detected from either engine speed signal,
Action of q Keeps to turn OFF the output to 3rd clutch ECMV solenoid.
OFF position.
Problem on
Machine can travel in F1 to F4, F7, F8, R1, R2, or R4 gear position only.
machine
q Input condition (ON/OFF) from ECMV fill switch of 3rd clutch can be checked with monitoring function.
Related
(Code: 02216, 02217)
information
played.

3. Start engine.
Failure of 3rd clutch Between TM7 (male) (1) and ground Resistance Min. 1 Mz
2
4. Start engine.
3
harness
3. Start engine.

4
4. Start engine.
GD535-5 40-137
(01)
Failure code [15SGMA] Malfunction of ECMV (3rd) 40 Troubleshooting
Circuit diagram related to 3rd clutch ECMV solenoid
40-138 GD535-5
(01)
40 Troubleshooting Failure code [15SHL1] Release Trouble of ECMV (4th)
Failure code [15SHL1] Release Trouble of ECMV (4th) 1
Action
Failure code Release trouble of ECMV (4th)
code Failure
L01 15SHL1
Even if the output to the 4th clutch ECMV solenoid is turned OFF, the clutch is not released when signal
Detail of failure
from fill switch is kept ON.
Action of
neutral.)
controller
Problem on
machine
q Input condition (ON/OFF) from ECMV fill switch of 4th clutch can be checked with monitoring function.
Related
(Code: 02216, 02217)
information
played.

Failure of 4th clutch 2. Disconnect connector TM14, and connect T-adapter to male side.
2
failure If failure code [15SHL1] still continues, the wiring harness is grounded or the transmission
(If failure code [15SHL1] is cleared, the 4th clutch fill switch has failed.)
4
harness
ground
5
GD535-5 40-139
(01)
Failure code [15SHL1] Release Trouble of ECMV (4th) 40 Troubleshooting
Circuit diagram related to 4th clutch ECMV solenoid
40-140 GD535-5
(01)
40 Troubleshooting Failure code [15SHMA] Malfunction of ECMV (4th)
Failure code [15SHMA] Malfunction of ECMV (4th) 1
Action
Failure code Malfunction of 4th clutch ECMV solenoid
code Failure
L03 15SHMA
q Even if signal is output to the 4th clutch ECMV solenoid, the clutch is not engaged when the signal from
fill switch is OFF.
Detail of failure q During output to 4th clutch ECMV solenoid, a clutch slipping is detected from either engine speed signal,
Action of q Keeps to turn OFF the output to 4th clutch ECMV solenoid.
OFF position.
Problem on
Machine can travel in F1 to F6, or R1 to R3 positions only.
machine
Related
(Code: 02216, 02217)
information
played.

3. Start engine.
Failure of 4th clutch Between TM14 (male) (1) and ground Resistance Min. 1 Mz
2
4. Start engine.
3
harness
3. Start engine.

4
4. Start engine.
GD535-5 40-141
(01)
Failure code [15SHMA] Malfunction of ECMV (4th) 40 Troubleshooting
Circuit diagram related to 4th clutch ECMV solenoid
40-142 GD535-5
(01)
40 Troubleshooting Failure code [15SJMA] Malfunction of ECMV (L/U)
Failure code [15SJMA] Malfunction of ECMV (L/U) 1
Action
Failure code Malfunction of ECMV (L/U)
code Failure
L03 15SJMA
During output to lockup clutch ECMV solenoid, a clutch slipping is detected from either engine speed signal,
Detail of failure transmission input shaft speed sensor signal, transmission intermediate shaft speed sensor signal, or
Action of q Keeps to turn OFF the output to lockup clutch ECMV solenoid.
OFF position.
Problem on Even if the MANUAL mode is selected by the transmission mode switch, the AUTO mode (Torque
machine Converter mode) is always selected.
q The output current command value to the lockup clutch ECMV solenoid can be checked with monitoring
Related
information
played.
Procedure: Start engine. + Operate the transmission mode selector switch (MANUAL mode).

Failure of lockup clutch 1. Check the transmission oil filter for clogging and other failure.
1 oil pressure or 2. See the Testing and adjusting, "Testing power train oil pressure", and make sure that
mechanical system clutch oil pressure is normal.
Failure of lockup clutch
GD535-5 40-143
(01)
Failure code [15U0NT] Overload of Inching Clutch 40 Troubleshooting
Failure code [15U0NT] Overload of Inching Clutch 1
Action
Failure code Inching clutch overload
code Failure
L02 15U0NT
The clutch temperature, that is estimated based on the inching clutch oil temp sensor, has exceeded 200
Detail of failure
°C
q Flashes the centralized warning lamp, and sounds the alarm buzzer 2 seconds. Then, it turns OFF the
Action of
lockup clutch.
controller
Problem on
The lockup clutch is turned OFF.
machine
After the repair has completed, follow the procedure below and check to see that no failure code is
Related
displayed.
information
Procedure: Turn starting switch to ON position.

As an event to detect an overheating of inching clutch has occurred at present or in the
1 Inching clutch overload past, locate the failure cause and damage and repair it (including inappropriate inching
operation).
Failure of transmission oil
2 temperature sensor Perform troubleshooting for failure code [DGF1KX].
system
40-144 GD535-5
(01)
40 Troubleshooting Failure code [2G42ZG] Accumulator Oil Pressure Low (Front)
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) 1
Action
Failure code Accumulator oil pressure low (front)
code Failure
(Machine monitor system)
L03 2G42ZG
When engine is running, the dropped pressure of front accumulator was detected by the front brake oil
Detail of failure
pressure switch.
Action of q Lights the centralized warning lamp and sounds the alarm buzzer.
controller q If cause of failure disappears, machine becomes normal by itself.
Problem on
When engine is running, the brake oil pressure caution lamp turns ON.
machine
q Input condition (ON/OFF) from front brake oil pressure switch can be checked with monitoring function.
(Code: 04510).
Related
information
played.

Dropped oil pressure of
1 Check the oil pressure of front brake accumulator (see the Testing and Adjusting).
front brake accumulator
Failure of front brake oil 2. Disconnect connector R15, and connect T-adapter to male side.
2 3. Start engine.
pressure switch
Between R15 (male) (1) and (2) Resistance Max. 1 z
2. Disconnect connectors TM39 and R15, and connect T-adapter to each female side.
Open circuit in wiring
3
harness Between TM39 (female) (6) and R15 (female) (1) Max. 1 z
Resistance
Between R15 (female) (2) and ground Max. 1 z
Short circuit or ground 2. Disconnect connectors TM39 and R15, and connect T-adapter to female side of R15.
4
fault in wiring harness
Between R15 (female) (1) and (2) Resistance Min. 1 Mz
Failure of transmission If no failure is found by above checks, transmission controller is defective. (Since this is an
5
controller internal defect, troubleshooting cannot be performed.)
GD535-5 40-145
(01)
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) 40 Troubleshooting
Circuit diagram related to the brake accumulator
40-146 GD535-5
(01)
40 Troubleshooting Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear)
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) 1
Action
Failure code Accumulator oil pressure low (rear)
code Failure
L03 2G43ZG
When engine is running, the dropped pressure of rear accumulator was detected by the rear brake oil
Detail of failure
pressure switch.
Problem on
When engine is running, the brake oil pressure caution lamp turns ON.
machine
q Input condition (ON/OFF) from front brake oil pressure switch can be checked with monitoring function.
(Code: 04510)
Related
information
played.

Dropped oil pressure of
1 Check the oil pressure of rear brake accumulator (see the Testing and Adjusting).
rear brake accumulator
Defective rear brake oil 2. Disconnect connector R16, and connect T-adapter to male side.
2 3. Start engine.
pressure switch
Between R16 (male) (1) and (2) Resistance Max. 1 z
2. Disconnect connectors TM40 and R16, and connect T-adapter to each female side.
3
harness Between TM40 (female) (37) and R16 (female) (1) Max. 1 z
Resistance
Between R16 (female) (2) and ground Max. 1 z
Short circuit or ground 2. Disconnect connectors TM40 and R16, and connect T-adapter to female side of R16.
4
5
GD535-5 40-147
(01)
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) 40 Troubleshooting
Circuit diagram related to the brake accumulator
40-148 GD535-5
(01)
40 Troubleshooting Failure code [989L00] Engine Controller Lock Caution 1
Failure code [989L00] Engine Controller Lock Caution 1 1
Action
Failure code Engine controller lock caution 1
code Failure
- 989L00
Detail of failure Engine controller lock failure is detected (Factor 1).
Action of q None in particular
Problem on
Engine does not start.
machine
q If this failure code occurs after replacement of machine monitor, you need to change the current pass-
word back to the password you used before panel replacement.
Related
information
played.

The machine monitor
1 This error may occur if the machine monitor is replaced.
was replaced.
GD535-5 40-149
(01)
Failure code [989M00] Engine Controller Lock Caution 2 40 Troubleshooting
Failure code [989M00] Engine Controller Lock Caution 2 1
Action
code Failure
- 989M00
Detail of failure Abnormal status of engine controller lock was detected (Factor 2).
Action of q None in particular
Problem on
machine
q If this failure code occurs after replacement of machine monitor, you need to change the current pass-
word back to the password you used before panel replacement.
Related
information
played.
q Procedure: Turn starting switch to ON position.

The machine monitor
1 This error may occur if the machine monitor is replaced.
was replaced.
Defective machine If the machine monitor is not replaced and if this failure code occurs, the machine monitor
2
monitor may have failed. (Since this is an internal defect, troubleshooting cannot be performed.)
40-150 GD535-5
(01)
40 Troubleshooting Failure code [989N00] Engine Controller Lock Caution 3
Failure code [989N00] Engine Controller Lock Caution 3 1
Action
code Failure
- 989N00
Detail of failure Abnormal status of engine controller lock was detected (Factor 3).
Action of q Automatic recovery is attempted.
Problem on
machine
Related
played.
information
q Procedure: System is recovered automatically, and the error is not reproduced.

Defective engine If this failure recurs, the engine controller may be defective. (Since this is an internal defect,
1
controller troubleshooting cannot be performed.)
GD535-5 40-151
(01)
Failure code [AB00KE] Charge Voltage Low 40 Troubleshooting
Failure code [AB00KE] Charge Voltage Low 1
Action
Failure code Charge Voltage Low
code Failure
L03 AB00KE
Detail of failure Power generation signal is not entered from alternator when engine is running.
Action of
Lights the centralized warning lamp and sounds the alarm buzzer.
controller
Problem on
If it is continued, the power voltage drops and machine may fail to travel.
machine
Related
The battery charge voltage can be checked with monitoring function. (Code: 04306)
information

2. Disconnect cable from R terminal of alternator.
3. Start engine.
1 Defective alternator a If a deteriorated battery is used or if machine is operated in cold climates, the voltage
may not rise for a while after engine startup.
Between alternator terminals R and E Voltage 24 to 30 V
Open circuit in wiring 2. Disconnect connector TM39, and connect T-adapter to female side.
2
harness
Between TM39 (female) (15) and alternator R terminal Resistance Max. 1 z
3
Circuit diagram related to alternator
40-152 GD535-5
(01)
40 Troubleshooting Failure code [AB00KY] Hot Short of Alternator R Terminal
Failure code [AB00KY] Hot Short of Alternator R Terminal 1
Action
Failure code Hot short of alternator R terminal
code Failure
L03 AB00KY
Detail of failure The signal of alternator R terminal is ON when power supply is OFF.
Action of Lights the centralized warning lamp and sounds the alarm buzzer when power supply is turned ON the next
controller time.
Problem on
If it is continued, the power voltage drops and machine may fail to travel.
machine
Related
The battery charge voltage can be checked with monitoring function. (Code: 04306)
information

2. Disconnect cable from R terminal of alternator.
3. Start engine.
1 Defective alternator a If a deteriorated battery is used or if machine is operated in cold climates, the voltage
may not rise for a while after engine startup.
Between alternator terminals R and E Voltage 24 to 30 V
Hot short circuit in wiring 2. Disconnect connector TM39, and connect T-adapter to female side.
2 3. Turn starting switch to ON position.
harness
Between TM39 (female) (15) and ground Voltage Max. 1 V
3
Circuit diagram related to alternator
GD535-5 40-153
(01)
Failure code [B@BAZG] Derating in speed due to engine oil pressure drop 40 Troubleshooting
Failure code [B@BAZG] Derating in speed due to engine oil pressure drop1
Action
Failure code Engine Oil Pressure Low
code Failure
(Engine controller system)
L03 B@BAZG
When engine was running, the voltage from engine oil pressure switch dropped to GND, and the engine
Detail of failure
controller detected the abnormal drop of engine oil pressure.
Action of q Lights the engine oil pressure caution lamp on the machine monitor.
controller q Lights the centralized warning lamp and sounds the alarm buzzer.
Problem on
If machine is used as it is, engine may be seized.
machine
q The signal of engine oil pressure switch is entered in the engine controller, and this code is transmitted
to the machine monitor through CAN communication.
Related q For the diagnosis of engine oil pressure switch during engine stopping, see Failure code [CA435].
played.

Engine oil pressure
dropped.
1 Engine oil pressure may drops. Check it and remove cause of failure if oil pressure is low.
(When system works
properly)
Defective engine oil If no failure is found in cause 1, engine oil pressure sensor system may be defective.
2
pressure sensor system Perform troubleshooting for failure code [CA435].
40-154 GD535-5
(01)
40 Troubleshooting Failure code [B@BCNS] Engine Overheat
Failure code [B@BCNS] Engine Overheat 1
Action
Failure code Engine Water Overheat
code Failure
L02 B@BCNS
Detail of failure The engine coolant temperature exceeds its operating range when engine is running.
Action of q Lights the engine coolant caution lamp on the machine monitor.
controller q Lights the centralized warning lamp and sounds the alarm buzzer.
Problem on
If machine is used as it is, engine may be seized.
machine
q The signal voltage of engine coolant temperature sensor is entered in engine controller, and this data is
transmitted to the machine monitor through CAN communication.
q Input voltage from engine coolant sensor can be checked with monitoring function. (Code: 04105)
Related q Temperature detected by engine coolant temperature sensor can be checked with monitoring function.
information (Code: 04107)
played.

Overheating of engine
coolant Engine coolant may overheat. Check coolant temperature and remove cause of failure if
1
(When system works coolant overheats.
properly)
Defective engine coolant
If no failure is found by check on cause 1, engine coolant temperature sensor system may
2 temperature sensor
be defective. Perform troubleshooting for failure codes [CA144] and [CA145].
system
GD535-5 40-155
(01)
Failure code [B@CENS] T/C Oil Temp. Overheat 40 Troubleshooting
Failure code [B@CENS] T/C Oil Temp. Overheat 1
Action
Failure code Overheat of torque converter oil temperature
code Failure
L02 B@CENS
The voltage of torque converter oil temperature sensor dropped during engine running, and the transmission
Detail of failure
controller detected an overheat of torque converter oil temperature (approximately 120°C or above).
q Lights the torque converter oil temperature caution lamp on the machine monitor.
Action of
controller
q Lights the centralized warning lamp and sounds the alarm buzzer.
Problem on
If machine is used as it is, the torque converter may seize.
machine
q Signal from torque converter oil temperature is entered in the transmission controller, and its data is
transmitted to machine monitor through CAN communication.
q The input voltage and temperature sent from the torque converter oil temperature sensor can be checked
Related
by the monitoring function. (Code: 30101, 30100)
information
played.

Overheat of torque
converter oil temperature
1 The torque converter oil may overheat. If overheated, repair it.
(when system works
properly)
Failure of torque
2 converter oil temperature Perform troubleshooting for failure code [DGT1KX].
sensor system
40-156 GD535-5
(01)
40 Troubleshooting Failure code [B@CKNS] DIFF Oil Temp. Overheat
Failure code [B@CKNS] DIFF Oil Temp. Overheat 1
Action
Failure code Overheat of differential gear oil
code Failure
L02 B@CKNS
Detail of failure Differential gear oil temperature caution occurred. (Differential gear oil temperature exceeded 120°C)
Action of
controller
q Lights the differential gear oil temperature caution lamp.
Problem on
If machine is used as it is, the differential gear may seize.
machine
q The input voltage and temperature sent from the differential gear oil temperature sensor can be checked
by the monitoring function. (Code: 31910, 31909)
Related
information
played.

Overheat of differential
gear case oil temperature As an event to detect an overheating of differential gear case oil has occurred at present or
1
(When system works in the past, locate the failure cause and damage and repair it.
properly)
2. Disconnect connector R8, and connect T-adapter to male side.
Between R8 (male) (1) and (2) 25°C Resistance 38 to 49 kz
Failure of differential gear
2 (Temperature characteristics of oil
oil temperature sensor 100°C Resistance 3.7 to 4.0 kz
temperature sensor)
Between R8 (male) (1) and ground, and
All ranges Resistance Min. 1 Mz
between R8 (male) (2) and ground
2. Disconnect connector TM39, and connect T-adapter to female side.
3
Open or short circuit in a The resistance is the same as for the temperature characteristics table of oil tempera-
wiring harness ture sensor in cause 1 (25°C to 100°C)
Between TM39 (female) (14) and ground Resistance 3.7 to 49 kz
If no failure is found by check on cause 2, this check is not required.
Open circuit in wiring 2. Disconnect connectors TM39 and R8, and connect T-adapter to each female side.
4
harness
Between TM39 (female) (14) and R8 (female) (1) Resistance Max. 1 z
Ground fault in wiring 2. Disconnect connectors R8 and TM39, and connect T-adapter to either female side.
5
harness
Between R8 (female) (1) or TM39 (female) (14) and ground Resistance Min. 1 Mz
Hot short or short circuit 2. Disconnect connector R8, and connect T-adapter to female side.
of wiring harness
Between R8 (female) (1) and (2) Voltage Approx. 5 V
Failure of transmission If no failure is found by above checks, the transmission controller has failed. (Since this is
7
controller an internal defect, troubleshooting cannot be performed.)
GD535-5 40-157
(01)
Failure code [B@CKNS] DIFF Oil Temp. Overheat 40 Troubleshooting
Circuit diagram related to differential gear oil temperature sensor
40-158 GD535-5
(01)
40 Troubleshooting Failure code [B@HANS] HYD Oil Temp. Overheat
Failure code [B@HANS] HYD Oil Temp. Overheat 1
Action
Failure code Hydraulic Oil Temperature Overheat
code Failure
L02 B@HANS
The voltage of hydraulic oil temperature sensor dropped, and the machine monitor detected an overheat of
Detail of failure
hydraulic oil temperature (approximately 100°C or more) while engine is running.
q Lights the hydraulic oil temperature caution lamp on the machine monitor.
Action of
controller
Problem on
If machine is used as it is, hydraulic system components may be damaged.
machine
q Signal from hydraulic system oil temperature is entered in the transmission controller, and its data is
transmitted to machine monitor through CAN communication.
q The input voltage and temperature sent from the hydraulic oil temperature sensor can be checked by the
Related
monitoring function. (Code: 04404, 04401)
information
played.

Overheat of hydraulic oil
Hydraulic oil may be overheated. Check hydraulic oil temperature, and remove cause of
1 temperature (when
failure if hydraulic oil overheats.
system works properly)
Between R17 (male) (1) and (2) 25°C Resistance 38 to 49 kz
Failure of hydraulic oil
temperature sensor 100°C Resistance 3.7 to 4.0 kz
temperature sensor)
Between R17 (male) (1) and ground, and
between R17 (male) (2) and ground
3
wiring harness ture sensor in cause 1 (25°C to 100°C)
Between TM39 (female) (20) and (21) Resistance 3.7 to 49 kz
Open circuit in wiring 2. Disconnect connectors TM39 and R17, and connect T-adapter to each female side.
4
harness
Ground fault in wiring 2. Disconnect connectors R17 and TM39, and connect T-adapter to either female sidev.
5
harness Between R17 (female) (1) or TM39 (female) (20) and
ground
Hot short or short circuit 2. Disconnect connector R17, and connect T-adapter to female side.
of wiring harness
Between R17 (female) (1) and (2) Voltage Approx. 5 V
7
GD535-5 40-159
(01)
Failure code [B@HANS] HYD Oil Temp. Overheat 40 Troubleshooting
Circuit diagram related to hydraulic oil temperature sensor
40-160 GD535-5
(01)
40 Troubleshooting Failure code [CA111] Engine NE, controller internal error
Failure code [CA111] Engine NE, controller internal error 1
Action
Failure code Engine controller internal failure
code Failure
L03 CA111
Detail of failure Internal memory of engine controller or internal power supply circuit has failed.
Action of
None in particular
controller
q Engine may stop during running, or engine may not start again.
Problem on
q Centralized warning lamp lights up and alarm buzzer sounds (depending on the machine monitor set-
machine
ting).
Related
displayed.
information

Defective relevant
system
Defective engine
2 Perform troubleshooting for failure code [CA441].
controller system
GD535-5 40-161
(01)
Failure code [CA115] Engine NE, Bkup speed sensor error 40 Troubleshooting
Failure code [CA115] Engine NE, Bkup speed sensor error 1
Action
Failure code Failure of engine NE or Backup speed sensor
code Failure
L03 CA115
Detail of failure Both signals of engine Ne speed sensor and engine backup speed sensor are abnormal.
Action of
None in particular
controller
q Engine stops.
Problem on q Engine does not start.
machine q Centralized warning lamp lights up and alarm buzzer sounds (depending on the machine monitor set-
ting).
Related
displayed.
information

Poor connection of The Ne speed sensor cable and the backup speed sensor cable may not be connected
1
sensor connector securely (or incorrectly connected).
Failure of Ne speed
2 Perform troubleshooting for failure code [CA689], Steps 1 to 10).
sensor system
Failure of Bkup speed
sensor system
Defective engine If no failure is found by above checks, engine controller is defective. (Since this is an
4
40-162 GD535-5
(01)
40 Troubleshooting Failure code [CA122] Charge pressure sensor high error
Failure code [CA122] Charge pressure sensor high error 1
Action
Failure code Charge pressure sensor high error
code Failure
L03 CA122
High voltage was detected in the pressure signal circuit of charge (boost) pressure and temperature
Detail of failure
sensors.
Action of
Runs engine with the fixed charge pressure.
controller
q Engine output lowers.
Problem on
machine
ting).
q The input voltage from charge pressure sensor (boost pressure sensor) can be checked with monitoring
Related function. (Code: 36500)
played.
q If the sensor connector is unplugged, alarm [CA123] is output even in the normal state.

Defective wiring harness See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks
1
connector before troubleshooting" of "Related information on troubleshooting", and check it.
Failure of dual system
2 sensor power supply 2 If failure code [CA227] is also displayed, perform troubleshooting for it first.
system
2. Disconnect the BOOST PRESS & IMT connector.
Failure of boost pressure 3. Turn starting switch to ON position.
3
and temperature sensor If failure code [CA122] changes to [CA123], the boost pressure sensor has failed.
Temperature sensor failure code [CA153] is also displayed simultaneously.
Ignore this code. This code is output because the sensor connector is being unplugged.
Short circuit in wiring 2. Disconnect connectors ECM and BOOST PRESS & IMT, and connect T-adapter to
4 female side of ECM.
harness
Between ECM (female) (37) and (44) Resistance Min. 100 kz
Hot short circuit in wiring 2. Disconnect connector BOOST PRESS & IMT, and insert T-adapter into connector ECM.
5 3. Turn starting switch ON (with connector BOOST PRESS & IMT disconnected).
harness
Between ECM (44) and (47) Voltage Max. 1 V
6
GD535-5 40-163
(01)
Failure code [CA122] Charge pressure sensor high error 40 Troubleshooting
Circuit diagram related to charge pressure sensor
40-164 GD535-5
(01)
40 Troubleshooting Failure code [CA123] Charge pressure sensor low error
Failure code [CA123] Charge pressure sensor low error 1
Action
Failure code Charge pressure sensor low error
code Failure
L03 CA123
Low voltage was detected in the pressure signal circuit of charge (boost) pressure and temperature
Detail of failure
sensors.
Action of
Runs engine with the fixed charge pressure.
controller
Problem on
machine
ting).
Related q After the repair has completed, follow the procedure below and check to see that no failure code is dis-
information played.
q Because the T-adapter for sensor connection is a socket, the voltage cannot be checked by checking the
disconnection of wiring harness and sensor connector.
q If the sensor connector is disconnected, this code is output.

1
Defective power supply
2 system of charge (boost) If failure code [CA187] or [CA227] is also displayed, perform troubleshooting for it first.
pressure sensor
2. Disconnect connectors CAM SENSOR, FUEL RAIL PRESS, BOOST PRESS & IMT,
and ECM.
Short circuit in wiring 3. Connect T-adapter to female side of ECM.
3
harness
Ground fault in wiring 2. Disconnect connectors ECM and BOOST PRESS & IMT, and connect T-adapter to
4 female side of ECM.
harness
Between ECM (female) (44) and ground Resistance Min. 100 kz
5 If no failure is found by above checks, wiring harness may have open circuit. (*)
harness
If failure is not found by check on causes 1 to 5, but found by check on cause 6, the sensor
is defective.
Failure of boost pressure 1. Turn the starting switch to OFF position.
and temperature sensor 2. Insert T-adapter into connector ECM.
6
(Incorrect input voltage of 3. Turn starting switch to ON position.
engine controller)
Sensor Min. 0.3 to
Between ECM (44) and (47) Voltage
output 4.7 V
7
* See the "Diagnosis of open harness in pressure sensor system" of "Related information on troubleshooting".
GD535-5 40-165
(01)
Failure code [CA123] Charge pressure sensor low error 40 Troubleshooting
Circuit diagram related to charge pressure sensor
40-166 GD535-5
(01)
40 Troubleshooting Failure code [CA131] Throttle sensor high error
Failure code [CA131] Throttle sensor high error 1
Action
Failure code Throttle position sensor high error
code Failure
L03 CA131
Detail of failure High voltage appears in throttle position sensor signal circuit.
Action of Turn the accelerator pedal OFF, and set the throttle opening to 0%. Then, turn the accelerator pedal ON,
controller set the throttle opening to 50%, and run the engine.
q Full throttle position cannot be set.
Problem on
machine
ting).
q Input voltage from throttle position sensor can be checked with monitoring function. (Code: 03000)
q The opening of accelerator pedal, detected by throttle position sensor, can be checked with monitoring
played.

1
Defective throttle sensor
2 If failure code [CA2185] is also displayed, perform troubleshooting for it first.
power supply system
Short circuit in wiring 2. Disconnect connectors EC2 and T9A, and connect T-adapter to either female side.
3
harness Between EC2 (female) (9) and (22), or between T9A
Resistance Min. 100 kz
(female) (1) and (2)
Hot short circuit in wiring 2. Disconnect connector T9A, and connect T-adapter to female side.
harness
Between T9A (female) (2) and ground Voltage Max. 1 V
2. Insert T-adapter into connector T9A.
3. Turn starting switch to ON position.
Failure of accelerator
5 pedal (throttle position Depress the accelerator
Voltage 3.7 to 4.0 V
sensor) pedal.
Between T9A (2) and (3)
When accelerator pedal is
released
If no failure is found by above checks, engine controller is defective. (Since this is an
internal defect, troubleshooting cannot be performed.)
Reference
2. Insert T-adapter into connector EC2.
Defective engine 4. Operate the accelerator pedal and perform troubleshooting.
6
controller 4.75 to 5.25
Between EC2 (22) and (23) Power supply Voltage
V
Depress the accelerator
pedal.
Between EC2 (9) and (23)
released
GD535-5 40-167
(01)
Failure code [CA131] Throttle sensor high error 40 Troubleshooting
Circuit diagram related to throttle sensor
40-168 GD535-5
(01)
40 Troubleshooting Failure code [CA132] Throttle sensor low error
Failure code [CA132] Throttle sensor low error 1
Action
Failure code Throttle position sensor low error
code Failure
L03 CA132
Detail of failure Low voltage appears in throttle position sensor signal circuit.
Problem on
machine
ting).
q Input voltage from throttle position sensor can be checked with monitoring function. (Code: 03000)
q The opening of accelerator pedal, detected by throttle position sensor, can be checked with monitoring
played.

1
If failure code [CA2186] is also displayed, perform troubleshooting for it first.
2. Check that the system operating lamp is off, and then turn the battery disconnect switch
to OFF position.
(When the battery disconnect switch is not installed, disconnect the cable from the
battery negative (-) terminal.)
3. Disconnect connectors T9A and T9B, and connect T-adapter to female side.
Defective throttle sensor 4. Turn the battery disconnect switch to ON position.
2
power supply system (When the battery disconnect switch is not installed, connect the cable to the battery
negative (-) terminal.)
4.75 to 5.25
Between T9A (female) (1) and (3) Voltage
V
4.75 to 5.25
Between T9B (female) (1) and (2) Voltage
V
to OFF position.
3. Disconnect connectors EC2, T9A, T9B, TM39, and TM40, and connect T-adapter to
each female side.
If no failure is found by check on cause 2, this check is not
Open circuit in wiring required. Resistance Min. 100 kz
3
harness Between EC2 (female) (22) and T9A (female) (1)
required. Resistance Max. 10 z
Between EC2 (female) (23) and T9A (female) (3)
Between EC2 (female) (9) and T9A (female) (2) Resistance Max. 10 z
Between TM39 (female) (4) and T9B (2) Resistance Max. 10 z
Between TM40 (female) (1) and T9B (1) Resistance Max. 10 z
GD535-5 40-169
(01)
Failure code [CA132] Throttle sensor low error 40 Troubleshooting

Short circuit in wiring 2. Disconnect connectors EC2 and T9A, and connect T-adapter to either female side.4
4
harness
Between EC2 (female) (9) and (23), or between T9A
Ground fault in wiring 2. Disconnect connectors EC2 and T9A, and connect T-adapter to either female side.
5
harness
Between EC2 (female) (9) or T9A (female) (2) and ground Resistance Min. 100 kz
Failure of accelerator
6 pedal (throttle position Depress the accelerator
sensor) pedal.
Between T9A (2) and (3)
released
Reference
2. Insert T-adapter into connector EC2.
Defective engine 4. Operate the accelerator pedal and perform troubleshooting.
7
controller 4.75 to 5.25
Between EC2 (22) and (23) Power supply Voltage
V
Depress the accelerator
pedal.
released
40-170 GD535-5
(01)
40 Troubleshooting Failure code [CA132] Throttle sensor low error
GD535-5 40-171
(01)
Failure code [CA144] Coolant sensor high error 40 Troubleshooting
Failure code [CA144] Coolant sensor high error 1
Action
Failure code Coolant temperature sensor high error
code Failure
L01 CA144
Detail of failure High voltage appears in the engine coolant sensor signal circuit.
Action of
Runs engine with the fixed coolant temperature.
controller
Problem on q Engine startability is poor in low temperature.
machine q The overheat prevention function does not work.
q Temperature detected by engine coolant temperature sensor can be checked with monitoring function.
(Code: 04107)
Related
played.
information
q If the temperature sensor connector is unplugged, this code is output.
q Because the T-adapter for sensor connection is a socket, the T-adapter cannot be connected to the wir-
ing harness.

1
2. Disconnect connector COOLANT TEMP, and connect socket to male side.
Regard coolant temperature sensor as normal if its resistance is 700 z to 37 kz when
coolant temperature is 0°C or more.
Defective coolant 0°C Resistance 30 to 37 kz

2
temperature sensor 25°C Resistance 9.3 to 10. 7 kz
Between COOLANT TEMP (male) (A) and
(B) 50°C Resistance 3.2 to 3.8 kz
(Coolant temperature characteristics)
80°C Resistance 1.0 to 1.3 kz
95°C Resistance 700 to 800 z

2. Disconnect connector ECM, and connect T-adapter to female side.
Open or short circuit in a Use temperature sensor resistance characteristics table for check on cause 2 as resis-
3 tance criteria.
wiring harness
Between ECM (female) (15) and (38) (when coolant 700 z to 37
Resistance
temperature is 0°C or more) kz
4
40-172 GD535-5
(01)
40 Troubleshooting Failure code [CA144] Coolant sensor high error
Circuit diagram related to coolant temperature sensor
GD535-5 40-173
(01)
Failure code [CA145] Coolant sensor low error 40 Troubleshooting
Failure code [CA145] Coolant sensor low error 1
Action
Failure code Coolant temperature sensor low error
code Failure
L01 CA145
Detail of failure Low voltage appears in the engine coolant sensor signal circuit.
Action of
Runs engine with the fixed coolant temperature.
controller
Problem on q Engine startability is poor in low temperature.
machine q The overheat prevention function does not work.
q Temperature detected by engine coolant temperature sensor can be checked with monitoring function.
(Code: 04107)
Related
information
played.
q If the temperature sensor connector is disconnected, the high error code is output instead of this code.

1
2. Disconnect connector COOLANT TEMP, and connect socket to male side.
Regard coolant temperature sensor as normal if its resistance is 700 z to 37 kz when
coolant temperature is 0°C or more.
0°C Resistance 30 to 37 kz

Defective coolant Between COOLANT TEMP (male) (A) and
2
temperature sensor (B) 50°C Resistance 3.2 to 3.8 kz
(Coolant temperature characteristics)

Entire coolant
Between (B) and ground temperature Resistance Min. 100 kz
range
Short circuit in wiring a Use temperature sensor resistance characteristics table for check on cause 2 as resis-
3 tance criteria.
harness
Between ECM (female) (15) and (38) (when coolant 700 z to 37
Resistance
temperature is 0°C or more) kz
Ground fault in wiring 2. Disconnect connectors ECM and COOLANT TEMP, and connect T-adapter to female
4 side of ECM.
harness
5
40-174 GD535-5
(01)
40 Troubleshooting Failure code [CA145] Coolant sensor low error
Circuit diagram related to coolant temperature sensor
GD535-5 40-175
(01)
Failure code [CA153] Charge temperature sensor high error 40 Troubleshooting
Failure code [CA153] Charge temperature sensor high error 1
Action
Failure code Charge air temperature sensor high error
code Failure
L01 CA153
High voltage was detected in the temperature signal circuit of charge (boost) pressure and temperature
Detail of failure
sensors.
Action of
Runs engine with the fixed charge temperature.
controller
Problem on
The engine protection function does not work at the boost temperature.
machine
q The input voltage from charge temperature sensor (boost temperature sensor) can be checked with mon-
itoring function. (Code: 18501)
q Temperature sensed by charge temperature sensor (boost temperature sensor) can be checked with
monitoring function. (Code: 18500)
information played.
q Because the T-adapter for sensor connection is a socket, the T-adapter cannot be connected to the wir-
ing harness.
q If the temperature sensor connector is disconnected, this code is output.

1
2. Disconnect connector BOOST PRESS & IMT, and connect socket to male side.
-40°C Resistance 41 kz to 48 kz
5.4 kz to 6.1
Defective charge 0°C Resistance
2 kz
temperature sensor Between BOOST PRESS & IMT (male) (3)
and (4) 1.6 kz to 1.8
30°C Resistance
Charge temperature characteristics kz
3
Open or short circuit in a Use the charge temperature and resistance characteristics table of charge temperature
wiring harness sensor for check on cause 2 as resistance criteria.
Between ECM (female) (23) and (47) Resistance 80 z to 48 kz
4
40-176 GD535-5
(01)
40 Troubleshooting Failure code [CA153] Charge temperature sensor high error
Circuit diagram related to charge temperature sensor
GD535-5 40-177
(01)
Failure code [CA154] Charge temperature sensor low error 40 Troubleshooting
Failure code [CA154] Charge temperature sensor low error 1
Action
Failure code Charge air temperature sensor low error
code Failure
L01 CA154
Low voltage was detected in the temperature signal circuit of charge (boost) pressure and temperature
Detail of failure
sensors.
Action of
Runs engine with the fixed charge temperature.
controller
Problem on
The engine protection function does not work at the boost temperature.
machine
q The input voltage from charge temperature sensor (boost temperature sensor) can be checked with mon-
Related monitoring function. (Code: 18500)
information q If the temperature sensor connector is disconnected, the high error code is output instead of this code.
played.

1
2. Disconnect connector BOOST PRESS & IMT, and connect socket to male side.
5.4 kz to 6.1
Defective charge 0°C Resistance
2 kz
temperature sensor Between BOOST PRESS & IMT (male) (3)
and (4) 1.6 kz to 1.8
30°C Resistance
(Charge temperature characteristics) kz
3
Short circuit in wiring a Use the charge temperature and resistance characteristics table of charge temperature
harness sensor for check on cause 2 as resistance criteria.
Between ECM (female) (23) and (47) Resistance 80 z to 48 kz
Ground fault in wiring 2. Disconnect connectors ECM and BOOST PRESS & IMT, and connect T-adapter to
4
harness female side of ECM.
5
40-178 GD535-5
(01)
40 Troubleshooting Failure code [CA154] Charge temperature sensor low error
Circuit diagram related to charge temperature sensor
GD535-5 40-179
(01)
Failure code [CA155] Speed derating error by high charge temperature 40 Troubleshooting
Failure code [CA155] Speed derating error by high charge temperature 1
Action
Failure code Speed derating error by high charge temperature
code Failure
L03 CA155
The charge (boost) pressure and temperature sensor detects the temperature above the upper limit of
Detail of failure
control.
Action of
Limits engine output and runs engine.
controller
Problem on q Engine stops.
ting).
Related
information
played.

As the cooling performance of aftercooler may have dropped, check the following points.
Dropped cooling
q Looseness or damage of fan belt
1 performance of
q Insufficient cooling air volume
aftercooler
q Clogging of aftercooler fins
Abnormal increase of
As the turbocharger outlet temperature may have increased abnormally, inspect the related
2 turbocharger outlet
parts.
temperature
Failure of charge
If no failure is found by above checks, the charge temperature system may have failed.
Perform troubleshooting for failure codes [CA153] and [CA154].
system
40-180 GD535-5
(01)
40 Troubleshooting Failure code [CA187] Sensor power supply 2 low error
Failure code [CA187] Sensor power supply 2 low error 1
Action
Failure code Sensor power supply 2 voltage low error
code Failure
L03 CA187
Detail of failure Low voltage appears in the sensor power supply 2 circuit.
Action of q Runs engine with the fixed charge (boost) pressure and charge (boost) temperature.
controller q Limits engine output and runs engine.
Problem on q Deteriorated startability
ting).
Related
played.
information

1
2. Disconnect following connectors one by one in order, and turn starting switch ON each
time.
If this failure code is not displayed, disconnected sensor or engine wiring harness is
defective.
a Other (many) failure codes are output simultaneously. This is because connector is dis-
Defective sensor or connected. Ignore failure codes other than this [CA187].
2
wiring harness Sensor and wiring harness Connector
Boost pressure and temperature sensor BOOST PRESS & IMT
Common rail pressure sensor FUEL RAIL PRESS
Bkup sensor CAM SENSOR
Engine harness ECM
2. Disconnect connector ECM and connect T-adapter to male side.
Defective engine 3. Turn starting switch ON with engine wiring harness disconnected.
3
controller
4.75 to 5.25
Between ECM (male) (37) and (47) Voltage
V
GD535-5 40-181
(01)
Failure code [CA187] Sensor power supply 2 low error 40 Troubleshooting
Circuit diagram related to sensor power supply 2 circuit
40-182 GD535-5
(01)
40 Troubleshooting Failure code [CA221] Atmospheric pressure sensor high error
Failure code [CA221] Atmospheric pressure sensor high error 1
Action
Failure code Atmospheric pressure sensor high error
code Failure
L01 CA221
Detail of failure High voltage appears in atmospheric pressure sensor signal circuit.
Action of
Runs engine with the fixed atmospheric pressure.
controller
Problem on q Engine output lowers.
machine q Deteriorated startability
q Input voltage from atmospheric pressure sensor can be checked with monitoring function. (Code: 37401)
q The atmospheric pressure detected by atmospheric pressure sensor can be checked with monitoring
played.

1
Failure of sensor power
2 If failure code [CA352] or [CA386] is also displayed, perform troubleshooting for it first.
supply 1 system
Defective atmospheric 2. Disconnect connector AMB. AIR PRESSURE.
pressure sensor
If failure code [CA221] changes to [CA222], the sensor is defective.
2. Disconnect connectors ECM and AMB. AIR PRESSURE, and connect T-adapter to
Short circuit in wiring either female side.
4
harness
Between ECM (female) (33) and (3), or between AMB.
AIRPRESSURE (female) (1) and (3)
2. Disconnect connector AMB. AIR PRESSURE.
3. Connect T-adapter to female side of connector AMB. AIR PRESSURE, or insert T-
Hot short circuit in wiring adapter into connector ECM.
5
harness 4. Turn starting switch ON (with connector AMB. AIR PRESSURE disconnected).
Between ECM (3) to (38), or between AMB. AIR
Voltage Max. 1 V
PRESSURE (female) (3) and (2)
6
GD535-5 40-183
(01)
Failure code [CA221] Atmospheric pressure sensor high error 40 Troubleshooting
Circuit diagram related to atmospheric pressure sensor
40-184 GD535-5
(01)
40 Troubleshooting Failure code [CA222] Atmospheric pressure sensor low error
Failure code [CA222] Atmospheric pressure sensor low error 1
Action
Failure code Atmospheric pressure sensor low error
code Failure
L01 CA222
Detail of failure Low voltage appears in atmospheric pressure sensor signal circuit.
Action of
controller
machine q Deteriorated startability
q Input voltage from atmospheric pressure sensor can be checked with monitoring function. (Code: 37401)
q The atmospheric pressure detected by atmospheric pressure sensor can be checked with monitoring
played.

1
If failure code [CA352] or [CA386] is also displayed, perform troubleshooting for it first.
Failure of atmospheric
2. Disconnect connector AMB. AIR PRESSURE, and connect T-adapter to female side.
2 pressure sensor power
supply system
Between AMB. AIR PRESSURE (female) (1) Power supply 4.75 to 5.25
Voltage
and (2) input V
2. Disconnect connectors AMB. AIR PRESSURE and ECM, and connect T-adapters to
each female side.
If the power input on cause 2 is normal, this check is not
required.
Resistance Max. 10 z
Between ECM (female) (33) and AMB. AIR PRESSURE
Short circuit in wiring (female) (1)
3
harness
If the power input on cause 2 is normal, this check is not
required.
(female) (2)
(female) (3) (sensor output)
Ground fault in wiring either female side.
4
harness
Between ECM (female) (3) and ground, or between AMB.
AIR PRESSURE (female) (3) and ground
Short circuit in wiring either female side.
5
harness
Between ECM (female) (3) and (38), or between AMB. AIR
PRESSURE (female) (2) and (3)
GD535-5 40-185
(01)
Failure code [CA222] Atmospheric pressure sensor low error 40 Troubleshooting

is defective.
Defective atmospheric 1. Turn the starting switch to OFF position.
pressure sensor 2. Insert T-adapter into connector ECM.
6
((Incorrect input voltage 3. Turn starting switch to ON position.
at engine controller)
Sensor
Between ECM (3) and (38) Voltage 0.5 to 4.5 V
output
7
Circuit diagram related to atmospheric pressure sensor
40-186 GD535-5
(01)
40 Troubleshooting Failure code [CA227] Sensor power supply 2 high error
Failure code [CA227] Sensor power supply 2 high error 1
Action
Failure code Sensor power supply 2 high error
code Failure
L03 CA227
Detail of failure High voltage appears in the sensor power supply 2 circuit.
Action of q Runs engine with the fixed charge pressure and charge temperature.
controller q Limits engine output and runs engine.
ting).
Related
displayed.
information

supply 2 system
GD535-5 40-187
(01)
Failure code [CA234] Engine overspeed 40 Troubleshooting
Failure code [CA234] Engine overspeed 1
Action
Failure code Engine Overspeed
code Failure
L02 CA234
Detail of failure The engine speed exceeded the limit of control speed.
Action of
Stops fuel injection until the engine drops below the normal speed.
controller
q Engine speed fluctuates.
Problem on
machine
ting).
q Engine speed can be checked with monitoring function.
(Code: 01002)
Related
information
played.
Procedure: Idle the engine at high speed.

1 Improper fuel is used. Fuel used may be improper. Check it.
As the installed equipment may be operated incorrectly, instruct operator on how to use the
2 Improper machine usage
equipment properly.
Defective engine If no failure is found by checks on causes 1 and 2, engine controller may be defective.
3
controller (Since this is an internal defect, troubleshooting cannot be performed.)
40-188 GD535-5
(01)
40 Troubleshooting Failure code [CA238] Ne speed sensor power supply error
Failure code [CA238] Ne speed sensor power supply error 1
Action
Failure code Ne speed sensor power supply error
code Failure
L03 CA238
Detail of failure Low voltage appears in the engine Ne speed sensor power circuit.
Action of
Controls the engine using the Bkup speed sensor signals.
controller
q The engine stops (when Bkup speed sensor is also defective).
q The engine does not start (when Bkup speed sensor is also defective).
Problem on q Engine startability is poor.
machine q Engine rotation is hunting.
ting).
Related
displayed.
information

1
2. Disconnect following connectors one by one in order and turn starting switch ON each
time.
a If this failure code is not displayed, disconnected sensor or engine wiring harness is
Defective sensor or defective.Other (many) failure codes are output simultaneously. This is because con-
2 nector is disconnected. Ignore failure codes other than this [CA238].
wiring harness
Sensor and wiring harness Connector
Ne speed sensor CRANK SENSOR
Engine harness ECM
3
controller
4.75 to 5.25
V
Circuit diagram related to Ne speed sensor
GD535-5 40-189
(01)
Failure code [CA271] IMV short-circuit error 40 Troubleshooting
Failure code [CA271] IMV short-circuit error 1
Action
Failure code IMV short-circuit error
code Failure
L03 CA271
Detail of failure The drive circuit of supply pump actuator has shorted.
Action of
None in particular
controller
q The engine speed does not increase from low idle speed.
Problem on
q The common rail system fuel pressure is higher than the command value.
machine
ting).
Related
displayed.
information

1
Failure of supply pump 2. Disconnect connector CP3 PUMP REGULATOR.
actuator
If failure code [CA271] changes to [CA272], the supply pump actuator is defective.
Short circuit or ground
3
fault in wiring harness Between ECM (female) (2) and (32) Resistance 1 to 5 z
Short circuit in wiring 2. Disconnect connectors ECM and CP3 PUMP REGULATOR, and connect T-adapter to
4 female side of either ECM or CP3 PUMP REGULATOR.
harness
Between ECM (female) (2) and (3) or between CP3 PUMP
REGULATOR (female) (1) and (2)
Ground fault in wiring 2. Disconnect connectors ECM and CP3 PUMP REGULATOR, and connect T-adapter to
5 female side of either ECM or CP3 PUMP REGULATOR.
harness
Between ECM (female) (2) and ground, or between CP3
PUMP REGULATOR (female) (1) and ground
6
40-190 GD535-5
(01)
40 Troubleshooting Failure code [CA271] IMV short-circuit error
Circuit diagram related to IMV/IMA
GD535-5 40-191
(01)
Failure code [CA272] IMV open circuit 40 Troubleshooting
Failure code [CA272] IMV open circuit 1
Action
Failure code IMV open circuit
code Failure
L03 CA272
Detail of failure The drive circuit of supply pump actuator has opened.
Action of
None in particular
controller
q Although the engine starts, it is unstable.
Problem on q The common rail system fuel pressure is higher than the command value.
ting).
Related
displayed.
information

1
Failure of supply pump 2. Disconnect connector CP3 PUMP REGULATOR.
2
actuator
Between CP3 PUMP REGULATOR (female) (1) and (2) Resistance Max. 5 z
Open or short circuit in 2. Disconnect connector ECM, and connect T-adapter to female side.
3
wiring harness
Between ECM (female) (2) and (32) Resistance Max. 5 z
2. Disconnect connectors ECM and CP3 PUMP REGULATOR, and connect T-adapters to
each female side.
4
harness Between ECM (female) (2) and CP3 PUMP REGULATOR
(1)
Between ECM (female) (32) and CP3 PUMP REGULATOR
(2)
2. Disconnect connector CP3 PUMP REGULATOR.
3. Insert T-adapter into connector ECM, or connect T-adapter to female side of connector
CP3 PUMP REGULATOR.
Hot short circuit in wiring 4. Turn starting switch to ON position (keep connector CP3 PUMP REGULATOR discon-
5
harness nected), and measure the resistance when one minute or more have passed.
a As they are pulse voltages, the average voltage is displayed on the multimeter.
Between ECM (2) and (32) or between CP3 PUMP
Voltage Max. 3V
REGULATOR (female) (1) and (2)
6
40-192 GD535-5
(01)
40 Troubleshooting Failure code [CA272] IMV open circuit
Circuit diagram related to IMV/IMA
GD535-5 40-193
(01)
Failure code [CA322] Injector #1 (L/B #1) open/short 40 Troubleshooting
Failure code [CA322] Injector #1 (L/B #1) open/short 1
Action
Failure code Injector #1 (L/B #1) circuit has opened or shorted.
code Failure
L03 CA322
Detail of failure The drive circuit of injector No. 1 has opened or shorted.
Action of
None in particular
controller
q Poor engine combustion or hunting occurs.
ting).
played.
Related
information
q While engine is running normally, approximately 65 V of pulse voltage is supplied to injector (+) side. Be-
cause it is pulse voltage, it cannot be measured by using multimeter.

1
2. Disconnect connectors INJECTOR CYL 1&2, and connect T-adapter to male side.
2 Defective injector No. 1
Between INJECTOR CYL 1&2 (male) (3) and (4) Resistance Max. 2 z
Between INJECTOR CYL 1&2 (male) (3) and ground Resistance Min. 100 kz
Open circuit or ground
3
fault in wiring harness Between ECM (female) (45) and (53) Resistance Max. 2 z
2. Disconnect connectors ECM and INJECTOR CYL 1&2, and connect T-adapter to each
female side.
4
harness Between ECM (female) (45) and INJECTOR CYL 1&2
Resistance Max. 2 z
(female) (3)
Between ECM (female) (53) and INJECTOR CYL 1&2
Resistance Max. 2 z
(female) (4)
Ground fault in wiring 2. Disconnect connectors ECM and INJECTOR CYL 1&2, and connect T-adapter to either
5 female side.
harness
Between ECM (female) (45) or INJECTOR CYL 1&2
(female) (3) and ground
40-194 GD535-5
(01)
40 Troubleshooting Failure code [CA322] Injector #1 (L/B #1) open/short

2. Disconnect connectors ECM and INJECTOR CYL 1&2, and connect T-adapter to
female side of ECM.
Check by using multimeter in continuity mode.
Short circuit in wiring
6
harness Between ECM (female) (45) and each pin other than pin No conductivity
(45) (No sound is heard.)
Between ECM (female) (53) and each pin other than pin No conductivity
7
Circuit diagram related to injector #1
GD535-5 40-195
(01)
Action
code Failure
L03 CA323
Action of
None in particular
controller
ting).
played.
Related
information

1
3
2. Disconnect connectors ECM and INJECTOR CYL 5&6, and connect T-adapter to each
female side.
4
Resistance Max. 2 z
(female) (3)
Resistance Max. 2 z
(female) (4)
5 female side.
harness
40-196 GD535-5
(01)

female side of ECM.
6
7
GD535-5 40-197
(01)
Action
Code Failure
L03 CA324
Action of
None in particular
controller
ting).
played.
Related
information

1
3
2. Disconnect connectors ECM and INJECTOR CYL 3&4, and connect T-adapters to each
female side.
4
Resistance Max. 2 z
(female) (3)
Resistance Max. 2 z
(female) (4)
5 female side.
harness
40-198 GD535-5
(01)

female side of ECM.
6
7
GD535-5 40-199
(01)
Action
code Failure
L03 CA325
Action of
None in particular
controller
ting).
played.
Related
information

1
3
2. Disconnect connectors ECM and INJECTOR CYL 5&6, and connect T-adapter to either
female side.
4
Resistance Max. 2 z
(female) (1)
Resistance Max. 2 z
(female) (2)
5 female side.
harness
40-200 GD535-5
(01)

female side of ECM.
6
7
GD535-5 40-201
(01)
Action
code Failure
L03 CA331
Action of
None in particular
controller
ting).
played.
Related
information

1
3
female side.
4
Resistance Max. 2 z
(female) (2)
Resistance Max. 2 z
(female) (1)
5 female side.
harness
40-202 GD535-5
(01)

female side of ECM.
6
7
GD535-5 40-203
(01)
Action
code Failure
L03 CA332
Action of
None in particular
controller
ting).
played.
Related
information

1
3
female side.
4
Resistance Max. 2 z
(female) (2)
Resistance Max. 2 z
(female) (1)
5 female side.
harness
40-204 GD535-5
(01)

female side of ECM.
6
7
GD535-5 40-205
(01)
Failure code [CA342] Data compatibility error in engine controller 40 Troubleshooting
Failure code [CA342] Data compatibility error in engine controller 1
Action
Failure code Data compatibility error in engine controller
code Failure
L03 CA342
Detail of failure A data compatibility error has occurred in engine controller.
Action of
None in particular
controller
q The engine may run normally, may stop, or may fail to start.
Problem on
machine
ting).
Related
displayed.
information

Defective relevant
system
Failure of power voltage
system
40-206 GD535-5
(01)
40 Troubleshooting Failure code [CA351] Injector drive circuit error
Failure code [CA351] Injector drive circuit error 1
Action
Failure code Injector drive circuit error
code Failure
L03 CA351
Detail of failure The drive power supply circuit of injector has failed.
Action of
controller
q Exhaust smoke is black.
q Unstable combustion occurs.
machine q Engine does not start.
ting).
Related
displayed.
information

Defective relevant
system
Failure of power voltage
system
GD535-5 40-207
(01)
Failure code [CA352] Sensor power supply 1 low error 40 Troubleshooting
Failure code [CA352] Sensor power supply 1 low error 1
Action
Failure code Sensor power supply 1 voltage low error
code Failure
L03 CA352
Detail of failure Low voltage appears in the sensor power supply 1 circuit.
Action of
controller
ting).
Related
displayed.
information

1
2. Disconnect following connectors one by one in order and turn starting switch ON each
time.
3. Each time troubleshooting is finished, return to step 1.
If this failure code is not displayed, disconnected sensor or engine wiring harness is
Defective sensor or defective.
2 a Other (many) failure codes are output simultaneously. This is because connector is dis-
wiring harness
connected. Ignore failure codes other than this [CA352].
Sensor and wiring harness Connector
Ambient pressure sensor AMB. AIR PRESSURE
Engine harness ECM
3
controller
4.75 to 5.25
V
40-208 GD535-5
(01)
40 Troubleshooting Failure code [CA352] Sensor power supply 1 low error
Circuit diagram related to sensor power supply 1 circuit
GD535-5 40-209
(01)
Failure code [CA386] Sensor power supply 1 high error 40 Troubleshooting
Failure code [CA386] Sensor power supply 1 high error 1
Action
Failure code Sensor power supply 1 voltage high error
code Failure
L03 CA386
Detail of failure High voltage appears in the sensor power supply 1 circuit.
Action of
controller
ting).
Related
displayed.
information

supply 1 system
40-210 GD535-5
(01)
40 Troubleshooting Failure code [CA428] Water-in-fuel sensor high error
Failure code [CA428] Water-in-fuel sensor high error 1
Action
Failure code Water-in-fuel sensor high error
code Failure
L01 CA428
Detail of failure High voltage appears in signal circuit of water-in-fuel sensor at fuel prefilter.
Action of
None in particular
controller
Problem on
Water separator monitor does not work normally.
machine
q The signal status (ON or OFF) of water-in-fuel sensor (of fuel prefilter) can be checked with monitoring
Related
information
played.

1
Failure of water-in-fuel 2. Disconnect connector WIF1, and connect T-adapter to female side.
2 If water is in fuel prefilter, drain it.
sensor at fuel prefilter
Between WIF1 (female) (1) and (2) Resistance Min. 100 kz
3
wiring harness Between ECM (female) (14) and (47)
(Resistance of water-in-fuel sensor)
Open circuit in wiring 2. Disconnect connectors ECM and WIF1, and connect T-adapters to each female side.
4
harness
Between ECM (female) (14) and WIF1 (female) (1) Resistance Max. 10 z
Between ECM (female) (47) and WIF1 (female) (2) Resistance Max. 10 z
2. Disconnect connectors ECM and WIF1, and connect T-adapter to female side of ECM.
Short circuit in wiring Check by using multimeter in continuity mode.
5
harness
6
GD535-5 40-211
(01)
Failure code [CA428] Water-in-fuel sensor high error 40 Troubleshooting
Circuit diagram related to water-in-fuel sensor
40-212 GD535-5
(01)
40 Troubleshooting Failure code [CA429] Water-in-fuel sensor low error
Failure code [CA429] Water-in-fuel sensor low error 1
Action
Failure code Water-in-fuel sensor low error
code Failure
L01 CA429
Detail of failure Low voltage appears in signal circuit of water-in-fuel sensor at fuel prefilter.
Action of
None in particular
controller
Problem on
Water separator monitor does not work normally.
machine
q The signal status (ON or OFF) of water-in-fuel sensor (of fuel prefilter) can be checked with monitoring
Related
information
played.

1
2. Disconnect connector WIF1, and connect T-adapter to female side.
Failure of water-in-fuel If water is in fuel prefilter, drain it.
2
sensor at fuel prefilter
Between WIF1 (female) (1) and (2) Resistance Min. 100 kz
Between WIF1 (female) (1) and ground Resistance Min. 100 kz
Short circuit or ground
3 Between ECM (female) (14) and (47)
fault in wiring harness Resistance Min. 100 kz
(Resistance of water-in-fuel sensor)
2. Disconnect connectors ECM and WIF1, and connect T-adapter to female side of ECM.
Short circuit in wiring Check by using multimeter in continuity mode.
4
harness
Ground fault in wiring 2. Disconnect connectors ECM and WIF1, and connect T-adapter to either female side.
5
harness
Between ECM (female) (14) or WIF1 (female) (1) and
ground
6
GD535-5 40-213
(01)
Failure code [CA429] Water-in-fuel sensor low error 40 Troubleshooting
Circuit diagram related to water-in-fuel sensor
40-214 GD535-5
(01)
40 Troubleshooting Failure code [CA431] Idle validation switch error
Failure code [CA431] Idle validation switch error 1
Action
Failure code Idle validation switch error
code Failure
L01 CA431
Detail of failure An error occurred in Idle Validation Switch signal 1 or 2 (IVS1 or IVS2).
Action of
Runs the engine with throttle opening detected by the throttle position sensor.
controller
Problem on
machine
q The input condition (ON/OFF status) of Idle Validation signal 1 can be checked by using the monitoring
function (Code: 18300).
Related
information
played.

1
2. Insert T-adapter into connector T9B.
Defective power supply 3. Turn starting switch to ON position.
2 If voltage is abnormal, go to check on cause 4.
system
4.75 to 5.25
Between T9B (1) and (2) Voltage
V
Defective accelerator If abnormal, diagnose the wiring harness on causes 4 and 5. If the harness is normal, the
3
pedal accelerator pedal is defective.
Between T9A (5) and (4) See the IVS1 of Figure 1.
Between T9A (6) and (4) See the IVS2 of Figure 1.
to OFF position.
3. Disconnect connectors T9A, T9B, EC2, TM39, and TM40, and connect T-adapters to
each female side.
4
harness Between EC2 (female) (32) and T9A (female) (4) Resistance Max. 10 z
Between TM40 (female) (1) and T9B (female) (1) Resistance Max. 10 z
Between TM39 (female) (4) and T9B (female) (2) Resistance Max. 10 z
GD535-5 40-215
(01)
Failure code [CA431] Idle validation switch error 40 Troubleshooting

to OFF position.
Short circuit in wiring battery negative (-) terminal.)
5
harness
3. Disconnect connectors T9A and EC2, and connect T-adapter to female side of EC2.
Between EC2 (female) (1) and each pin other than (1) Resistance Min. 100 kz
to OFF position.
Failure of transmission 3. Insert T-adapters into connectors TM39 and TM40.
6 4. Turn the battery disconnect switch to ON position.
controller
(When the battery disconnect switch is not installed, connect the cable to the battery
4.75 to 5.25
Between TM40 (1) and TM39 (4) Voltage
V
Reference
Defective engine 2. Insert T-adapter into connector EC2.
7
controller 3. Turn starting switch to ON position.
Between EC2 (11) and (32) See the IVS1 of Figure 1.
Between EC2 (1) and (32) See the IVS2 of Figure 1.
40-216 GD535-5
(01)
40 Troubleshooting Failure code [CA431] Idle validation switch error
Circuit diagram related to Idle Validation circuit
GD535-5 40-217
(01)
Failure code [CA431] Idle validation switch error 40 Troubleshooting
Fig. 1
Pedal stroke: Stroke of accelerator pedal
Output voltage: Output voltages (at pin 2 of connector
T9A, and pin 9 of EC2)
IVS1: Signal voltage of Idle Validation switch 1
Switch gap: Area where both IVS1 and IVS2 signals
are turned OFF
40-218 GD535-5
(01)
40 Troubleshooting Failure code [CA432] Idle validation action error
Failure code [CA432] Idle validation action error 1
Action
Failure code Idle validation action error
code Failure
L03 CA432
Detail of failure The idle validation switch signal does not match the throttle sensor signal (signal inconsistency).
1. If the idle validation switch signal shows that the accelerator pedal is OFF, and if the throttle sensor signal
shows that the accelerator pedal is ON: the throttle opening is controlled to 0% when the idle validation
signal shows that the accelerator pedal is OFF. Also, the throttle opening is controlled to 50% when the
Action of
accelerator pedal is shown to be ON.
controller
2. If idle validation switch signal indicates that the accelerator pedal is ON, and if the throttle sensor signal
shows that the accelerator pedal is OFF: the throttle opening is controlled to 0% (and the engine speed
is fixed to the low idle speed).
q The engine speed does not increase from low idling speed.
Problem on
machine
ting).
Related q Input voltage from throttle position sensor can be checked with monitoring function. (Code: 03000)
information q The opening of accelerator pedal, detected by throttle position sensor, can be checked with monitoring
played.

Idle validation switch If an error occurs in idle validation switch signal, perform troubleshooting for failure code
1
signal error [CA431] (Perform troubleshooting for cause 2 and later for the throttle position sensor).
2 If abnormal, go to check on cause 4.
system
4.75 to 5.25
Between T9A (1) and (3) Voltage
V
Defective accelerator 3. Turn starting switch to ON position.
3 If abnormal, diagnose the wiring harness on causes 4 and 5. If the harness is normal, the
pedal
accelerator pedal is defective.
Between T9A (2) and (3) See the output voltage of Figure 1.
2. Disconnect connectors T9A and EC2, and connect T-adapters to each female side.
4
Open circuit in wiring Between EC2 (female) (22) and T9A (female) (1) Resistance Max. 10 z
harness
Short circuit in wiring 2. Disconnect connectors T9A and EC2, and connect T-adapter to female side of EC2.
5
harness
GD535-5 40-219
(01)
Failure code [CA432] Idle validation action error 40 Troubleshooting

Reference
Defective engine 1. Turn the starting switch to OFF position.
6 2. Insert T-adapter into connector EC2.
controller
See the output voltage of Figure 1 on the
next page.
Circuit diagram related to Idle Validation circuit
40-220 GD535-5
(01)
40 Troubleshooting Failure code [CA432] Idle validation action error
Fig. 1
Pedal stroke: Stroke of accelerator pedal
Output voltage: Output voltages (at pin 2 of connector
T9A, and pin 9 of EC2)
Switch gap: Area where both IVS1 and IVS2 signals
are turned OFF
GD535-5 40-221
(01)
Failure code [CA435] Engine oil pressure switch error 40 Troubleshooting
Failure code [CA435] Engine oil pressure switch error 1
Action
Failure code Engine oil pressure switch error
code Failure
L01 CA435
Detail of failure An error occurred in the engine oil pressure switch signal circuit.
Action of
None in particular
controller
Problem on q The engine protect function by hydraulic pressure does not work.
machine q The engine oil pressure is not displayed normally.
played.
Procedure: Turn starting switch to ON position, or start engine.
Related q When oil pressure is low (when engine is stopped), the engine oil pressure switch is closed (turned ON).
information When oil pressure is high (when engine is running), the switch is opened (turned OFF).
q If this failure code is output, the engine controller checks if the oil pressure switch is closed (ON), that is,
the voltage is set to the "GND level" or not only when the engine is stopped.
q When engine is running, an error of the engine oil pressure switch is checked with failure code [B@BAZG].

1
Defective engine oil 2. Disconnect connector OIL PRESSURE SWITCH, and connect T-adapter to male side.
2
pressure switch
Between OIL PRESSURE SWITCH (male) (1) and ground Resistance Max. 10 z
3
wiring harness
Between ECM (female) (17) and ground Resistance Max. 10 z
4
Circuit diagram related to engine oil pressure switch
40-222 GD535-5
(01)
40 Troubleshooting Failure code [CA441] Power supply voltage low error
Failure code [CA441] Power supply voltage low error 1
Action
Failure code Battery Voltage Low Error
code Failure
L01 CA441
Detail of failure Low voltage occurs in engine controller power circuit.
Action of
None in particular
controller
q Engine stops.
Problem on q Engine startability is poor.
ting).
Related
played.
information

Loose or corroded
1 As battery terminals may be loose or corroded, check them.
battery terminals
Loose terminal or partial 1. Turn the starting switch to OFF position.

2
open circuit at terminal Check terminals of alternator, battery relay, ground terminal (ET103), etc.
3
Improper battery power 2. Perform troubleshooting with starting switch at OFF position and when starting engine.
4
supply
Between positive (+) and negative (-) battery terminals Voltage 20 to 30 V
2. Insert T-adapter into connector ET104.
5 Defective alternator 3. Start engine. (Engine speed: Middle or faster)
27.5 to 29.5
Between ET104 (1) and ground Voltage
V
Reference
1. Turn starting switch to OFF position, and disconnect battery ground.
Defective engine 2. Insert T-adapter into connector EC3.
6
controller 3. Connection battery ground.
4. Measure the voltage when the starting switch is OFF and when engine is started.
Between EC3 (3) and (1) Voltage 20 to 30 V
Between EC3 (4) and (2) Voltage 20 to 30 V
GD535-5 40-223
(01)
Failure code [CA441] Power supply voltage low error 40 Troubleshooting
Circuit diagram related to power supply voltage
40-224 GD535-5
(01)
40 Troubleshooting Failure code [CA442] Power supply voltage high error
Failure code [CA442] Power supply voltage high error 1
Action
Failure code Power supply voltage high error
code Failure
L03 CA442
Detail of failure High voltage (Min. 36 V) is generated in controller power supply voltage circuit.
Action of
None in particular
controller
q Engine may stop.
Problem on
machine
ting).
Related
displayed.
information

Defective engine
1 controller power supply Perform troubleshooting for failure code [CA441].
system
GD535-5 40-225
(01)
Failure code [CA449] Common rail pressure high error 2 40 Troubleshooting
Failure code [CA449] Common rail pressure high error 2 1
Action
Failure code Common rail pressure high error 2
code Failure
L03 CA449
Detail of failure A high voltage error (2) occurred in the common rail system circuit.
Action of
controller
q The engine sound level increases during no loading or during low loading.
ting).
q Signal voltage from common rail pressure sensor can be checked with monitoring function. (Code:
36401)
q The common rail pressure detected by the common rail pressure sensor can be checked with monitoring
Related
information
played.

Defective relevant
system
Air may be in low-pressure circuit. Check it according to the following procedure.
Air insertion into low- 1. Remove the pressure inspection plug (at outlet side) of fuel main filter.
2
pressure circuit 2. Operate the feed pump of fuel prefilter.
3. Check the fuel and air leakage from the pressure inspection plug.
For check of fuel return circuit pressure, see Testing and adjusting, "Testing fuel pressure".
Failure of fuel return
3 During low idle or during Max. 0.02 MPa
circuit devices Pressure of fuel return circuit
cranking {Max. 0.19 kg/cm2}
Failure of common rail
4 Perform troubleshooting for failure codes [CA451] and [CA452].
pressure sensor
For check of leakage from pressure limiter, see Testing and adjusting, "Testing fuel return
rate and leakage".
5 Defective pressure limiter
Leakage from pressure
At low idle 0 cc (No leakage)
limiter
6 Defective supply pump If no failure is found by preceding checks, the supply pump may be defective.
40-226 GD535-5
(01)
40 Troubleshooting Failure code [CA451] Common rail pressure sensor high error
Failure code [CA451] Common rail pressure sensor high error 1
Action
Failure code Common rail pressure sensor high error
code Failure
L03 CA451
Detail of failure High voltage appears in signal circuit of common rail pressure sensor.
Action of
controller
q Engine speed or output drops.
ting).
36401)
q The common rail pressure detected by the common rail pressure sensor can be checked with monitor-
ing function. (Code: 36400)
information played.
q If the connector of common rail pressure sensor is disconnected, this code is output.
q Because the T-adapter for sensor connection is a socket, the voltage cannot be checked by checking
the disconnection of wiring harness and sensor connector.

1
2 pressure sensor power If failure code [CA227] or [CA187] is also displayed, perform troubleshooting for it first.
supply
2. Disconnect connectors CAM SENSOR, FUEL RAIL PRESS, BOOST PRESS & IMT,
Short circuit in wiring and ECM.
3
harness 3. Connect T-adapter to female side of ECM.
2. Disconnect connector FUEL RAIL PRESS, and insert T-adapter into connector ECM.
Hot short circuit in wiring 3. Turn starting switch ON (with connector FUEL RAIL PRESS disconnected).
4
harness a ECM (25) pin is connected to the 5V power via the resistance in engine controller.
Between ECM (25) and (47) Voltage Approx. 5 V
5 If no failure is found by above checks, wiring harness may have open circuit. (*)
harness
is defective.
Failure of common rail 1. Turn the starting switch to OFF position.
pressure sensor 2. Insert T-adapter into connector ECM.
6
(Incorrect input voltage of 3. Turn starting switch to ON position.
engine controller)
Sensor
Between ECM (25) and (47) Voltage 0.2 to 4.6 V
output
7
* See the "Diagnosis of open harness in pressure sensor system" of "Related information on troubleshooting".
GD535-5 40-227
(01)
Failure code [CA451] Common rail pressure sensor high error 40 Troubleshooting
Circuit diagram related to common rail pressure sensor
40-228 GD535-5
(01)
40 Troubleshooting Failure code [CA452] Common rail pressure sensor low error
Failure code [CA452] Common rail pressure sensor low error 1
Action
Failure code Common rail pressure sensor low error
code Failure
L03 CA452
Detail of failure Low voltage appears in signal circuit of common rail pressure sensor.
Action of
controller
q Engine speed or output drops.
ting).
36401)
q The common rail injection pressure detected by the common rail pressure sensor can be checked with
Related monitoring function. (Code: 36400)
played.
q If the sensor connector is disconnected, [CA451] is output even in the normal state.

1
2 pressure sensor power If failure code [CA187] or [CA227] is also displayed, perform troubleshooting for it first.
supply
Make sure that failure code [CA187] is not output.
Failure of common rail 2. Disconnect connector FUEL RAIL PRESS.
3
pressure sensor 3. Turn starting switch to ON position.
If failure code [CA452] changes to [CA451], the sensor is defective.
Ground fault in wiring 2. Disconnect connectors ECM and FUEL RAIL PRESS, and connect T-adapter to female
4 side of ECM.
harness
Short circuit in wiring 2. Disconnect connectors ECM and FUEL RAIL PRESS, and connect T-adapter to female
5 side of ECM.
harness
6
GD535-5 40-229
(01)
Failure code [CA452] Common rail pressure sensor low error 40 Troubleshooting
Circuit diagram related to common rail pressure sensor
40-230 GD535-5
(01)
40 Troubleshooting Failure code [CA488] Torque derating error by high charge temperature
Failure code [CA488] Torque derating error by high charge temperature 1
Action
Failure code Torque derating error by high charge temperature
code Failure
L03 CA488
Detail of failure The temperature signal of the boost pressure and temperature sensor exceeded the upper limit of control.
Action of
controller
Problem on
machine
ting).
q The boost temperature can be checked with monitoring function.
(Code: 18500)
Related
information
played.

Dropped cooling As the cooling performance of aftercooler may have dropped, check the following points.
1 performance of q Insufficient cooling air volume
aftercooler q Clogging of aftercooler fins
Abnormal increase of
As the turbocharger outlet temperature may have increased abnormally, inspect the related
2 turbocharger outlet
parts.
temperature
Failure of charge
3 temperature sensor Perform troubleshooting for failure codes [CA153] and [CA154].
system
GD535-5 40-231
(01)
Failure code [CA553] Common rail pressure high error 1 40 Troubleshooting
Failure code [CA553] Common rail pressure high error 1 1
Action
Failure code Common rail pressure high error 1
code Failure
L03 CA553
Detail of failure A high voltage error (1) occurred in the common rail injection circuit.
Action of
None in particular
controller
q The engine sound level increases during no loading or during low loading.
ting).
36401)
Related
information
played.

Defective relevant
system
As the ground terminal connection may be poor, check the following terminals.
q Ground terminal of machine (Negative (-) terminal of battery)
Poor connection of
2 q Ground terminal of engine
ground terminal
q Ground terminal of engine controller
q Ground terminal of starting switch
Damaged O-ring of
3 As the O-ring of supply pump actuator may be damaged, check it.
supply pump actuator
pressure sensor
40-232 GD535-5
(01)
40 Troubleshooting Failure code [CA559] Supply pump pressure low error 1
Failure code [CA559] Supply pump pressure low error 1 1
Action
Failure code Supply pump pressure low error 1
code Failure
L03 CA559
Detail of failure A low voltage error (1) occurred in the common rail injection circuit.
Action of
None in particular
controller
q Engine cannot start or engine is hard to start.
Problem on
machine
ting).
q Common rail injection pressure can be checked with monitoring function.
(Code: 36400)
Related
information
played.

1 Improper fuel is used. As the fuel used may be improper, check it.
2 External leakage of fuel As the fuel may leak externally, check it. (Visually inspect it while engine is low idle.)
See Note 1 for troubleshooting. For check of fuel low pressure circuit, see Testing and
adjusting, "Testing fuel pressure".
Negative inlet pressure of
At high idle Max. -50.7 MPa
fuel supply pump (at outlet
Failure of low pressure (When engine can start) {Max. -380 mmHg}
3 side of fuel prefilter)
circuit devices
Pressure of fuel low- At cranking 0.3 to 1.1 MPa
pressure circuit (When engine cannot start) {3.1 to 11.3 kg/cm2}
(inlet pressure of fuel main At low idle 0.5 to 1.3 MPa
filter) (When engine can start) {5.1 to 13.3 kg/cm2}
For check of leakage from pressure limiter, see Testing and adjusting, "Testing fuel return
rate and leakage".
4 Defective pressure limiter
Leakage from pressure
At low idle 0 cc (No leakage)
limiter
For check of fuel return rate from injector, see Testing and adjusting, "Testing fuel
discharge, return and leakage".
At cranking
5 Defective injector Max. 90 cc/min
(When engine cannot start)
Return rate from injector
At low idle
Max. 180 cc/min
(When engine can start)
For check of fuel return rate from supply pump, see Testing and adjusting, "Testing fuel
discharge, return and leakage".
At cranking
6 Defective supply pump Max. 140 cc/min
Return rate from supply (When engine cannot start)
pump At low idle
Max. 1000 cc/min
(When engine can start)
pressure sensor
GD535-5 40-233
(01)
Failure code [CA559] Supply pump pressure low error 1 40 Troubleshooting
Note 1: Check low-pressure fuel circuit devices for following items.

1) Remaining quantity of fuel
2) Clogging of fuel tank breather
3) Leakage from or clogging of low-pressure fuel piping
4) Clogging of fuel prefilter
5) Clogging of fuel main filter
6) Replace fuel filter when problem is not removed even if no clogging is found.
40-234 GD535-5
(01)
40 Troubleshooting Failure code [CA689] Engine Ne speed sensor error
Failure code [CA689] Engine Ne speed sensor error 1
Action
Failure code Failure of engine Ne speed sensor
code Failure
L03 CA689
Detail of failure An error occurred in a signal from engine Ne speed sensor.
Action of
Uses signals from engine Bkup speed sensor, and continues to control.
controller
q Engine rotation is hunting.
q Engine startability is poor.
Problem on
machine
ting).
played.
q As the speed sensor consists of a wheel sensor and electronic circuit (but not coils), you cannot deter-
Related mine the normal sensor operation by simply measuring the resistance of speed sensor using a multime-
information ter.
q Under normal conditions, the 5V pulse voltage is output from the speed sensor, and you cannot measure
it using a multimeter.
q A speed sensing wheel is installed inside of vibration damper of crankshaft. The hole of this wheel is de-
tected when the crankshaft rotates.

1
Failure of Ne speed
2 If failure code [CA238] is also displayed, perform troubleshooting for it first.
sensor power system
Failure or incorrect
mounting (such as loose As the engine Ne speed sensor may be broken or may be installed improperly (loosened),
3
mounting) of engine Ne check it.
speed sensor
2. Disconnect connector CRANK SENSOR, and connect T-adapter to female side.
Input failure of Ne speed 3. Turn starting switch to ON position.
4
sensor power
Between CRANK SENSOR (female) (1) and Power supply 4.75 to 5.25
Voltage
(2) input V
2. Disconnect connectors ECM and CRANK SENSOR.
required.
Between ECM (female) (16) and CRANK SENSOR (female)
Open circuit in wiring (1)
5
harness If no failure is found by check on cause 4, this check is not
required.
(2)
(3)
GD535-5 40-235
(01)
Failure code [CA689] Engine Ne speed sensor error 40 Troubleshooting

2. Disconnect connectors ECM and CRANK SENSOR.
Short circuit in wiring Between ECM (female) (16) and (27), or between CRANK
6 Resistance Min. 100 kz
harness SENSOR (female) (1) and (3)
Between ECM (female) (27) and (48), or between CRANK
SENSOR (female) (2) and (3)
Ground fault in wiring 2. Disconnect connectors ECM and CRANK SENSOR.
7
harness Between ECM (female) (27) or CRANK SENSOR (female)
(3) and ground
Turn the starting switch to OFF position.
Hot short circuit in wiring Disconnect connector CRANK SENSOR.
8 Turn starting switch to ON position.
harness
Between CRANK SENSOR (female) (3) and ground Voltage Max. 1 V
Damaged or loosened
9 Check the speed sensing ring.
speed sensing ring
Failure of Ne speed If no failure is found in above checks, Ne speed sensor is defective. (Since this is an
10
sensor internal defect, troubleshooting cannot be performed.)
11
Circuit diagram related to engine Ne speed sensor
40-236 GD535-5
(01)
40 Troubleshooting Failure code [CA731] Engine Bkup speed sensor phase error
Failure code [CA731] Engine Bkup speed sensor phase error 1
Action
Failure code Engine Bkup speed sensor phase error
code Failure
L03 CA731
Detail of failure A phase error was detected from signals of engine Ne speed sensor and engine backup speed sensor.
Action of
Continues to control by using engine Ne sensor signals.
controller
q Engine cannot start or engine is hard to start.
q Idling speed is unstable.
Problem on
machine
ting).
Related
displayed.
information

Damaged engine Ne
1 As the engine Ne speed sensor may be broken, check it.
speed sensor
Damaged engine Bkup
2 As the engine Bkup speed sensor may be broken, check it.
speed sensor
Speed sensing wheel on crankshaft side may be installed improperly or damaged. Check it
Improper mounting or
1. Align the paint mark (M1) of damper with the top surface (M2) of Ne speed sensor.
damage of speed
3 a It is not the compression top dead center of cylinder No. 1. (Approximately 80°
sensing wheel on
before compression top dead center)
crankshaft side
2. Installation is correct if the center of oval hole (WS) of speed sensing wheel locates on
the top surface (M2) of Ne speed sensor.
Speed detection ring on camshaft side may be installed improperly or damaged. Check it
Improper installation or 1. Align the paint mark (M1) of damper with the top surface (M2) of Ne speed sensor.
damage of speed a It is not the compression top dead center of cylinder No. 1. (Approximately 80°
4
sensing ring on camshaft before compression top dead center)
side 2. Remove the Bkup speed sensor.
3. Installation is correct if twin groove (single rib) (B) of speed sensing ring is visible through
sensor mounting hole (H).
Incorrect timing between
5 As the timing may be incorrect between crankshaft and camshaft, check this timing.
crankshaft and camshaft
As the ground terminal connection may be poor, check the following terminals.
q Ground terminal of machine (Negative (-) terminal of battery)
Poor connection of
6 q Ground terminal of engine
ground terminal
q Ground terminal of engine controller
q Ground terminal of starting switch
GD535-5 40-237
(01)
Failure code [CA731] Engine Bkup speed sensor phase error 40 Troubleshooting
40-238 GD535-5
(01)
40 Troubleshooting Failure code [CA757] All continuous data lost error
Failure code [CA757] All continuous data lost error 1
Action
Failure code All continuous data lost error
code Failure
L03 CA757
Detail of failure The entire data of engine controller has been lost.
Action of
None in particular
controller
q Engine may stop, and it may fail to start again.
Problem on q The monitoring function (engine controller system) of machine monitor may not operate normally.
ting).
Related
displayed.
information

Defective relevant
system
Failure of power supply
circuit
GD535-5 40-239
(01)
Failure code [CA778] Engine Bkup speed sensor error 40 Troubleshooting
Failure code [CA778] Engine Bkup speed sensor error 1
Action
Failure code Engine Bkup speed sensor error
code Failure
L03 CA778
Detail of failure An error was detected in engine Bkup speed (CAM) sensor signal.
Action of
Continues to control by using engine Ne speed sensor signals.
controller
ting).
played.
q As the speed sensor consists of a wheel sensor and electronic circuit (but not coils), you cannot deter-
Related mine the normal sensor operation by simply measuring the resistance of speed sensor using a multime-
information ter.
q Under normal conditions, the 5V pulse voltage is output from the speed sensor, you cannot measure it
using a multimeter.
q The speed sensor detects a groove of speed sensing ring (during rotation) that is mounted on the cam-
shaft.

1
2 If failure code [CA187] or [CA227] is also displayed, perform troubleshooting for it first.
supply 2 system
Damage or incorrect
mounting (such as loose
Engine Bkup speed (CAM) sensor may be damaged or installed improperly (loosened).
3 mounting) of engine
Check it.
Bkup speed (CAM)
sensor
Input failure of engine 2. Disconnect connector CAM SENSOR , and connect T-adapter to female side.
4 Bkup speed sensor 3. Turn starting switch to ON position.
power 4.75 to 5.25
Between CAM SENSOR (female) (1) and (2) Power supply Voltage
V
2. Disconnect connectors ECM and CAM SENSOR, and connect T-adapters to each
female side.
Between ECM (female) (37) and CAM SENSOR (female)
Open circuit in wiring Resistance Max. 10 z
5 (1)
harness
(2)
(3)
40-240 GD535-5
(01)
40 Troubleshooting Failure code [CA778] Engine Bkup speed sensor error

2. Disconnect connectors ECM and CAM SENSOR, and connect T-adapter to either
female side.
6 Between ECM (female) (26) and (37), or between CAM
harness Resistance Min. 100 kz
Between ECM (female) (26) and (47), or between CAM
2. Disconnect connectors ECM and CAM SENSOR, and connect T-adapter to either
Ground fault in wiring female side.
7
harness
Between ECM (female) (26) or CAM SENSOR (female) (3)
and ground
Hot short circuit in wiring 2. Disconnect connector CAM SENSOR, and connect T-adapter to female side.
harness
Between CAM SENSOR (female) (3) and ground Voltage Max. 1 V
Loose mounting of speed Remove the engine Bkup speed (CAM) sensor, and check it through hole (H).
9
sensing ring a If the speed sensing ring (B) is loosely mounted, follow the "Reference" instructions.
Failure of engine Bkup If no abnormality is found by above checks, engine Bkup speed (CAM) sensor is defective.
10
speed (CAM) sensor (Since this is an internal defect, troubleshooting cannot be performed.)
11
GD535-5 40-241
(01)
Failure code [CA778] Engine Bkup speed sensor error 40 Troubleshooting
Circuit diagram related to engine Bkup speed sensor
Reference: CA778 (107 series engine) 3. Remove front cover (2).

Check the camshaft ring for looseness. 4. Remove front seal (3).
Remove the front cover, and check the camshaft ring (RING): Ring
for
looseness.
See "Removal and installation of engine front seal" of
"Disassembly and assembly".
Prepare the front seal, LG-7 liquid gasket, and front
seal tool (795-799-6400)
Removal
1. Remove the fan belt. For details, see "Removal
and installation of fan belt" of "Disassembly and
assembly".
2. Remove damper assembly (1).
(DP): Dowel pin
5. Check mounting bolts (4) of camshaft ring (5) for
looseness.
3 Mounting bolts (4): 10 ± 2 Nm
(DP): Dowel pin
40-242 GD535-5
(01)
40 Troubleshooting Failure code [CA778] Engine Bkup speed sensor error
Installation
For the drawing, see the "Removal" section.
1. Install front cover (2).
2 Front cover: LG-7 liquid gasket
2. See "Removal and installation of engine front seal"
of "Disassembly and assembly".
1) Install front seal (3).
2) Install Dowel pin (DP), and install the damper
assembly.
3) Install fan belt and fan.
4) Install the cooling assembly.
GD535-5 40-243
(01)
Failure code [CA1633] KOMNET (CAN communication) error 40 Troubleshooting
Failure code [CA1633] KOMNET (CAN communication) error 1
Action
Failure code KOMNET (CAN communication) error
code Failure
L03 CA1633
The engine controller has detected a communication error in the CAN (KOMNET) communication circuit
Detail of failure
between engine controller and transmission controller or machine monitor.
Action of q Operates the machine in default mode, or holds the status of error occurrence.
q Information passed through CAN (KOMNET) communication may not be transmitted normally, and the
Problem on machine may not operate normally. (Failure status varies depending on the failure location.)
ting).
Related
displayed.
information

1 Blown fuse If fuse No. 4 of FB2 fuse box is blown, the circuit may be shorted in the controller.
If fuse is not burnt out, this check is not required.
to OFF position.
Defective engine (When the battery disconnect switch is not installed, disconnect the cable from the
2 battery negative (-) terminal.)
controller
3. Disconnect connector EC3 and connect T-adapter to male side.
q Measured value: Approx. 9 to 20 kz
q If it is 10 z or less, the engine controller may have failed (internal short circuit).
Between EC3 (male) (3) and (1) Resistance Min. 10 z
to OFF position.
3. Disconnect connector EC3, and connect T-adapter to female side.
4. If fuse is blown, replace it in advance.
Defective power supply
to engine controller
6. Turn the starting switch to ON position.
Perform troubleshooting for failure code [DB2RKR], cause 2).
Between EC3 (female) (3) and (1) or ground Voltage 20 to 30 V
Between EC3 (female) (4) and (2) or ground Voltage 20 to 30 V
If fuse No. 15 of FB1 fuse box is blown, the circuit may be grounded. In this case, perform
4 Blown fuse
check on cause 9 first.
to OFF position.
Defective CAN battery negative (-) terminal.)
5
terminating resistor
3. Disconnect connectors CAN1 and FP1, and connect T-adapter to male side.
Between CAN1 (male) (A) and (B) Resistance 120 ± 12 z
Between FP1 (male) (11) and (12) Resistance 120 ± 12 z
40-244 GD535-5
(01)
40 Troubleshooting Failure code [CA1633] KOMNET (CAN communication) error

CAN communication line
a The 120 z CAN terminating resistor is also located in machine monitor. That is, 2 CAN
terminating resistors of 120 z are connected in parallel. When circuit resistance is mea-
sured at connector of controller other than machine monitor, if combined resistance is
60 z, wiring harness does not have open circuit.
to OFF position.
3. Disconnect connectors EC2, TM40, L80A, CAN1, and FP1 one by one, and connect T-
Open or short circuit in
6 adapter to female side of its connector.
wiring harness
a If circuit is shorted (resistance between terminals is 10 z or below), disconnect all of
terminals EC2, TM40, L80A, CAN1, and FP2, and check them again. Locate the short
circuit between wiring harnesses or the short circuit in the controller.
Between EC2 (female) (46) and (47) Resistance Approx. 60 z
Between TM40 (female) (32) and (22) Resistance Approx. 60 z
Between L80A (female) (10) and (11) Resistance Approx. 60 z
Between CAN1 (female) (A) and (B) Resistance Approx. 120 z
Between FP1 (female) (11) and (12) Resistance Approx. 120 z
to OFF position.
3. Disconnect connectors EC2, TM40, L80A, CAN1, and FP1, and connect T-adapters to
female side of each connector.
Between TM40 (female) (32) and FP1 (female) (11) Resistance Max. 10 z
Locate the open circuit of
7 Between TM40 (female) (22) and FP1 (female) (12) Resistance Max. 10 z
wiring harness.
Between TM40 (female) (32) and EC2 (female) (46) Resistance Max. 10 z
Between TM40 (female) (22) and EC2 (female) (47) Resistance Max. 10 z
Between TM40 (female) (32) and L80A (female) (10) Resistance Max. 10 z
Between TM40 (female) (22) and L80A (female) (11) Resistance Max. 10 z
Between EC2 (female) (46) and CAN1 (female) (A) Resistance Max. 10 z
Between EC2 (female) (47) and CAN1 (female) (B) Resistance Max. 10 z
Starting switch ACC signal
to OFF position.
3. Insert T-adapter into connectors TM41, L80B, FP1, and EC2.
4. Turn the battery disconnect switch to ON position.
Open circuit in wiring (When the battery disconnect switch is not installed, connect the cable to the battery
8
harness negative (-) terminal.)
Between TM41 (14) or (24) and (31) Voltage 20 to 30 V
Between L80B (3) and (1) Voltage 20 to 30 V
Between FP1 (3) and (2) Voltage 20 to 30 V
Between EC2 (39) and ground Voltage 20 to 30 V
GD535-5 40-245
(01)
Failure code [CA1633] KOMNET (CAN communication) error 40 Troubleshooting

Starting switch ACC signal
to OFF position.
9 3. Disconnect connectors TM41, L80B, and FP1, and connect T-adapter to either female
harness side.
Between any of TM41 (female) (14), (24) L80B (female) (3)
and FP1 (female) (3) and the ground
Between EC2 (female) (39) and ground Resistance Min. 100 kz
10
11
40-246 GD535-5
(01)
40 Troubleshooting Failure code [CA1633] KOMNET (CAN communication) error
Circuit diagram related to CAN
GD535-5 40-247
(01)
Failure code [CA2185] Throttle sensor power supply high error 40 Troubleshooting
Failure code [CA2185] Throttle sensor power supply high error 1
Action
Failure code Throttle sensor power supply voltage high error
code Failure
L03 CA2185
Detail of failure High voltage (Min. 5.25 V) appears in throttle sensor power supply circuit.
Problem on
machine
ting).
Related
displayed.
information

1
2. Disconnect connector T9A, and turn starting switch to ON position.
2
Defective throttle sensor a Other (many) failure codes are output simultaneously. This is because connector is
(accelerator pedal) unplugged. Ignore failure codes other than this [CA2185].
If this failure code disappears, throttle sensor is defective.
2. Disconnect connectors EC2, EC3 and T9A, and connect T-adapter to female side of
EC2 and EC3.
3
harness Between EC2 (female) (22) and each pin other than EC2
(female) (22) pin.
Between EC2 (female) (22) and EC3 (female) (3) Resistance Min. 100 kz
2. Disconnect connector T9A, and connect T-adapter to female side.
Hot short circuit in wiring 3. Turn starting switch to ON position.
4
harness
4.75 to 5.25
Between T9A (female) (1) and ground Voltage
V
Defective engine 3. Turn starting switch to ON position.
5
controller
4.75 to 5.25
Between EC2 (female) (22) and (23) Voltage
V
40-248 GD535-5
(01)
40 Troubleshooting Failure code [CA2185] Throttle sensor power supply high error
GD535-5 40-249
(01)
Failure code [CA2186] Throttle sensor power supply low error 40 Troubleshooting
Failure code [CA2186] Throttle sensor power supply low error 1
Action
Failure code Throttle sensor power supply voltage low error
code Failure
L03 CA2186
Detail of failure Low voltage appears in throttle sensor power supply circuit.
Problem on
machine
ting).
Related
displayed.
information

1
2. Disconnect connector T9A, and turn starting switch to ON position.
2
Defective throttle sensor a Other (many) failure codes are output simultaneously. This is because connector is dis-
(accelerator pedal) connected. Ignore failure codes other than this [CA2186].
If this failure code disappears, throttle sensor is defective.
Ground fault in wiring 2. Disconnect connectors EC2 and T9A, and connect T-adapter to either female side.
3
harness
Between EC2 (female) (22) or T9A (female) (1) and ground Resistance Min. 100 kz
Short circuit in wiring 2. Disconnect connectors EC2 and T9A, and connect T-adapter to female side of EC2.
4
harness Between EC2 (female) (22) and each pin other than EC2
(female) (22) pin.
2. Disconnect connector EC2 and connect T-adapter to male side.
5
controller
4.75 to 5.25
Between EC2 (female) (22) and (23) Voltage
V
40-250 GD535-5
(01)
40 Troubleshooting Failure code [CA2186] Throttle sensor power supply low error
GD535-5 40-251
(01)
Failure code [CA2249] Supply pump pressure low error 2 40 Troubleshooting
Failure code [CA2249] Supply pump pressure low error 2 1
Action
Failure code Supply pump pressure low error 2
code Failure
L03 CA2249
Detail of failure A low voltage error (2) occurred in the common rail injection circuit.
Action of
controller
Problem on
machine
ting).
36401)
Related
information
played.

Supply pump pressure
low error
40-252 GD535-5
(01)
40 Troubleshooting Failure code [CA2311] Abnormality in IMV (IMA) solenoid
Failure code [CA2311] Abnormality in IMV (IMA) solenoid 1
Action
Failure code IMV solenoid failure
code Failure
L03 CA2311
Detail of failure Resistance of supply pump actuator circuit is unusually high or low.
Action of
None in particular
controller
Problem on
machine
ting).
Related
displayed.
information

1 IMV solenoid failure Perform troubleshooting for failure codes [CA271] and [CA272].
GD535-5 40-253
(01)
Failure code [CA2555] Intake heater relay open circuit 40 Troubleshooting
Failure code [CA2555] Intake heater relay open circuit 1
Action
Failure code Intake heater relay open circuit
code Failure
L01 CA2555
Detail of failure Short circuit is in preheat relay drive circuit (primary circuit).
Action of
None in particular
controller
Problem on Intake air heater does not work in auto preheating mode (resulting in degraded startability and emission of
machine white smoke at low temperature).
played.
Related
Procedure: Turn starting switch to ON position (charge temperature: Max. -4°C).
information
q Troubleshooting of this failure code covers circuits from engine controller to primary circuit (coil) of pre-
heat relay SP40.
q For troubleshooting of heater relay and secondary circuit of heater relay and preheat relay SP40, see
following E-mode troubleshooting (E-2).

1
2. Disconnect relay SP40, and connect T-adapter to male side.
Between SP40 (male) (1) and (2) Resistance 200 to 400 z
Defective preheating
2 1. Turn the starting switch to OFF position.
relay
2. Replace relay SP40 with another one.
If this failure code disappears, original preheat relay SP40 is defective.
Open or short circuit in 2. Disconnect connector EC2, and connect T-adapter to female side.
3
wiring harness a Resistance of preheat relay coil
Between EC2 (female) (40) and ground Resistance 200 to 400 z
Open circuit in wiring 2. Disconnect connector EC2 and relay SP40, and connect T-adapter to female side.
4
harness
Between EC2 (female) (40) and SP40 (female) (1) Resistance Max. 10 z
Between SP40 (female) (2) and ground Resistance Max. 10 z
2. Disconnect connector EC2 and relay SP40, and connect T-adapter to female side of
Short circuit in wiring EC2.
5 Check by using multimeter in continuity mode.
harness
No continuity
Between EC2 (female) (40) and each pin other than pin (40)
(No sound is heard.)
6
40-254 GD535-5
(01)
40 Troubleshooting Failure code [CA2555] Intake heater relay open circuit
Circuit diagram related to preheat relay
GD535-5 40-255
(01)
Failure code [CA2556] Intake heater relay short circuit 40 Troubleshooting
Failure code [CA2556] Intake heater relay short circuit 1
Action
Failure code Intake heater relay short circuit
code Failure
L01 CA2556
Detail of failure Short circuit is in preheat relay drive circuit (primary circuit).
Action of
None in particular
controller
Problem on Intake air heater does not work in auto preheating mode (resulting in degraded startability and emission of
machine white smoke at low temperature).
played.
Related
Procedure: Turn starting switch to ON position (charge temperature: Max. -4°C).
information
q Troubleshooting of this failure code covers circuits from engine controller to primary circuit (coil) of pre-
heat relay SP40.
q For troubleshooting of heater relay and secondary circuit of heater relay and preheat relay SP40, see
following E-mode troubleshooting (E-2).

1
2. Disconnect relay SP40, and connect T-adapter to male side.
Defective preheating
relay
2. Replace preheat relay SP40 with another one.
If this failure code disappears, original preheat relay SP40 is defective.
Ground fault in wiring 2. Disconnect connector EC2 and relay SP40, and connect T-adapter to either female side.
3
harness Between EC2 (female) (40) or SP40 (female) (1) and
ground
2. Disconnect connector EC2 and relay SP40, and connect T-adapter to female side of
Short circuit in wiring EC2.
harness
No continuity
Between EC2 (female) (40) and each pin other than pin (40)
5
40-256 GD535-5
(01)
40 Troubleshooting Failure code [CA2556] Intake heater relay short circuit
Circuit diagram related to preheat relay
GD535-5 40-257
(01)
Failure code [D160KA] Disconnection of Backup Light Relay 40 Troubleshooting
Failure code [D160KA] Disconnection of Backup Light Relay 1
Action
Failure code Open circuit of backup lamp relay output
code Failure
L01 D160KA
As the circuit of backup lamp relay primary side (coil side) has opened, the transmission controller cannot
Detail of failure
turn ON the backup lamp relay.
Action of
Turns OFF the output to the backup lamp relay.
controller
Problem on q Backup lamp does not light.
machine q Backup buzzer does not sound.
Related played.
information Procedure: Turn starting switch to ON position. + Gear shift lever
q Output state (ON/OFF) to backup lamp relay can be checked with monitoring function. (Code: 03705)

Between TM42 (male) (1) and (2) Resistance 200 to 400 z
Defective backup lamp 1. Turn the starting switch to OFF position.
1
relay 2. Replace the backup lamp relay TM42 with a relay (5-pin) of the same type.
4. Shift the gear shift lever to "R" position.
If backup lamp becomes normal, original backup lamp relay TM42 is defective.
a Resistance of backup lamp relay coil
Between TM40 (female) (18) and ground Resistance 200 to 400 z
Open circuit in wiring If no failure is found by above checks, this check is not required.
2
harness 1. Turn the starting switch to OFF position.
2. Disconnect connectors TM40 and TM42, and connect T-adapters to each female side.
Between TM42 (female) (2) and ground Resistance Max. 1 z
If no failure is found by above checks, transmission controller is defective. (Since this is an
Reference
Failure of transmission
controller 4. Shift the gear shift lever to perform troubleshooting.
Gear shift lever: R (Reverse) Voltage 20 to 30 V
Between TM40 (female) (18)
and (31) Gear shift lever: Other than
Voltage Max. 1 V
above
40-258 GD535-5
(01)
40 Troubleshooting Failure code [D160KA] Disconnection of Backup Light Relay
Circuit diagram related to backup lamp relay
GD535-5 40-259
(01)
Failure code [D160KB] Ground Fault of Backup Light Relay 40 Troubleshooting
Failure code [D160KB] Ground Fault of Backup Light Relay 1
Action
Failure code Grounding of backup lamp relay output
code Failure
L01 D160KB
As the circuit of backup lamp relay primary side (coil side) has grounded, the transmission controller cannot
Detail of failure
turn ON the backup lamp relay.
Action of Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF
controller position.
Problem on q Backup lamp does not light.
machine q Backup buzzer does not sound.
Related played.
information Procedure: Turn starting switch to ON position. + Gear shift lever
q Output state (ON/OFF) to back lamp relay can be checked with monitoring function. (Code: 03705)

Defective backup lamp 1. Turn the starting switch to OFF position.
1
relay 2. Replace the backup lamp relay TM42 with a relay (5-pin) of the same type.
4. Shift the gear shift lever to "R" (Reverse) position.
If backup lamp becomes normal, original backup lamp relay TM42 is defective.
2
harness Between TM42 (female) (1) or TM40 (female) (18) and
ground
Reference
Failure of transmission 3. Turn starting switch to ON position.
3
controller
4. Shift the gear shift lever to perform troubleshooting.
Gear shift lever: R (Reverse) Voltage 20 to 30 V
Between TM40 (female) (18)
and (31) Gear shift lever: Other than
Voltage Max. 1 V
above
40-260 GD535-5
(01)
40 Troubleshooting Failure code [D160KB] Ground Fault of Backup Light Relay
Circuit diagram related to back lamp relay
GD535-5 40-261
(01)
Failure code [D160KY] Hot Short of Back Lamp Relay Output 40 Troubleshooting
Failure code [D160KY] Hot Short of Back Lamp Relay Output 1
Action
Failure code Hot short of back lamp relay output
code Failure
L01 D160KY
As a hot short occurs in back lamp relay output, the current continues to flow even if it is not output to the
Detail of failure
back lamp relay primary circuit (coils).
Action of
Turns OFF the output to the back lamp relay primary circuit (coils).
controller
Problem on q Backup lamp continues to light.
machine q Backup buzzer continues to sound.
q Output state (ON/OFF) to back lamp relay can be checked with monitoring function. (Code: 03705)
q This failure code shows a failure of the primary side (coil side) circuit of back lamp relay. The failure of
Related the secondary circuit (contact side) cannot be detected.
played.

harness
Between TM42 (female) (1) and ground Voltage Max. 4.5 V
Reference
Failure of transmission 2. Insert T-adapter into connector TM40.
controller
Gear shift lever: R (Reverse) 20 to 30 V
Between TM40 (18) and (31) Gear shift lever: Other than Voltage
Max. 1 V
above
40-262 GD535-5
(01)
40 Troubleshooting Failure code [D160KY] Hot Short of Back Lamp Relay Output
Circuit diagram related to back lamp relay
GD535-5 40-263
(01)
Failure code [D19JKZ] Personal Code Relay Abnormality 40 Troubleshooting
Failure code [D19JKZ] Personal Code Relay Abnormality 1
Action
Failure code Personal Code Relay Abnormality
code Failure
L03 D19JKZ
q No current flows or large current flows when the output to primary circuit (coil) of personal code relay is
Detail of failure turned ON.
q Current flows when the output to primary circuit (coil) of personal code relay is turned OFF.
Problem on
None in particular
machine
q Output signal (ON/OFF) to personal code relay can be checked with monitoring function. (Code: 04700)
information played.

If fuse No. 2 has blown in fuse box FB1, the circuit may be shorted to ground. (Go to check
1 Blown fuse
on cause 4.)
2. Replace the personal code relay SP32 and stop lamp relay SP16.
3. Start engine.
Personal code relay If this failure code disappears, original personal code relay SP32 is defective.
2
abnormality Reference
2. Disconnect connector SP32, and connect T-adapter to male side.
Between connector SP32 (male) (1) and (2) Resistance 200 to 400 z
2. Disconnect connectors FP1 and SP32, and connect T-adapter to each female side.
Open circuit in wiring 3. Remove fuse No.15 of fuse box FB1.
3
harness
Between FP1 (female) (4) and SP32 (female) (2) Max. 1 z
Resistance
Between FB1-15 and SP32 (female) (1) Max. 1 z
2. Disconnect connectors FP1 and SP32, and connect T-adapter to female side of FP1 or
SP32.
4 3. Remove fuse No. 15 of fuse box FB1.
harness
Between FP1 (female) (4) or SP32 (female) (2) and ground Min. 1 Mz
Resistance
Between FB1-15 or SP32 (female) (1) and ground Min. 1 Mz
Defective machine If no failure is found by above checks, the machine monitor is defective. (Since this is an
5
monitor internal defect, troubleshooting cannot be performed.)
40-264 GD535-5
(01)
40 Troubleshooting Failure code [D19JKZ] Personal Code Relay Abnormality
Circuit diagram related to personal code relay
GD535-5 40-265
(01)
Failure code [D19KKZ] Failure of Diff Control Relay 40 Troubleshooting
Failure code [D19KKZ] Failure of Diff Control Relay 1
Action
Failure code Failure of differential gear control relay output circuit
code Failure
L01 D19KKZ
Detail of failure The primary side (coil side) circuit of differential gear lock relay is opened or shorted to ground.
q Turns OFF the output to differential lock relay.
q If the circuit is opened or shorted to ground, the machine becomes normal by itself when cause of failure
Action of
disappears.
controller
q If the circuit is shorted to ground, machine is not recovered to normal status until the starting switch is
turned to OFF position.
Problem on
The differential gear does not work normally.
machine
q Output state (ON/OFF) to differential lock relay can be checked with monitoring function.
(Code: 03705)
Related
information
played.
Procedure: Turn starting switch to ON position. + Operate the differential gear lock switch (ON).

Failure of differential gear 1. Turn the starting switch to OFF position.
1
lock relay 2. Replace the differential gear lock relay TM43 with the same type of relay.
4. Turn ON the differential gear lock switch.
If it becomes normal, original differential gear lock relay TM43 is defective.
a Resistance of differential gear lock relay coils
2 If no failure is found by above checks, this check is not required.
harness
2. Disconnect connectors TM40 and TM43, and connect T-adapter to each female side.
3
ground
Short circuit in wiring 2. Disconnect connectors TM40 and TM43, and connect T-adapter to female side of TM43.
harness
Between TM43 (female) (1) and (2) Resistance Min. 1 Mz
40-266 GD535-5
(01)
40 Troubleshooting Failure code [D19KKZ] Failure of Diff Control Relay

Reference
5
controller 4. Turn ON the differential gear lock switch.
Turn OFF the differential
Voltage 20 to 30 V
Between TM40 (female) (8) gear lock switch.
and (31) Turn ON the differential gear
Voltage Max. 1 V
lock switch.
Circuit diagram related to differential gear lock relay
GD535-5 40-267
(01)
Failure code [D1EHKA] Disconnection of Engine Start Relay 40 Troubleshooting
Failure code [D1EHKA] Disconnection of Engine Start Relay 1
Action
Failure code Open circuit of engine start relay output
code Failure
L03 D1EHKA
Detail of failure No current flows when output to the primary circuit (coil) of engine start relay is turned ON.
Action of
None in particular
controller
Problem on
The engine cannot start.
machine
q Engine start relay output signal can be checked with monitoring function. (Code: 03706)
information played.

2. Replace engine start relay SP17 with the same type of relay.
Failure of engine start If it becomes normal, original engine start relay SP17 is defective.
1
relay
Check ground terminal FT11 for loose connection or rusting.
Open circuit in wiring 2. Disconnect connectors TM41 and SP17, and connect T-adapter to each female side.
2
harness
Between SP17 (female) (1) and TM41 (female) (8) Max. 1 z
Resistance
Between SP17 (female) (2) and ground Max. 1 z
3
Circuit diagram related to engine start relay
40-268 GD535-5
(01)
40 Troubleshooting Failure code [D1EHKB] Ground Fault of Engine Start Relay
Failure code [D1EHKB] Ground Fault of Engine Start Relay 1
Action
Failure code Output circuit of engine start relay is shorted to ground.
code Failure
L03 D1EHKB
Detail of failure Large current flows when output to the primary circuit (coil) of engine start relay is turned ON.
Action of
Turns OFF the output to engine start relay.
controller
Problem on
machine
information played.

If it becomes normal, original engine start relay SP17 is defective.
Failure of engine start
1
relay 1. Turn the starting switch to OFF position.
Between SP17 (male) (1) and (2) 200 to 400 z
Resistance
Between SP17 (male) (1) and ground Min. 1 Mz
Ground fault in wiring 2. Disconnect connectors TM41 and SP17, and connect T-adapter to either female side.
2
harness Between TM41 (female) (8) or SP17 (female) (1) and
Resistance Max. 1 z
ground
3
GD535-5 40-269
(01)
Failure code [D1EHKY] Hot Short of Engine Start Relay 40 Troubleshooting
Failure code [D1EHKY] Hot Short of Engine Start Relay 1
Action
Failure code Output circuit of engine start relay is hot shorted.
code Failure
L03 D1EHKY
Detail of failure Current flows when the output to primary circuit (coil) of engine start relay is turned OFF.
Action of
None in particular
controller
Problem on
machine
information played.

Failure of engine start If it becomes normal, original engine start relay SP17 is defective.
1
relay
2. Disconnect connectors TM41 and SP17, and connect T-adapter to either female side.
2
harness
Between TM41 (female) (8) or SP17 (female) (1) and
Voltage Max. 4.5 V
ground
3
40-270 GD535-5
(01)
40 Troubleshooting Failure code [D1FBKB] Ground Fault of Sol. Self-Holding Relay
Failure code [D1FBKB] Ground Fault of Sol. Self-Holding Relay 1
Action
Failure code Solenoid Self-Holding Relay Output Ground Fault
code Failure
L03 D1FBKB
When controller drives primary circuit (coil) of solenoid self-holding relay, excessive current flows
Detail of failure
through circuit.
Action of
Stops driving solenoid self-holding relay circuit.
controller
q Gear speed is held in NEUTRAL and machine cannot travel.
Problem on
q Radiator fan rotates at its maximum speed and may be damaged.
machine
q Fan changes its rotating direction to normal while fan is rotating in reverse.
q Output signal of transmission controller self-holding relay can be checked with monitoring.
information q After completion of repair, check if the failure code is cleared by the following procedure.
Procedure: Turn the starting switch to ON position.

2. Replace solenoid self-holding relay (SP43) with another relay of same type.
Defective solenoid power If condition becomes normal, original solenoid self-holding relay is defective.
1 holding relay
(transmission) q Reference
Resistance Between SP43 (male) (1) and (2) 200 to 400 Ω
Ground fault in wiring 2. Disconnect connectors TM41 and SP43, and connect T-adapter to either female side.
2 harness (contact with
ground circuit) Between ground and TM41 (female) (4) or SP43 (female)
Resistance Min. 1 MΩ
(1)
Short circuit in wiring 2. Disconnect connectors TM41 and SP43, and connect T-adapter to either female side.
3
harness Between TM41 (female) (4) and (21), or between SP43
Defective transmission If no failure is found by preceding checks, transmission controller is defective.
4
GD535-5 40-271
(01)
Failure code [D1FBKB] Ground Fault of Sol. Self-Holding Relay 40 Troubleshooting
Circuit diagram related to relay of transmission solenoid power holding relay
40-272 GD535-5
(01)
40 Troubleshooting Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2
Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 1
Action
Failure code CAN2 (KOMTRAX) communication failure 2
code Failure
L03 D8AQK4
Detail of failure Machine monitor cannot recognize the KOMTRAX terminal on the CAN2 communication line (KOMNET/c).
Action of
Does not update the communication information.
controller
Problem on
machine
q 4 different failure codes, [D8AQK4], [D8AQKR], [DAQQKR], and [DB2QKR], are used for defective CAN
communication by CAN2. When all of these 4 failure codes are displayed simultaneously on screen,
ground fault, short circuit, or hot short circuit may occur in wiring harness (CAN communication line).
q Since each controller and machine monitor are connected directly to battery, they are supplied with pow-
Related er even after starting switch is turned to OFF position.
information q Since signal of active CAN communication line is pulse voltage, it cannot be measured by using multim-
eter.
played.

Failure of CAN2
1 Perform troubleshooting for failure code [D8AQKR].
communication system
GD535-5 40-273
(01)
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) 40 Troubleshooting
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) 1
Action
Failure code CAN2 communication failure (KOMTRAX)
code Failure
- D8AQKR
Detail of failure Machine monitor cannot recognize the KOMTRAX terminal on the CAN2 communication line (KOMNET/c).
Action of
None
controller
Problem on
None
machine
q 4 different failure codes, [D8AQK4], [D8AQKR], [DAQQKR], and [DB2QKR], are used for defective CAN
communication by CAN2. When all of these 4 failure codes are displayed simultaneously on screen,
ground fault, short circuit, or hot short circuit may occur in wiring harness (CAN communication line).
Related er even after starting switch is turned to OFF position.
information q Since signal of active CAN communication line is pulse voltage, it cannot be measured by using multim-
eter.
played.

1 Failure of slow-blow fuse Remove slow-blow fuse ET48.
If the slow-blow fuse has blown, the circuit may be shorted to ground.
2 Blown fuse If fuse No. 4 of FB2 fuse box is blown, the circuit may be shorted to ground.
Defective CAN
3 Perform checks on causes 4 to 9 in troubleshooting for failure code [DB2QKR].
communication 2 system
Defective KOMTRAX If no failure is found by above checks, the KOMTRAX terminal is defective. (Since this is an
4
terminal internal defect, troubleshooting cannot be performed.)
5
40-274 GD535-5
(01)
40 Troubleshooting Failure code [D8AQKR] CAN2 Discon (KOMTRAX)
Circuit diagram related to KOMTRAX
GD535-5 40-275
(01)
Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) 40 Troubleshooting
Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) 1
Action
Failure code Failure of non-volatile memory in machine monitor
code Failure
L03 DAF0KT
Detail of failure No data can be written into or read from non-volatile memory of the machine monitor.
Problem on
The service meter, odometer and other set values change.
machine
Related
displayed.
information

Defective machine
1 Since this is an internal defect, troubleshooting cannot be performed.
monitor
40-276 GD535-5
(01)
40 Troubleshooting Failure code [DAF0MB] Monitor ROM Abnormality
Failure code [DAF0MB] Monitor ROM Abnormality 1
Action
Failure code Failure of memory (ROM) in machine monitor
code Failure
- DAF0MB
Detail of failure The program of machine monitor was overwritten. (Program error)
Problem on q The display on the machine monitor is unreliable.
machine q Data cannot be sent or received normally to/from each controller.
Related
displayed.
information

Defective machine
monitor
GD535-5 40-277
(01)
Failure code [DAF0MC] Monitor Error 40 Troubleshooting
Failure code [DAF0MC] Monitor Error 1
Action
Failure code Machine monitor operation failure
code Failure
- DAF0MC
Detail of failure Malfunction of machine monitor
Problem on q The display on the machine monitor is unreliable.
machine q Data cannot be sent or received normally to/from each controller.
Related
displayed.
information

Defective machine
monitor
40-278 GD535-5
(01)
40 Troubleshooting Failure code [DAF3KK] Controller Power Source Low (MON)
Failure code [DAF3KK] Controller Power Source Low (MON) 1
Action
Failure code Dropped voltage of battery direct power supply (MON)
code Failure
- DAF3KK
Detail of failure The constant power voltage of machine monitor has dropped below 18 V.
Action of q Disables data writing in memory.
Problem on q The monitor screen may not be displayed.
machine q As data writing into non-volatile memory is disabled, the information reliability drops.
q No failure code is displayed on the machine monitor.
information played.

1 Failure of slow-blow fuse If slow-blow fuse ET48 is blown, the circuit may be shorted to ground.
If fuse No. 1 has blown in fuse box FB1, the circuit may be shorted to ground. (See the
2 Blown fuse
Harness grounding.)
to OFF position.
3. Disconnect connector FP1, and connect T-adapter to female side.
Between FP1 (female) (1) and (2) 20 to 30 V
Open circuit in wiring Voltage
3 Between FP1 (female) (6) and (7) 20 to 30 V
harness
If the fuse or slow-blow fuse blows, replace it.
to OFF position.
Between battery relay ET46 terminal and FP1 (female) (1)
Max. 1 z
or (6) Resistance
Between FP1 (female) (2) or (7) and ground Max. 1 z
Ground fault in wiring 2. Remove fuse No. 1 of FB1 fuse box, Disconnect connector FP1, and connect T-adapter
4 to female side.
harness
Between FB1-1 or FP1 (female) (1) or (6) and ground Resistance Min. 1 Mz
5
GD535-5 40-279
(01)
Failure code [DAF3KK] Controller Power Source Low (MON) 40 Troubleshooting
Circuit diagram related to battery relay
40-280 GD535-5
(01)
40 Troubleshooting Failure code [DAFLKA] Op Lamp Open Cir (Mon)
Failure code [DAFLKA] Op Lamp Open Cir (Mon) 1
Action
Failure code System Operating Lamp Open Circuit (Monitor)
code Failure
- DAFLKA
Monitor controller has detected an open circuit because the output line voltage of system operating lamp is
Detail of failure approximately 5V or less for approximately 3 seconds after starting switch is turned to ON position, during
which monitor controller does not drive.
q Stops driving system operating lamp.
Action of
controller
OFF position.
Problem on
None in particular
machine
q Do not turn the battery disconnect switch to OFF position while the system operating lamp is lit. If battery
disconnect switch is set to OFF position, the data stored in monitor controller memory may be destroyed.
q Although monitor controller cannot light up system operating lamp, no trouble will result unless battery
disconnect switch is turned to OFF position.
Related
q When controller lights up system operating lamp, output circuit voltage is at low level.
information
q Since no controller drives system operating lamp for approximately 3 seconds after starting switch is
turned to ON position, open circuit can be detected.
q After repair is completed, check if the failure code is cleared by the following procedure.

1 Defective fuse 4. Remove fuse-2 in fuse box FB2.
If fuse is blown out, circuit probably has ground fault.
Open circuit in wiring 2. Turn the battery disconnect switch to OFF position
harness (wire breakage 3. Disconnect connectors FP1 and R23, and connect T-adapter to each female side.
2
or defective contact of
connector)
Between FP1 (female) (10) and R23 (female) (2) Max. 1 Ω
Resistance
Between R23 (female) (1) and battery relay (ET46) terminal Max. 1 Ω
Defective monitor If no failure is found by preceding checks, monitor controller is defective. (Since this is an
3
controller internal defect, troubleshooting cannot be performed).
GD535-5 40-281
(01)
Failure code [DAFLKA] Op Lamp Open Cir (Mon) 40 Troubleshooting
Circuit diagram related to system operating lamp
40-282 GD535-5
(01)
40 Troubleshooting Failure code [DAFLKB] Op Lamp Shrt Cir (Mon)
Failure code [DAFLKB] Op Lamp Shrt Cir (Mon) 1
Action
Failure code System Operating Lamp Short Circuit (Monitor)
code Failure
- DAFLKB
Monitor controller has detected a short circuit because voltage of output circuit does not become specified
Detail of failure
level and below while monitor controller drives system operating lamp.
q Stops driving the system operating lamp.
Action of
controller
OFF position.
Problem on
None in particular
machine
q Do not turn the battery disconnect switch to OFF position while the system operating lamp is lit. If battery
disconnect switch is set to OFF position, the data stored in monitor controller memory may be destroyed.
q Although monitor controller cannot light up system operating lamp, no trouble will result unless battery
Related
disconnect switch is turned to OFF position.
information
q After repair is completed, check if the failure code is cleared by the following procedure.

2. Turn the battery disconnect switch to OFF position
3. Remove fuse-2 in fuse box FB2.
4. Disconnect connectors FP1, TM41, L80A, R23, and CAN, and connect T-adapter to
female side of R23.
Resistance Between R23 (female) (1) and (2) Min. 1 MΩ
Short circuit in wiring 3. Disconnect connector R23.
1
harness 4. Disconnect connectors FP1, TM41, L80A, and CAN, and connect T-adapter to each
female side.
Between CAN (female) (4) and each pin other than pin (4) No continuity
Between TM41 (female) (34) and each pin other than pin
No continuity
(34)
Continuity
Between L80A (female) (15) and each pin other than pin
No continuity
(15)
Between FP1 (female) (10) and each pin other than pin (10) No continuity
Defective monitor If no failure is found by preceding checks, monitor controller is defective. (Since this is an
2
controller internal defect, troubleshooting cannot be performed).
GD535-5 40-283
(01)
Failure code [DAFLKB] Op Lamp Shrt Cir (Mon) 40 Troubleshooting
40-284 GD535-5
(01)
40 Troubleshooting Failure code [DAQ0KK] Controller Power Source Low (T/M)
Failure code [DAQ0KK] Controller Power Source Low (T/M) 1
Action
Failure code Dropped voltage of controller power supply (T/M)
code Failure
L03 DAQ0KK
Detail of failure When engine is running, the voltage of controller power circuit has dropped below 18 V.
controller q If cause of failure disappears, machine becomes normal by itself. (However, the gear is held to the neutral
position until the lever is shifted to the N position.)
Problem on
The machine stops.
machine
Related
displayed.
information

If the 30A slow-blow fuse has blown, the circuit may be shorted to ground. In this case,
1 Failure of slow-blow fuse
perform check on cause 4 first.
If fuse No. 3 of FB1 fuse box is blown, the circuit may be shorted to ground. In this case,
2 Blown fuse
Ground cable
to OFF position.
Between each of terminals TM41 (female) (21), (31) to (33)
Resistance Max. 1 z
and ground
3 2. Check that the system operating lamp is off, and then turn the battery disconnect switch
harness
to OFF position.
If the slow-blow fuse or fuse is not burnt out, this check is not required.
Ground fault in wiring to OFF position.
4 (When the battery disconnect switch is not installed, disconnect the cable from the
harness
Between TM41 (female) (1) and ground Resistance Min. 1 Mz
5 Defective alternator Perform troubleshooting for failure code [AB00MA].
GD535-5 40-285
(01)
Failure code [DAQ0KK] Controller Power Source Low (T/M) 40 Troubleshooting

Reference
to OFF position.
Failure of transmission battery negative (-) terminal.)
6
controller 3. Insert T-adapter into connector TM41.
Between TM41 (1) and (21) or (31) Voltage 20 to 30 V
Between TM41 (11) and (32) or (33) Voltage 20 to 30 V
Circuit diagram related to transmission controller power supply
40-286 GD535-5
(01)
40 Troubleshooting Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M)
Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M) 1
Action
Failure code Abnormality of non-volatile memory (T/M)
code Failure
L01 DAQ0KT
Detail of failure Information in the ROM (non-volatile memory) of transmission controller is abnormal.
q Sets entire data of ROM (non-volatile memory) to default values.
Action of
controller
OFF position.
Problem on q The transmission shift feeling may become poor.
machine q The inching feeling may become poor.
Related
displayed.
information

Since this is an internal defect, troubleshooting cannot be performed.
1 (If there is no visible failure on the machine after performing all initial settings of work
controller
equipment controller, controller may be used as it is.)
GD535-5 40-287
(01)
Failure code [DAQ0MC] T/M Con Error 40 Troubleshooting
Failure code [DAQ0MC] T/M Con Error 1
Action
Failure code Controller operation error (T/M)
code Failure
- DAQ0MC
Detail of failure The controller malfunctions (unexpected control).
Action of
Resets the controller CPU and restarts the machine.
controller
Problem on
Returns to the initial state that was selected when starting switch is set to ON position.
machine
Related
displayed.
information

controller
40-288 GD535-5
(01)
40 Troubleshooting Failure code [DAQ1KA] Disconnection of Key SW ACC
Failure code [DAQ1KA] Disconnection of Key SW ACC 1
Action
Failure code Disconnection of KEY_SIG (ACC) signal line
code Failure
L03 DAQ1KA
Detail of failure Although engine is running, the ACC signal of key switch is not entered in the transmission controller.
q Erroneously recognizes the key OFF processing, and tries to hold the speed gear when the machine is
Action of
traveling.
controller
q If the gear is shifted to Neutral position, the machine cannot travel.
Problem on q The machine can continue to travel when traveling.
machine q If the gear is shifted to Neutral, the machine cannot travel.
Related
displayed.
information

to OFF position.
Open circuit in wiring Between TM41 (female) (14) and (21) 20 to 30 V

1 Voltage
harness Between TM41 (female) (24) and (31) 20 to 30 V
If no failure is found by above checks, this check is not required.
to OFF position.
Between TM41 (female) (14) and ACC terminal Max. 1 z
Resistance
Between TM41 (female) (24) and ACC terminal Max. 1 z
2
GD535-5 40-289
(01)
Failure code [DAQ1KA] Disconnection of Key SW ACC 40 Troubleshooting
Circuit diagram related to transmission controller key switch ACC signal circuit
40-290 GD535-5
(01)
40 Troubleshooting Failure code [DAQ2KK] Solenoid Power Source Low (T/M)
Failure code [DAQ2KK] Solenoid Power Source Low (T/M) 1
Action
Failure code Dropped solenoid power source voltage (T/M)
code Failure
L03 DAQ2KK
When starting switch is set to ON position (with engine stopped or running), the voltage of controller power
Detail of failure
supply circuit is normal but the voltage of solenoid power circuit has dropped below 18 V.
OFF position.
Problem on
The machine stops.
machine
Related
displayed.
information

If the 60A slow-blow fuse of holder 1 has blown, the circuit may be shorted to ground. In
this case, perform check on cause 4 first.
2 Blown fuse
Ground cable
to OFF position.
Between each of terminals TM41 (female) (21), (31) to (33)
Resistance Max. 1 z
and ground
harness
to OFF position.
Between TM41 (female) (12) or (22) and (33) Voltage 20 to 30 V
Ground fault in wiring to OFF position.
harness
5 Defective alternator Perform troubleshooting for failure code [AB00MA].
GD535-5 40-291
(01)
Failure code [DAQ2KK] Solenoid Power Source Low (T/M) 40 Troubleshooting

Reference
to OFF position.
6
controller 4. Turn the battery disconnect switch to ON position.
Between TM41 (2) to (21) and (31) Voltage 20 to 30 V
Between TM41 (12) and (32) Voltage 20 to 30 V
Circuit diagram related to transmission controller power supply
40-292 GD535-5
(01)
40 Troubleshooting Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M)
Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M) 1
Action
Failure code Inconsistency of model selection signal (T/M)
code Failure
L03 DAQ9KQ
q The model setting ID of the controller is incorrect.
q The model information obtained from machine monitor does not match the model information being
Detail of failure
stored in the controller.
q The model information stored in the controller is other than the available model information.
Action of
controller
OFF position.
Problem on
If the machine is traveled, the transmission system may be damaged.
machine
Related
displayed.
information

Incorrect machine model The machine model setting of machine monitor is probably incorrect. After replacing the
1 setting by machine machine monitor or transmission controller, set the options correctly. For details, see
monitor Testing and Adjusting.
Incorrect installation of Incorrect transmission controller may be installed. Check the part number, and install the
2
transmission controller correct transmission controller.
Failure of machine
If no failure is found by above checks, the machine monitor or transmission controller is
3 monitor or transmission
defective. (Since this is an internal defect, troubleshooting cannot be performed.)
controller
GD535-5 40-293
(01)
Failure code [DAQLKA] Op Lamp Open Cir (T/M Cont) 40 Troubleshooting
Failure code [DAQLKA] Op Lamp Open Cir (T/M Cont) 1
Action
Failure code System Operating Lamp Open Circuit (Transmission Controller)
code Failure
- DAQLKA
Transmission controller has detected an open circuit because the output line voltage of system operating
Detail of failure lamp is 5 V or less for approximately 3 seconds after starting switch is turned to ON position, during which
transmission controller does not drive.
q Even if cause of failure is eliminated, machine does not become normal until starting switch is turned to
Action of
OFF position.
controller
q Stops driving system operating lamp.
Problem on
System operating lamp may not light up while controller is performing end processing
machine
q While controller is performing end processing, if battery disconnect switch is set to “OFF” position, fan
stops suddenly and may be damaged. In addition, initial learning data may not be saved resulting in in-
creased shifting shocks.
q Although transmission controller cannot turn on the system operating lamp, no trouble will result unless
battery disconnect switch is turned to OFF position.
Related
q Do not turn the battery disconnect switch to “OFF” position while the system operating lamp is lit.
information
q Since no controller drives system operating lamp for approximately 3 seconds after starting switch is
turned to ON position, open circuit can be detected.
q After completion of repair, check if the failure code is cleared by the following procedure.

1 Defective fuse If fuse is blown out, circuit probably has ground fault.
8. Disconnect connectors R23 and TM41, and connect T-adapter to each female side.
2 harness (wire breakage
or defective contact) Between battery relay (ET46) terminal and R23 (female) (1) Max. 1 Ω
Resistance
Between R23 (female) (2) and TM41 (female) (34) Max. 1 Ω
3
40-294 GD535-5
(01)
40 Troubleshooting Failure code [DAQLKA] Op Lamp Open Cir (T/M Cont)
GD535-5 40-295
(01)
Failure code [DAQLKB] Op Lamp Shrt Cir (T/M Cont) 40 Troubleshooting
Failure code [DAQLKB] Op Lamp Shrt Cir (T/M Cont) 1
Action
Failure code System Operating Lamp Output Short Circuit (Transmission)
code Failure
- DAQLKB
Transmission controller determines that system operating lamp circuit shorts because voltage of output
Detail of failure
circuit does not become low level while transmission controller drives system operating lamp.
q Stops driving the system operating lamp.
Action of
controller
OFF position.
q When controller drives system operating lamp, large current flows through circuit and controller may be
burnt out.
q System operating lamp may not light up while controller is performing end processing
Problem on
REMARK
machine
While controller is performing end processing, if battery disconnect switch is set to “OFF” position, fan
stops suddenly and may be damaged. In addition, initial learning data may not be saved resulting in
increased shifting shocks.
q Although transmission controller cannot turn on the system operating lamp, no trouble will result unless
Related
battery disconnect switch is turned to OFF position.
information

3. Remove fuse-2 in fuse box FB2.
4. Disconnect connectors FP1, TM41, L80A, R23, CAN, and connect T-adapter to female
side of R23.
Resistance Between R23 (female) (1) and (2) Min. 1 MΩ
Short circuit in wiring 3. Disconnect connector R23.
1 4. Disconnect connectors FP1, TM41, L80A, and CAN, and connect T-adapter to each
harness
female side.
Between CAN (female) (4) and each pin other than pin (4) No continuity
Between TM41 (female) (34) and each pin other than pin
No continuity
(34)
Continuity
Between L80A (female) (15) and each pin other than pin
No continuity
(15)
Between FP1 (female) (10) and each pin other than pin (10) No continuity
2
40-296 GD535-5
(01)
40 Troubleshooting Failure code [DAQLKB] Op Lamp Shrt Cir (T/M Cont)
GD535-5 40-297
(01)
Failure code [DAQQKR] CAN2 Discon (Transmission Con) 40 Troubleshooting
Failure code [DAQQKR] CAN2 Discon (Transmission Con) 1
Action
Failure code CAN2 communication failure (T/M)
code Failure
L03 DAQQKR
Machine monitor system cannot recognize the transmission controller on the CAN2 communication line
Detail of failure
(KOMNET/r).
Action of
Flashes the centralized warning lamp and sounds the alarm buzzer.
controller
Problem on
Machine monitor system may not operate normally, or the machine monitor may not display normally.
machine
q The start of CAN communication is specified to each controller by sending an ACC signal of starting
switch.
er even after starting switch is turned to OFF position.
Related
q Since signal of active CAN communication line is pulse voltage, it cannot be measured by using multim-
information
eter.
played.

Failure of power supply
1 to the transmission Perform troubleshooting for failure code [DAQ0KK].
controller
Failure of CAN2
2 Perform checks on causes 4 to 9 in troubleshooting for failure code [DB2QKR].
communication system
3
4
40-298 GD535-5
(01)
40 Troubleshooting Failure code [DAQRMA] Inconsistency of Option Selection (T/M)
Failure code [DAQRMA] Inconsistency of Option Selection (T/M) 1
Action
Failure code Inconsistency of option settings (T/M)
code Failure
L03 DAQRMA
q The option setting ID of the controller is incorrect.
Detail of failure q The differential gear setting information obtained from machine monitor does not match the option infor-
mation being stored in the controller.
Action of
controller
OFF position.
Problem on
machine
Related
displayed.
information

controller
GD535-5 40-299
(01)
Failure code [DB2QKR] CAN2 Discon (Engine Con) 40 Troubleshooting
Failure code [DB2QKR] CAN2 Discon (Engine Con) 1
Action
Failure code CAN2 communication failure (Engine controller)
code Failure
L03 DB2QKR
Detail of failure Machine monitor cannot recognize the engine controller over CAN2 communication line (KOMNET/r).
Action of
Lights the centralized warning lamp and sounds the alarm buzzer.
controller
Problem on
Machine monitor system may not operate normally, or the machine monitor may not display normally.
machine
q Start of CAN communication is recognized by each controller when ACC signal of starting switch is re-
ceived.
er even after starting switch is turned to OFF position.
Related
q Since signal of active CAN communication line is pulse voltage, it cannot be measured by using multim-
information
eter.
played.

1 Blown fuse If fuse No.4 of FB2 fuse box is blown, the engine controller may have shorted.
Defective engine 2. Disconnect connector EC3 and connect T-adapter to male side.
2
controller
Between EC3 (male) (3) and (1) Min. 10 z
Resistance
Between EC3 (male) (4) and (2) Min. 10 z
Check ground terminal 103 for looseness and rusting.
3
to engine controller a Perform troubleshooting for failure code [CA441].
Between EC3 (female) (3) and (1) 20 to 30 V
Voltage
Between EC3 (female) (4) and (2) 20 to 30 V
2. Disconnect connectors FP1 and CAN1, and connect T-adapters to each male side.
Defective CAN
4
terminating resistor Between CAN1 (male) (A) and (B) 120 ± 12 z
Resistance
Between FP1 (male) (11) and (12) 120 ± 12 z
40-300 GD535-5
(01)
40 Troubleshooting Failure code [DB2QKR] CAN2 Discon (Engine Con)

CAN communication line
to OFF position.
3. Disconnect related connectors, and connect T-adapter to female side of the connector
to be measured.
q The 120 z CAN terminating resistor is also located in machine monitor. That is, 2 CAN
terminating resistors of 120 z are connected in parallel. When circuit resistance is mea-
sured at connector of controller other than machine monitor, if combined resistance is
5 60 z, wiring harness does not have open circuit.
wiring harness
q If open circuit is found (resistance between 2 terminals is 1 z or below), disconnect all
CAN communication connectors of every controller and check whether short circuit oc-
curs in wiring harness or inside controller.
Between EC2 (female) (46) and (47) Approx. 60 z
Between FP1 (female) (11) and (12) Approx. 120 z
Between TM40 (female) (32) and (22) Resistance Approx. 60 z
Between L80A (female) (10) and (11) Approx. 60 z
Between CAN1 (female) (A) and (B) Approx. 120 z
ACC signal of starting switch (The start of CAN communication is not recognized.)
to OFF position.
3. Disconnect connectors to be measured and insert T-adapters.
Between EC2 (39) and EC3 (1) 20 to 30 V
Between FP1 (3) and (2) 20 to 30 V
Voltage
Between TM41 (14) or (24) and (21) 20 to 30 V
Between CAN (2) and (12) 20 to 30 V
Open circuit in wiring If the wiring harness is normal (not opened or shorted), this check is not required.
harness
to OFF position.
3. Disconnect related connectors, and connect T-adapter to female side of the connector
to be measured.
Between FP1 (female) (11) and EC2 (female) (46) Max. 1 z
Between FP1 (female) (12) and EC2 (female) (47) Max. 1 z
Between FP1 (female) (11) and TM40 (female) (32) Max. 1 z
Between FP1 (female) (12) and TM40 (female) (22) Max. 1 z
Resistance
Between FP1 (female) (11) and L80A (female) (10) Max. 1 z
Between FP1 (female) (12) and L80A (female) (11) Max. 1 z
Between EC2 (female) (46) and CAN1 (female) (A) Max. 1 z
Between EC2 (female) (47) and CAN1 (female) (B) Max. 1 z
GD535-5 40-301
(01)
Failure code [DB2QKR] CAN2 Discon (Engine Con) 40 Troubleshooting

If the wiring harness is normal (not opened or shorted), measure resistance at any one
place in each case.
to OFF position.
Ground fault in wiring battery negative (-) terminal.)
7 3. Disconnect all related connectors, and connect T-adapter to female side of the
harness
connector to be measured.
Between L80A (female) (1) EC2 (female) (46) or TM40
Min. 1 Mz
Resistance
Between L80A (female) (11), EC2 (female) (47) or TM40
Min. 1 Mz
If the wiring harness is normal (not opened or shorted), measure resistance at any one
place in each case.
to OFF position.
3. Disconnect connectors to be measured and insert T-adapters.
Open circuit or hot short
8 (When the battery disconnect switch is not installed, connect the cable to the battery
circuit in wiring harness negative (-) terminal.)
a Voltage of CAN H and CAN L is 2.5 ± 1 V including during communication, so regard
wiring harness as normal if measured voltage is 1 to 4 V.
1 to 4 V
Voltage
1 to 4 V
If all 3 failure codes [D8AQKR], [DAQQKR], [DB2QKR] are displayed:
Identify which controller is defective by disconnecting them one by one from CAN
communication line by repeating the following steps 1 to 5.
to OFF position.
Failure of engine (When the battery disconnect switch is not installed, disconnect the cable from the
controller, transmission battery negative (-) terminal.)
9 controller, machine 3. Disconnect each CAN communication connector of engine controller (connector EC2),
monitor, or KOMTRAX transmission controller (connector TM40), KOMTRAX terminal (connector L80A), and
terminal machine monitor (connector FP1) one by one in turn.
Has the number of displayed failure codes If YES, the disconnected controller is
decreased from 3? defective.
10
11
40-302 GD535-5
(01)
40 Troubleshooting Failure code [DB2QKR] CAN2 Discon (Engine Con)
Circuit diagram related to CAN2 communication
GD535-5 40-303
(01)
Failure code [DD1PKB] Abnormality of RPM Switch 40 Troubleshooting
Failure code [DD1PKB] Abnormality of RPM Switch 1
Action
Failure code Failure of RPMset switch
code Failure
L03 DD1PKB
q The SET and RESUME lamps of the set switch turn ON simultaneously.
Detail of failure
q When the set switch is operated, the SET or RESUME lamp is kept ON.
Action of q Flashes the centralized warning lamp and sounds the alarm buzzer.
controller q Sets the RPMset set function to the OFF mode.
Problem on
The RPMset set switch is turned OFF, and it cannot be used any more.
machine
Related
information

2. Disconnect connectors TM38 and TM41, and connect T-adapter to female side of TM41.
Short circuit in wiring Between TM41 (female) (2) and (20) Resistance Min. 1 Mz
1
harness
2
harness
Between TM41 (female) (20) and (21) Voltage Max. 1 V
3
40-304 GD535-5
(01)
40 Troubleshooting Failure code [DD1PKB] Abnormality of RPM Switch
Circuit diagram related to RPM set switch and RPM set mode switch
GD535-5 40-305
(01)
Failure code [DD1QKB] Abnormality of RPM Set Mode Switch 40 Troubleshooting
Failure code [DD1QKB] Abnormality of RPM Set Mode Switch 1
Action
Failure code Failure of RPMset set mode switch
code Failure
L03 DD1QKB
q The AUTO and MANUAL lamps of the set switch turn ON simultaneously.
Detail of failure
q When the set switch is operated, the AUTO or MANUAL lamp is kept ON.
controller q Sets the RPM set function to the OFF mode.
Problem on
The RPM set function is turned OFF, and it cannot be used any more.
machine
Related
information

Short circuit in wiring Between TM37 (female) (4) and (5) Resistance Min. 1 Mz
1
harness
2
harness
3
40-306 GD535-5
(01)
40 Troubleshooting Failure code [DD1QKB] Abnormality of RPM Set Mode Switch
Circuit diagram related to RPM switch and RPM mode switch
GD535-5 40-307
(01)
Failure code [DDB6L4] Parking brake signal error 40 Troubleshooting
Failure code [DDB6L4] Parking brake signal error 1
Action
Failure code Parking brake signal combination error
code Failure
L03 DDB6L4
Detail of failure Both the parking signal and no-parking signal turned ON or OFF.
controller q This error is recovered when the normal shift lever "P" combination signals are entered.
q The parking brake operates when the gear shift lever is shifted to N or P position and when the speed is
Problem on
1.0 km/h or less.
machine
q The parking brake does not operate if the gear shift lever is any position other than N or P.
q Input condition (ON/OFF or shift lever position) from the shift lever can be checked with monitoring func-
tion. (Code: 02213)
Related
information
played.
Procedure: Turn starting switch to ON position. + Operate gear shift lever.

If fuse No. 11 of FB1 fuse box blows, the circuit may be shorted to ground. (Go to check on
1 Blown fuse
cause 3.)
2. Remove fuse No. 11 of the FB1 fuse box.
Open circuit in wiring Between FB1-11 and TM36 (female) (1) Resistance Max. 1 z
2
harness
Ground fault in wiring Between FB1-11 or TM36 (female) (1) and ground Resistance Min. 1 Mz
3
ground
ground
to OFF position.
Short circuit in wiring battery negative (-) terminal.)
4
harness 3. Disconnect connectors TM36, TM40 and TM41, and connect T-adapter to female side
of TM36.
Between TM36 (female) (5) and each pin other than pin (5) Resistance Min. 1 Mz
40-308 GD535-5
(01)
40 Troubleshooting Failure code [DDB6L4] Parking brake signal error

to OFF position.
3. Disconnect connector TM36, and connect T-adapter to female side (with the gear shift
Hot short circuit in wiring lever removed).
harness
6 Failure of gear shift lever Perform troubleshooting for failure code [DF10KA].
Failure of transmission internal defect, troubleshooting cannot be performed.)
7
controller Reference
When you check the voltage, see failure code [DF10KA].
Circuit diagram related to gear shift lever
GD535-5 40-309
(01)
Failure code [DDTHKA] Disconnection of Fill Switch (FH) 40 Troubleshooting
Failure code [DDTHKA] Disconnection of Fill Switch (FH) 1
Action
Failure code Disconnection of FH-clutch fill switch
code Failure
L01 DDTHKA
When signal is output to the FH-clutch ECMV solenoid, the clutch is engaged but signal from fill switch is
Detail of failure
not turned ON.
q None in particular
Action of
controller
OFF position.
Problem on
Large shock occurs during gear shift.
machine
(Code: 02216)
Related
information
played.

Failure of FH-clutch fill
1 Perform troubleshooting for failure code [15SCMA].
switch
40-310 GD535-5
(01)
40 Troubleshooting Failure code [DDTJKA] Disconnection of Fill Switch (FL)
Failure code [DDTJKA] Disconnection of Fill Switch (FL) 1
Action
Failure code Disconnection of FL-clutch fill Switch
code Failure
L01 DDTJKA
When signal is output to the FL-clutch ECMV solenoid, the clutch is engaged but signal from fill switch is not
Detail of failure
turned ON.
Action of
controller
OFF position.
Problem on
machine
(Code: 02216)
Related
information
played.

Failure of FL-clutch fill
1 Perform troubleshooting for failure code [15SDMA].
switch
GD535-5 40-311
(01)
Failure code [DDTKKA] Disconnection of Fill Switch (1st) 40 Troubleshooting
Failure code [DDTKKA] Disconnection of Fill Switch (1st) 1
Action
Failure code Disconnection of 1st-clutch fill switch
code Failure
L01 DDTKKA
When signal is output to the 1st-clutch ECMV solenoid, the clutch is engaged but signal from fill switch is
Detail of failure
not turned ON.
Action of
controller
OFF position.
Problem on
machine
(Code: 02217)
Related
information
played.

Failure of 1st-clutch fill
1 Perform troubleshooting for failure code [15SEMA].
switch
40-312 GD535-5
(01)
40 Troubleshooting Failure code [DDTLKA] Disconnection of Fill Switch (2nd)
Failure code [DDTLKA] Disconnection of Fill Switch (2nd) 1
Action
Failure code Disconnection of 2nd clutch fill switch
code Failure
L01 DDTLKA
When signal is output to the 2nd clutch ECMV solenoid, the clutch is engaged but signal is not output from
Detail of failure
the fill switch.
Action of
controller
OFF position.
Problem on
machine
(Code: 02217)
Related
information
played.

Failure of 2nd clutch fill
1 Perform troubleshooting for failure code [15SFMA].
switch
GD535-5 40-313
(01)
Failure code [DDTMKA] Disconnection of Fill Switch (3rd) 40 Troubleshooting
Failure code [DDTMKA] Disconnection of Fill Switch (3rd) 1
Action
Failure code Disconnection of 3rd-clutch fill switch
code Failure
L01 DDTMKA
When signal is output to the 3rd-clutch ECMV solenoid, the clutch is engaged but signal is not sent from the
Detail of failure
fill switch.
Action of
controller
OFF position.
Problem on
machine
q Input condition (connection/disconnection) from ECMV fill switch of 3rd clutch can be checked with mon-
Related
information
played.

Failure of 3rd-clutch fill
1 Perform troubleshooting for failure code [15SGMA].
switch
40-314 GD535-5
(01)
40 Troubleshooting Failure code [DDTNKA] Disconnection of Fill Switch (R)
Failure code [DDTNKA] Disconnection of Fill Switch (R) 1
Action
Failure code Disconnection of R-clutch fill switch
code Failure
L01 DDTNKA
When signal is output to the R-clutch ECMV solenoid, the clutch is engaged but signal from fill switch is not
Detail of failure
turned ON.
Action of
controller
OFF position.
Problem on
machine
(Code: 02216)
Related
information
played.

Failure of R-clutch fill
1 Perform troubleshooting for failure code [15SBMA].
switch
GD535-5 40-315
(01)
Failure code [DDTPKA] Disconnection of Fill Switch (4th) 40 Troubleshooting
Failure code [DDTPKA] Disconnection of Fill Switch (4th) 1
Action
Failure code Disconnection of 4th-clutch fill switch
code Failure
L01 DDTPKA
When signal is output to the 4th-clutch ECMV solenoid, the clutch is engaged but signal from fill switch is
Detail of failure
not turned ON.
Action of
controller
OFF position.
Problem on
machine
(Code: 02217)
Related
information
played.

Failure of 4th-clutch
1 Perform troubleshooting for failure code [15SHMA].
40-316 GD535-5
(01)
40 Troubleshooting Failure code [DF10KA] Disconnection of Shift Lever Input
Failure code [DF10KA] Disconnection of Shift Lever Input 1
Action
Failure code Gear shift lever signal is not entered.
code Failure
L03 DF10KA
q The gear shift lever was in intermediate position and an illegal voltage combination was entered in the
transmission controller.
q The gear shift lever signal is not entered in the transmission controller due to short to ground or due to
Detail of failure
open circuit.
(Although the "NOTP" signal voltage is supplied to the controller, but no voltage is supplied to any gear
shift signal.)
q If machine is braked and if a speed less than 1.0 km/h continues 0.5 second, the lever is held in N posi-
tion.
Action of
q The recently entered normal speed gear or direction is kept.
controller
q However, if failure code [DF10L4] is detected simultaneously, machine does not become normal until
starting switch is turned to OFF position.
Problem on
The gear cannot be shifted.
machine
q Input condition (ON/OFF or shift lever position) from the gear shift lever can be checked with monitoring
function. (Code: 02211, 02212, 02213)
Related
information
played.

The gear shift lever is pressed by external force when the lever is not operated.
1 Incorrect operation
Shift lever is stopped in an intermediate position.
to OFF position.
3. Disconnect connectors TM36, TM40 and TM41, and connect T-adapter to each female
side.
Between TM36 (female) (3) and TM40 (25) Resistance Max. 1 z
2
harness Between TM36 (female) (8) and TM40 (5) Resistance Max. 1 z
GD535-5 40-317
(01)
Failure code [DF10KA] Disconnection of Shift Lever Input 40 Troubleshooting

to OFF position.
3. Disconnect connectors TM36, TM40 and TM41, and connect T-adapters to female side
of TM40 and TM41.
3
harness Between TM40 (female) (16) and ground Resistance Min. 1 Mz
4 Failure of gear shift lever See the Gear Shift Lever Output Table.
Between each pin of TM36 Lever position indicated by q Voltage 20 to 30 V

and ground Lever position indicated by Q Voltage Max. 1 V
Reference: Input voltage of transmission controller
5
controller
4. Shift the gear lever to perform troubleshooting.
See the Gear Shift Lever Output Table.
Between each pin of TM41 Lever position indicated by q Voltage 20 to 30 V

and ground Lever position indicated by Q Voltage Max. 1 V
40-318 GD535-5
(01)
40 Troubleshooting Failure code [DF10KA] Disconnection of Shift Lever Input
GD535-5 40-319
(01)
Failure code [DF10KA] Disconnection of Shift Lever Input 40 Troubleshooting
Gear Shift Lever Output Table
Gear shift lever signal

F R Not P P N 1st 2nd 3rd 4th 5th 6th 7th 8th
F8 q Q q Q Q Q Q Q Q Q Q Q q
F7 q Q q Q Q Q Q Q Q Q Q q Q
F6 q Q q Q Q Q Q Q Q Q q Q Q
F5 q Q q Q Q Q Q Q Q q Q Q Q
q Q q Q Q Q Q Q q Q Q Q Q
Gear speed of shift lever
F4
F3 q Q q Q Q Q Q q Q Q Q Q Q
F2 q Q q Q Q Q q Q Q Q Q Q Q
F1 q Q q Q Q q Q Q Q Q Q Q Q
N Q Q q Q q Q Q Q Q Q Q Q Q
P Q Q Q q q Q Q Q Q Q Q Q Q
R1 Q q q Q Q q Q Q Q Q Q Q Q
R2 Q q q Q Q Q q Q Q Q Q Q Q
R3 Q q q Q Q Q Q q Q Q Q Q Q
R4 Q q q Q Q Q Q Q q Q Q Q Q
TM36
(3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15)
(Gear shift lever)
Pin number
TM40
(25) (15) - - (35) (5) (36) (26) (16) (6) - - -
(Controller)
TM41
- - (40) (39) - - - - - - (9) (19) (29)
(Controller)
Notes: Voltage indicated by q: 20 to 30V, Voltage indicated by Q: 1V or less
40-320 GD535-5
(01)
40 Troubleshooting Failure code [DF10L4] Gear Speed/Travel Direction Signal Error
Failure code [DF10L4] Gear Speed/Travel Direction Signal Error 1
Action
Failure code Gear speed/travel direction signal error
code Failure
L03 DF10L4
Detail of failure An illegal voltage combination of N, F, R and 1 to 8 gear shift lever signals was entered.
q If machine is braked and if the speed less than 1.0 km/h continues 0.5 second, the gear shift lever is held
Action of in N position.
controller q The recently entered normal speed gear or direction is kept.
OFF position.
Problem on
The gear cannot be shifted.
machine
q Input condition (ON/OFF or shift lever position) from the shift lever can be checked with monitoring func-
tion. (Code: 02211, 02212, 02213)
Related
information
played.

to OFF position.
3. Disconnect connectors TM36, TM40 and TM41, and connect T-adapter to female side
of TM36.
1
harness Between TM36 (female) (8) and each pin other than pin (8) Resistance Min. 1 Mz
GD535-5 40-321
(01)
Failure code [DF10L4] Gear Speed/Travel Direction Signal Error 40 Troubleshooting

to OFF position.
3. Disconnect connector TM36, and connect T-adapter to female side (with the gear shift
lever removed).
Hot short circuit in wiring Between TM36 (female) (4) and (2) Voltage Max. 1 V
2
harness
3 Failure of gear shift lever Perform troubleshooting for failure code [DF10KA].
Failure of transmission internal defect, troubleshooting cannot be performed.)
4
controller Reference
When you check the voltage, see failure code [DF10KA].
40-322 GD535-5
(01)
40 Troubleshooting Failure code [DF10L4] Gear Speed/Travel Direction Signal Error
GD535-5 40-323
(01)
Failure code [DGF1KX] Out of Range of T/M Oil Temp. Sensor 40 Troubleshooting
Failure code [DGF1KX] Out of Range of T/M Oil Temp. Sensor 1
Action
Failure code Out of range of transmission oil temperature sensor
code Failure
L03 DGF1KX
Detail of failure The signal of transmission oil temperature sensor is outside of normal range (0.9 to 4.5 V).
Problem on
machine
q The input voltage and temperature sent from transmission oil temperature sensor can be checked by the
monitoring function. (Code: 32501, 32500)
Related
information
played.

Between TM19 (male) (1) and (2) 25°C Resistance 38 to 49 kz
Failure of transmission oil
temperature sensor 100°C Resistance 3.7 to 4.0 kz
temperature sensor)
Between TM19 (male) (1) and ground, and
between TM19 (male) (2) and ground
2
wiring harness ture sensor in cause 1 (25°C to 100°C).
3
harness
4
ground
Hot short or short circuit 2. Disconnect connector TM19, and connect T-adapter to female side.
of wiring harness
Between TM19 (female) (1) and (2) Voltage Approx. 5 V
6
40-324 GD535-5
(01)
40 Troubleshooting Failure code [DGF1KX] Out of Range of T/M Oil Temp. Sensor
Circuit diagram related to transmission oil temperature sensor
GD535-5 40-325
(01)
Failure code [DGH2KB] Ground Fault of Hydraulic Oil Temp. S 40 Troubleshooting
Failure code [DGH2KB] Ground Fault of Hydraulic Oil Temp. S 1
Action
Failure code Ground fault of hydraulic temperature sensor
code Failure
(Transmission system)
L01 DGH2KB
Hydraulic temperature Min. 150°C (Max. 0.97 V) was detected. (Hydraulic temperature signal circuit is
Detail of failure
shorted to ground.)
Action of
If cause of failure disappears, machine becomes normal by itself.
controller
Problem on
machine
The input voltage and temperature sent from hydraulic oil temperature sensor can be checked by the
Related
monitoring function.
information
(Code: 04404, 04401)

Between R17 (male) (1) and 25°C Resistance 38 to 49 kz
(2)
Failure of hydraulic oil
1 (Temperature characteristics 100°C Resistance 3.7 to 4.0 kz
temperature sensor
of oil temperature sensor)
Between R17 (male) (1) and
ground, and between R17 - (Always) Resistance Min. 1 Mz
(male) (2) and ground
Ground fault in wiring 2. Disconnect connectors TM39 and R17, and connect T-adapter to either female side.
2
harness Between TM39 (female) (20) or R17 (female) (1) and
ground
3 Hydraulic oil temperature:
controller Voltage 4.4 to 4.6 V
25°C
Between TM39 (20) and (21)
Hydraulic oil temperature:
100°C
40-326 GD535-5
(01)
40 Troubleshooting Failure code [DGH2KB] Ground Fault of Hydraulic Oil Temp. S
Circuit diagram related to hydraulic oil temperature sensor
GD535-5 40-327
(01)
Failure code [DGT1KX] Out of Range of T/C Oil Temp. Sensor 40 Troubleshooting
Failure code [DGT1KX] Out of Range of T/C Oil Temp. Sensor 1
Action
Failure code Out of range of torque converter oil temperature sensor input signal
code Failure
L01 DGT1KX
Detail of failure The signal of torque converter oil temperature sensor is outside of normal range (0.9 to 4.5 V).
Action of q Sends the torque converter oil temperature as the abnormal value to the machine monitor.
Problem on q An overheated torque converter cannot be sensed.
machine q Large shock occurs during gear shift.
q The input voltage and temperature sent from the torque converter oil temperature sensor can be checked
by the monitoring function.
Related (Code: 30101, 30100)
played.

Failure of torque
1 converter oil temperature 25°C Resistance 38 to 49 kz
Between TM17 (male) (1) and (2)
sensor 100°C Resistance 3.7 to 4.0 kz
Between TM17 (male) (1) or (2) and ground All ranges Resistance Min. 1 Mz
2
wiring harness ture sensor in cause 1 (25°C to 100°C).
Open circuit in wiring 2. Disconnect connectors TM39 and TM17, and connect T-adapters to each female side.
3
harness
4
ground
Hot short or short circuit 2. Disconnect connector TM17, and connect T-adapter to female side.
of wiring harness
Between TM17 (female) (1) and (2) Voltage Approx. 5 V
6
40-328 GD535-5
(01)
40 Troubleshooting Failure code [DGT1KX] Out of Range of T/C Oil Temp. Sensor
Circuit diagram related to torque converter oil temperature sensor
GD535-5 40-329
(01)
Failure code [DGT7KB] Ground Fault of Diff Oil Temp. S.(C) 40 Troubleshooting
Failure code [DGT7KB] Ground Fault of Diff Oil Temp. S.(C) 1
Action
Failure code Ground fault of differential gear oil temperature sensor
code Failure
(Transmission system)
L01 DGT7KB
Differential gear oil temperature Min. 150°C (Max. 0.97 V) was detected. (Differential lock oil temperature
Detail of failure
signal circuit is shorted to ground.)
Action of q Overheat of differential gear oil temperature is not detected.
controller q Turns ON the output to differential lock relay.
Problem on
The differential gear lock is turned OFF independent from switching.
machine
Related The input voltage and temperature sent from differential gear oil temperature sensor can be checked by the
information monitoring function. (Code: 31910, 31909)

Failure of differential gear Between R8 (male) (1) and (2) 25°C Resistance 38 to 49 kz
1
oil temperature sensor (Temperature characteristics of oil
temperature sensor) 100°C Resistance 3.7 to 4.0 kz
Between R8 (male) (1) or (2) and ground - (Always) Resistance Min. 1 Mz

Ground fault in wiring 2. Disconnect connectors TM39 and R8, and connect T-adapter to either female side.
2
harness
Between TM39 (female) (14) or R8 (female) (1) and ground Resistance Min. 1 Mz
3 Hydraulic oil temperature:
controller Voltage 4.4 to 4.6 V
Between TM39 (14) and 25°C
ground Hydraulic oil temperature:
100°C
Circuit diagram related to differential gear oil temperature sensor
40-330 GD535-5
(01)
40 Troubleshooting Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor
Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor 1
Action
Failure code Out of Range of torque converter input pressure sensor
code Failure
L01 DHT5KX
Detail of failure The voltage of torque converter oil pressure sensor has dropped below 0.3V or exceeded above 4.7V.
Action of
Sets the torque converter oil pressure to the specified oil pressure inside of controller, and controls it.
controller
Problem on
Large shock occurs during lock up.
machine
q The input voltage and temperature sent from torque converter oil temperature sensor can be checked by
the monitoring function. (Code: 30101, 30100)
Related
information
played.

1 Between TM39 (female) (22) or TM18 (female) (3) and
harness Min. 1 Mz
ground
Resistance
Min. 1 Mz
ground
harness
Failure of sensor power 3. Turn starting switch to ON position.
3 If power supply voltage is abnormal, go to check on cause 5.
supply system
Power supply
Between TM18 (1) and (3) (female) 4 to 6 V
voltage
Failure of torque 3. Turn starting switch to ON position.
4 converter oil pressure
sensor Sensor
Between TM18 (2) and (1) output 0.3 to 1.5 V
voltage
If the power voltage is normal, this check is not required.
5
Open circuit in wiring Max. 1 z
harness Between TM39 (female) (22) and TM18 (female) (3)
If the power voltage is normal, this check is not required. Resistance
Max. 1 z
Between TM39 (21) (female) and TM18 (female) (1)
Between TM39 (2) (female) and TM18 (female) (2) Max. 1 z
GD535-5 40-331
(01)
Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor 40 Troubleshooting

Reference
Failure of transmission 1. Turn the starting switch to OFF position.
6 2. Insert T-adapter into connector TM39.
controller
Between TM39 (21) and (22) 4 to 6 V
Voltage
Between TM39 (2) and (21) 0.3 to 1.5 V
40-332 GD535-5
(01)
40 Troubleshooting Failure code [DHT5L6] Failure of T/C Oil Press Sensor
Failure code [DHT5L6] Failure of T/C Oil Press Sensor 1
Action
Failure code Failure of torque converter oil pressure sensor
code Failure
L01 DHT5L6
Transmission controller detects oil pressure corresponding to the input voltage from torque converter oil
Detail of failure pressure sensor. (Even after engine is stopped, output voltage of torque converter oil pressure sensor does
not drop.) (Input voltage: Min. 0.66 V)
Action of
Sets the torque converter oil pressure to the specified oil pressure inside of controller, and controls it.
controller
Problem on
Large shock occurs during lock up.
machine
q The input voltage and temperature sent from torque converter oil temperature sensor can be checked by
the monitoring function. (Code: 30101, 30100)
Related
information
played.
Procedure: Turn starting switch to ON position, and wait for 10 seconds.

harness
Ignore the displayed failure codes.
Between TM39 (2) or TM18 (female) (2) and ground Voltage Max. 1 V
Failure of torque This is because the connector is unplugged, ignore failure code [DHT5KX].
2 converter oil pressure
sensor If failure code [DHT5L6] is no longer displayed, the torque converter oil pressure sensor
has failed.
If failure code [DHT5L6] is displayed, the wiring harness or transmission controller has
failed.
Reference
Failure of transmission 1. Turn the starting switch to OFF position.
3 2. Disconnect connector TM39.
controller
Between TM39 (21) and (22) 4 to 6 V
Voltage
Between TM39 (2) and (21) 0.3 to 1.5 V
GD535-5 40-333
(01)
Failure code [DHT5L6] Failure of T/C Oil Press Sensor 40 Troubleshooting
40-334 GD535-5
(01)
40 Troubleshooting Failure code [DJF1KA] Disconnection of Fuel Level Sensor
Failure code [DJF1KA] Disconnection of Fuel Level Sensor 1
Action
Failure code Open circuit of fuel level sensor
code Failure
L01 DJF1KA
Detail of failure The fuel level sensor circuit was opened.
Action of
None in particular
controller
Problem on
Fuel gauge is displayed abnormally.
machine
q The input resistance and voltage from the fuel level sensor can be checked with monitoring function.
(Code: 04201, 04200)
Related
information
played.

2. Disconnect connector ET39, and connect T-adapter to male side.
FULL Resistance Max. 7 z
1
Failure of fuel level 3/4 Resistance (10 z)
sensor Between ET39 (male) (1) and (2)
1/2 Resistance 32 z
(Fuel level characteristics table)
1/4 Resistance (50 z)
EMPTY Resistance Min. 85 z
2 Between TM39 (female) (19) and ground
wiring harness
Resistance accords with the fuel level sensor characteristics Resistance 10 to 80 z
table in cause 1.
Open circuit in wiring 2. Disconnect connectors TM39 and ET39, and connect T-adapter to each female side.
3
harness
Between TM39 (female) (19) and ET39 (female) (1) Resistance Max. 1 z
Between ET39 (female) (2) and ground Resistance Max. 1 z
2. Disconnect connector ET39, and connect T-adapter to female side.
Hot short or short circuit 3. Turn starting switch to ON position.
4
of wiring harness
Approx. 3 to 5
Between ET39 (female) (1) and (2) Voltage
V
5
GD535-5 40-335
(01)
Failure code [DJF1KA] Disconnection of Fuel Level Sensor 40 Troubleshooting
Circuit diagram related to fuel level sensor
40-336 GD535-5
(01)
40 Troubleshooting Failure code [DK70KX] Out of Range of Inching Potentio.
Failure code [DK70KX] Out of Range of Inching Potentio. 1
Action
Failure code Out of range of inching potentiometer input signal
code Failure
L03 DK70KX
Detail of failure The signal of inching angle sensor of the inching pedal is outside of normal range (0.4 to 4.5 V).
Action of
q Disables inching by shifting the lever to Neutral position.
controller
q If cause of failure disappears, machine becomes normal by itself when gear shift lever is in N position.
Problem on
Inching function does not work normally.
machine
q Input voltage from inching pedal angle sensor can be checked with monitoring function.
(Code: 44105)
Related
information
played.
Procedure: Turn starting switch to ON position. + Operating of inching pedal

2. Disconnect connector FL6, and connect T-adapter to male side.
Between FL6 (male) (A) and (C) Resistance 4.0 to 6.0 kz
Failure of inching angle
1 0.25 to 5.0
sensor Between FL6 (male) (B) and (A) Resistance
kz*
0.25 to 5.0
Between FL6 (male) (B) and (C) Resistance
kz*
1. Turn the starting switch to zOFF position.
to OFF position.
Open circuit in wiring 3. Disconnect connectors TM39, TM40 and FL6, and connect T-adapters to each female
2
harness side.
Between TM39 (female) (21) and FL6 (female) (C) Resistance Max. 1 z
Between TM39 (female) (7) and FL6 (female) (B) Resistance Max. 1 z
Between TM40 (female) (1) and FL6 (female) (A) Resistance Max. 1 z
to OFF position.
harness 3. Disconnect connectors TM39, TM40 and FL6, and connect T-adapter to either female side.
Between TM40 (female) (1) or FL6 (female) (A) and ground Resistance Min. 1 Mz
Between TM39 (female) (7) or FL6 (female) (B) and ground Resistance Min. 1 Mz
2. Disconnect connector FL6, and connect T-adapter to female side.
4
harness
Between FL6 (female) (A) and (C) Voltage Approx. 5 V
Between FL6 (female) (B) and (C) Voltage Max. 2.5 V
GD535-5 40-337
(01)
Failure code [DK70KX] Out of Range of Inching Potentio. 40 Troubleshooting

to OFF position.
3. Insert T-adapters into connectors TM39 and TM40.
controller (When the battery disconnect switch is not installed, connect the cable to the battery
Between TM40 (1) and TM39 (21) Voltage 4.6 to 5.4 V
Between TM39 (7) and (21) Voltage 0.4 to 4.5 V
* When you repeat to press the inching pedal, its resistance changes.
Circuit diagram related to inching pedal angle sensor
40-338 GD535-5
(01)
40 Troubleshooting Failure code [DKD0KX] Out of Range of Articulated Angle Sensor
Failure code [DKD0KX] Out of Range of Articulated Angle Sensor 1
Action
Failure code Out of range of articulated angle sensor input
code Failure
L01 DKD0KX
Detail of failure Signal of articulated angle sensor has exceeded the normal range.
Action of
If cause of failure disappears, machine becomes normal by itself.
controller
Problem on
The articulated angle sensor is not displayed correctly.
machine
q Input voltage from articulated angle sensor can be checked with monitoring function.
(Code: 43900)
information played.
Procedure: Start engine. + Articulated operation
q See "Articulated meter display is abnormal" for E mode.
No. Cause Procedure, meas(1)uring location, criteria, and remarks

2. Disconnect connector B11, and connect T-adapter to male side.
3. Turn starting switch to OFF and perform troubleshooting. Then, connect the connector
into its position.
4. Start engine, change the articulated angle, and return to Step 1.
Failure of articulated
1 Approx. 2.5
angle sensor Center Resistance
Between B11 (male) (A) and kz
(B) Left end stroke (25°) Approx. 1 to
Resistance
Right end stroke (25°) 3.8 kz
Between B11 (male) (A) and (C) Resistance Approx. 5 kz
2. Disconnect connectors TM39 and B11, and connect T-adapters to each female side.
2
Open circuit in wiring Between TM39 (female) (8) and B11 (female) (B) Resistance Max. 1 z
harness
Between TM39 (female) (21) and B11 (female) (A) Resistance Max. 1 z
Between TM39 (female) (22) and B11 (female) (C) Resistance Max. 1 z
2. Disconnect connectors TM39 and B11, and connect T-adapter to either female side.
3 Between TM39 (female) (8) or B11 (female) (B) and ground Resistance Min. 1 Mz
harness
Between TM39 (female) (22) or B11 (female) (C) and
ground
2. Disconnect connector B11, and connect T-adapter to female side.
4
harness
Between B11 (female) (B) and (A) Voltage Max. 3 V
Between B11 (female) (C) and (A) Voltage Approx. 5 V
GD535-5 40-339
(01)
Failure code [DKD0KX] Out of Range of Articulated Angle Sensor 40 Troubleshooting
No. Cause Procedure, meas(1)uring location, criteria, and remarks

3. Turn starting switch to ON position, then perform troubleshooting.
4. Start engine, change the articulated angle, and return to Step 3.
5 Center Voltage Approx. 2.4 V
controller
Between TM39 (8) and (21) Left end (25°) Approx. 1 to
Voltage
Right end (25°) 3.8 V
Between TM39 (22) and (21) Voltage Approx. 5 V
Circuit diagram related to articulated angle sensor
40-340 GD535-5
(01)
40 Troubleshooting Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor
Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor 1
Action
Failure code Disconnection of transmission input shaft speed sensor
code Failure
L03 DLF1KA
Detail of failure As the circuit of transmission input shaft speed sensor was opened, the speed signal is not entered.
q Fixes the relative engine speed to 300 rpm, and controls it.
Action of
q Keeps to turn OFF the output to lockup clutch.
controller
OFF position.
Problem on q A clutch slip cannot be ascertained.
machine q The lockup mechanism does not work.
q The transmission input shaft speed and the input speed sent from the sensor can be checked by the mon-
Related
information
played.
Procedure: Start engine. + Travel

Failure of transmission 2. Disconnect connector TM20, and connect T-adapter to male side.
1
input shaft speed sensor 500 to 1,000
Between TM20 (male) (1) and (2) Resistance
z
Poor adjustment of
The transmission input shaft speed sensor may be adjusted incorrectly. Adjust it by
2 transmission input shaft
referring to Testing and adjusting, "Adjusting the transmission speed sensor".
speed sensor
Open or short circuit in If resistance is 1 Mz or higher, wiring harness has open circuit. If it is 1 z or below, wiring
3 harness has short circuit.
wiring harness
500 to 1000
Between TM40 (female) (40) and (39) Resistance
z
4
harness
5
GD535-5 40-341
(01)
Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor 40 Troubleshooting
Circuit diagram related to transmission input shaft speed sensor
40-342 GD535-5
(01)
40 Troubleshooting Failure code [DLF1LC] Failure of T/M Input Speed Sensor
Failure code [DLF1LC] Failure of T/M Input Speed Sensor 1
Action
Failure code Hot short or ground fault of transmission input shaft speed sensor
code Failure
L03 DLF1LC
Although each clutch of L/U, FH, FL, R, 1, 2, 3 and 4 operates normally, the speed signal sent from
Detail of failure
transmission input shaft speed sensor is abnormal.
q Fixes the relative speed to 300 rpm, and controls it.
Action of
q Keeps to turn OFF the output to lockup clutch.
controller
OFF position.
Problem on q A clutch slip cannot be judged.
q The input shaft speed sent from the transmission input shaft speed sensor can be checked by the mon-
Related
information
played.

1 500 to 1000
input shaft speed sensor Between TM20 (male) (1) and (2) Resistance
z
wiring harness
500 to 1000
z
3
ground
harness
5
GD535-5 40-343
(01)
Failure code [DLF1LC] Failure of T/M Input Speed Sensor 40 Troubleshooting
Circuit diagram related to transmission input shaft speed sensor
40-344 GD535-5
(01)
40 Troubleshooting Failure code [DLF2KA] Disconnection of T/M Inter. Speed Sensor
Failure code [DLF2KA] Disconnection of T/M Inter. Speed Sensor 1
Action
Failure code Disconnection of transmission intermediate shaft speed sensor
code Failure
L03 DLF2KA
Detail of failure As the circuit of transmission intermediate shaft speed sensor is opened, the speed signal is not entered.
Action of q Fixes the relative speed to 300 rpm, and controls it.
OFF position.
Problem on
A clutch slip cannot be judged.
machine
q The input shaft speed sent from the transmission intermediate shaft speed sensor can be checked by the
Related
information
played.

Failure of transmission 2. Disconnect connector TM21, and connect T-adapter to male side.
1 intermediate shaft speed
sensor 500 to 1000
z
Poor adjustment of
transmission The transmission intermediate shaft speed sensor may be adjusted incorrectly. Adjust it by
2
intermediate shaft speed referring to Testing and adjusting, "Adjusting the transmission speed sensor".
sensor
wiring harness
500 to 1000
z
4
harness
5
GD535-5 40-345
(01)
Failure code [DLF2KA] Disconnection of T/M Inter. Speed Sensor 40 Troubleshooting
Circuit diagram related to transmission intermediate shaft speed sensor
40-346 GD535-5
(01)
40 Troubleshooting Failure code [DLF2LC] Failure of T/M Intermediate Speed Sensor
Failure code [DLF2LC] Failure of T/M Intermediate Speed Sensor 1
Action
Failure code Hot short or ground fault of transmission intermediate shaft speed sensor
code Failure
L03 DLF2LC
Although each clutch of L/U, FH, FL, R, 1, 2, 3 and 4 operates normally, the speed signal sent from
Detail of failure
transmission intermediate shaft speed sensor is abnormal.
Action of q Fixes the relative speed to 300 rpm, and controls it.
OFF position.
Problem on
A clutch slip cannot be judged.
machine
q The input shaft speed sent from the transmission intermediate shaft speed sensor can be checked by the
Related
information
played.

1 intermediate shaft speed 500 to 1000
sensor z
wiring harness
500 to 1000
z
3
ground
harness
5
GD535-5 40-347
(01)
Failure code [DLF2LC] Failure of T/M Intermediate Speed Sensor 40 Troubleshooting
Circuit diagram related to transmission intermediate shaft speed sensor
40-348 GD535-5
(01)
40 Troubleshooting Failure code [DLM3KA] Rad Fan Spd Sen Opn/Shrt Cir
Failure code [DLM3KA] Rad Fan Spd Sen Opn/Shrt Cir 1
Action
Failure code Radiator Fan Speed Sensor Open Circuit or Hot Short Circuit
code Failure
L01 DLM3KA
q No pulse voltage is input from fan speed sensor due to open circuit in fan speed sensor system.
q This failure code is displayed when the following conditions are satisfied.
Detail of failure
1. Input voltage is 3 to 4 V.
2. There is no record of pulse input.
Action of
OFF position.
controller
q Stops radiator fan feedback control.
Problem on
Target fan speed is not reached, and engine may overheat or fuel consumption may increase.
machine
q Radiator fan speed can be checked with monitoring. (Code: 10009)
Related
information
Procedure: Start the engine.

5. Disconnect connector RT8, and connect T-adapter to male side.
Defective radiator fan
1
speed sensor Between RT8 (male) (1) and (2) 2 to 3 kΩ
Resistance
Between RT8 (male) (1) and ground Min. 1 MΩ
Open circuit, short circuit, 2. Disconnect connector RT8, and connect T-adapter to female side.
ground fault, hot short 3. Turn the starting switch to ON position.
2 circuit in wiring harness, REMARK
or defective transmission Shake the wiring harness by hand while measuring the voltage. If the voltage becomes 0 V
controller while shaking, wiring harness has open circuit at around this point.
Voltage Between RT8 (female) (1) and (2) 1 to 4.5 V
Open or short circuit in 2. Disconnect connector TM40, and connect T-adapter to female side.
3
wiring harness
Resistance Between TM40 (female) (10) and (39) 2 to 3 kΩ
Open circuit in wiring 2. Disconnect connectors TM40 and RT8, and connect T-adapter to each female side.
4 harness (wire breakage
or defective contact)
Between TM40 (female) (10) and RT8 (female) (1) Max. 1 Ω
Resistance
5
GD535-5 40-349
(01)
Failure code [DLM3KA] Rad Fan Spd Sen Opn/Shrt Cir 40 Troubleshooting
Circuit diagram related to radiator fan speed sensor
40-350 GD535-5
(01)
40 Troubleshooting Failure code [DLM3LC] Rad Fan Spd Sen Sig Error
Failure code [DLM3LC] Rad Fan Spd Sen Sig Error 1
Action
Failure code Radiator Fan Speed Sensor Signal Abnormality
code Failure
L03 DLM3LC
Detail of failure No pulse voltage is input from fan speed sensor due to ground fault in fan speed sensor system.
Action of
OFF position.
controller
Problem on
machine
q Radiator fan speed can be checked with monitoring. (Code: 10009)
Related
information
Procedure: Start the engine, and run it in normal direction at 500 rpm and above.

1
speed sensor Between RT8 (male) (1) and (2) 2 to 3 kΩ
Resistance
2
wiring harness
Resistance Between TM40 (female) (10) and (39) 2 to 3 kΩ
Ground fault in wiring 2. Disconnect connectors TM40 and RT8, and connect T-adapter to either female side.
GND circuit) Between ground and TM40 (female) (10) or RT8 (female)
(1)
Hot short circuit in wiring 2. Disconnect connector RT8, and connect T-adapter to female side.
4 harness (contact with 3. Turn the starting switch to ON position.
24V circuit)
Voltage Between RT8 (female) (1) and (2) 3 to 4 V
5
Circuit diagram related to radiator fan speed sensor
GD535-5 40-351
(01)
Failure code [DLM3MB] Rad Fan Spd Sen Error 40 Troubleshooting
Failure code [DLM3MB] Rad Fan Spd Sen Error 1
Action
Failure code Radiator Fan Speed Sensor Function Deterioration
code Failure
L01 DLM3MB
Difference between actual speed and target speed of radiator fan exceeds certain value while engine is
Detail of failure
running and radiator fan is rotating in normal direction.
Action of
Stops radiator fan feedback control.
controller
Problem on
machine
q Target speed of radiator fan can be checked with monitoring. (Code: 10007)
Related q Radiator fan speed can be checked with monitoring. (Code: 10009)
Procedure: Start the engine.

q Increase hydraulic oil temperature to 50 °C and above, and turn the starting switch to
Variations in performance
OFF position once. Then start engine again and check if this failure code is displayed
1 due to hydraulic oil
again.
temperature
q If it is displayed again, perform following checks.
Defective fan speed
2 Perform troubleshooting for failure code [DLM3KA].
sensor system
Internal defect of fan Perform the troubleshooting for H mode, “Fan speed is abnormal (too high or low, or
3
motor stationary)”.
Defective fan pump
4 Perform troubleshooting for H mode, “Wheel brakes do not work or are weak”.
(brake pump)
40-352 GD535-5
(01)
40 Troubleshooting Failure code [DLT3KA] Disconnection of T/M output Speed Sensor
Failure code [DLT3KA] Disconnection of T/M output Speed Sensor 1
Action
Failure code Disconnection of transmission output shaft speed sensor
code Failure
L03 DLT3KA
Detail of failure As the circuit of transmission output shaft speed sensor was opened, the speed signal is not entered.
q Fixes the relative speed to 300 rpm, and controls it.
Action of q Holds the current gear during automatic gear shifting.
controller q Keeps to turn OFF the output to lockup clutch.
OFF position.
Problem on q A clutch slip cannot be judged.
q The input shaft speed sent from the transmission output shaft speed sensor can be checked by the mon-
Related
information
played.

Failure of transmission Disconnect connector TM22, and connect T-adapter to male side.
1 output shaft speed
sensor Approx. 500
to 1000 z
Poor adjustment of
The transmission output shaft speed sensor may be adjusted incorrectly. Adjust it by
referring to Testing and adjusting, "Adjusting the transmission speed sensor".
speed sensor
wiring harness
Approx. 500
to 1000 z
4
harness
5
GD535-5 40-353
(01)
Failure code [DLT3KA] Disconnection of T/M output Speed Sensor 40 Troubleshooting
40-354 GD535-5
(01)
40 Troubleshooting Failure code [DW4BKA] Disconnection of Parking Brake Valve
Failure code [DW4BKA] Disconnection of Parking Brake Valve 1
Action
Failure code Disconnection of parking brake valve output
code Failure
L03 DW4BKA
The parking brake solenoid circuit has opened, and the parking brake is not released normally.
Detail of failure (When the controller tried to flow current through the parking brake solenoid valve, the current does not
flow. Otherwise, current flows from any circuit to the parking brake solenoid valve.)
Action of
controller
Problem on
The parking brake is not released.
machine
played.
Related Procedure: Start engine. + Shift the lever (to any position other than P position, or to P position).
information q The parking brake is released only when the parking brake solenoid valve can be driven.
q The output status (ON/OFF) to the parking brake solenoid valve can be checked with monitoring function.
(Code: 03705)

Failure of parking brake 2. Disconnect connector R11, and connect T-adapter to male side.
1
solenoid valve
Between R11 (male) (1) and (2) Resistance 2 to 100 z
to OFF position.
Open or short circuit in battery negative (-) terminal.)
2
wiring harness 3. Disconnect connector TM41, and connect T-adapter to female side.
If resistance is 1 Mz or higher, wiring harness has open circuit. If it is 1z or below, wiring
harness has short circuit.
to OFF position.
Open circuit in wiring (When the battery disconnect switch is not installed, disconnect the cable from the
3
harness battery negative (-) terminal.)
3. Disconnect connectors TM41 and R11, and connect T-adapters to each female side.
Between R11 (female) (2) and ground Resistance Max. 1 z
4
GD535-5 40-355
(01)
Failure code [DW4BKA] Disconnection of Parking Brake Valve 40 Troubleshooting
Circuit diagram related to parking brake solenoid valve
40-356 GD535-5
(01)
40 Troubleshooting Failure code [DW4BKB] Ground Fault of Parking Brake Valve
Failure code [DW4BKB] Ground Fault of Parking Brake Valve 1
Action
Failure code Ground fault of parking brake valve output
code Failure
L03 DW4BKB
The parking brake solenoid circuit has shorted, and the parking brake is not released.
Detail of failure
(When the controller flowed the current through parking brake solenoid valve, abnormal current flowed.)
Action of
controller
Problem on
The parking brake is not released.
machine
q After the repair has completed, follow the procedure below and check to see that no failure code is displayed.
Procedure: Start engine. + Shift the lever (to any position other than P position).
Related
q The parking brake is released only when the parking brake solenoid valve is operated.
information
q The output status (ON/OFF) to the parking brake solenoid can be checked with monitoring function.
(Code: 03705)

Failure of parking brake
1
solenoid Between R11 (male) (1) and (2) Resistance 2 to 100 z
Between R11 (female) (1) and ground Resistance Min. 1 Mz
to OFF position.
Ground fault in wiring (When the battery disconnect switch is not installed, disconnect the cable from the
2
3. Disconnect connectors TM41 and R11, and connect T-adapter to either female side.
Between TM41 (female) (7) or R11 (female) (1) and ground Resistance Min. 1 Mz
to OFF position.
Short circuit in wiring (When the battery disconnect switch is not installed, disconnect the cable from the
3
3. Disconnect connectors TM41 and R11, and connect T-adapter to female side of R11.
4
GD535-5 40-357
(01)
Failure code [DW4BKB] Ground Fault of Parking Brake Valve 40 Troubleshooting
Circuit diagram related to parking brake solenoid
40-358 GD535-5
(01)
40 Troubleshooting Failure code [DW4BKY] Hot Short of Parking Brake Solenoid
Failure code [DW4BKY] Hot Short of Parking Brake Solenoid 1
Action
Failure code Hot short of parking brake release solenoid
code Failure
L03 DW4BKY
Detail of failure The parking brake solenoid circuit has hot shorted, and the parking brake does not work.
Problem on q The parking brake is not released.
machine q Auto idle stop does not work.
q The parking brake is released only when the parking brake solenoid valve is operated.
q The output status (ON/OFF) to the parking brake solenoid can be checked with monitoring function.
played.
Procedure: Start engine. + Shift the lever (P position).

Hot short circuit in wiring 2. Disconnect connector R11, and connect T-adapter to female side.
harness
Between R11 (female) (1) and ground Voltage Max. 4.5 V
to OFF position.
3. Disconnect connectors TM41 and R11, and connect T-adapter to female side of TM41.
No
Between TM41 (female) (7) and each pin other than pin (7) Continuity
conductivity
Since T-adapter is not available for connector R1, perform troubleshooting for short circuit
at R1 according to the following procedure.
harness
to OFF position.
3. Disconnect connectors TM39, TM40, TM41 and R11, and connect T-adapters to female
side of TM39, TM40 and TM41.
a Connectors TM39, TM40 and TM41 are used as transmission controller connectors,
and they use connector R1 as an intermediate connector.
Between TM41 (female) (7) and each pin of TM39 (female) No continuity
Conductive
3
GD535-5 40-359
(01)
Failure code [DW4BKY] Hot Short of Parking Brake Solenoid 40 Troubleshooting
Circuit diagram related to parking brake solenoid
40-360 GD535-5
(01)
40 Troubleshooting Failure code [DW7BKA] Rad Fan R Sol Opn Cir
Failure code [DW7BKA] Rad Fan R Sol Opn Cir 1
Action
Failure code Radiator Fan Reverse Solenoid Open Circuit
code Failure
L01 DW7BKA
Due to open circuit in radiator fan reverse solenoid system, no current flows through circuit when controller
Detail of failure
drives radiator fan reverse solenoid.
q Stops driving radiator fan reverse solenoid.
Action of q Disables fan reverse function.
controller q Even if cause of failure is eliminated, machine does not become normal until starting switch is turned to
OFF position.
Problem on
Fan cannot be rotated in reverse with fan reverse switch.
machine
q Output state (ON/OFF) to radiator fan reverse solenoid can be checked with monitoring function. (Code:
Related 03705)
Procedure: Turn the starting switch to ON position, and set the fan reverse switch to ON position.

Defective fan reverse 5. Disconnect connector RT6, and connect T-adapter to male side.
1 solenoid (internal open
circuit)
Between RT6 (male) (1) and (2) 35 to 45 Ω
Resistance
Between ground and each of RT6 (male) (1) and (2) Min. 1 MΩ
Open circuit, short circuit, 2. Disconnect connector RT6 and connect T-adapter to female side.
2 circuit in wiring harness, REMARK
or defective transmission Shake the wiring harness by hand while measuring the voltage. If the voltage becomes 0 V
controller while shaking, wiring harness has open circuit at around this point.
to OFF position.
Open or short circuit in (When the battery disconnect switch is not installed, disconnect the cable from the
3
wiring harness battery negative (-) terminal.)
Resistance Between TM41 (female) (13) and (28) 35 to 45 Ω
If no failure is found by checks on open and short circuit of wiring harness, this check is not
required.
to OFF position.
harness (wire breakage
or defective contact of battery negative (-) terminal.)
connector)
3. Disconnect connectors TM41 and RT6, and connect T-adapter to each female side.
Resistance
5
GD535-5 40-361
(01)
Failure code [DW7BKA] Rad Fan R Sol Opn Cir 40 Troubleshooting
Circuit diagram related to radiator fan reverse rotation solenoid
40-362 GD535-5
(01)
40 Troubleshooting Failure code [DW7BKB] Rad Fan R Sol Gnd Flt
Failure code [DW7BKB] Rad Fan R Sol Gnd Flt 1
Action
Failure code Radiator Fan Reverse Solenoid Ground Fault
code Failure
L01 DW7BKB
Due to ground fault in radiator fan reverse solenoid system, abnormal current flows through circuit when
Detail of failure
controller drives fan reverse solenoid.
q Stops driving radiator fan reverse solenoid.
controller q Even if cause of failure is eliminated, machine does not become normal until starting switch is turned to
OFF position.
Problem on
Fan cannot be rotated in reverse with fan reverse switch.
machine
Related 03705)
Procedure: Turn the starting switch to ON position, and set the fan reverse switch to ON position.

1
reverse solenoid Between RT6 (male) (1) and (2) 35 to 45 Ω
Resistance
Between ground and each of RT6 (male) (1) and (2) Min. 1 MΩ
to OFF position.
2 harness (contact with battery negative (-) terminal.)
GND circuit) 3. Disconnect connectors TM41 and RT6, and connect T-adapter to either female side.
Between ground and TM41 (female) (13) or RT6 (female)
(1)
1. Turn the starting switch to OFF position
to OFF position.
harness
3. Disconnect connectors TM41 and RT6, and connect T-adapter to either female side.
Between TM41 (female) (13) and TM41 (female) (28)
or between RT6 (female) (1) and (2)
4
GD535-5 40-363
(01)
Failure code [DW7BKB] Rad Fan R Sol Gnd Flt 40 Troubleshooting
Circuit diagram related to radiator fan reverse rotation soleno
40-364 GD535-5
(01)
40 Troubleshooting Failure code [DW7BKY] Rad Fan R Sol Shrt Cir
Failure code [DW7BKY] Rad Fan R Sol Shrt Cir 1
Action
Failure code Radiator Fan Reverse Solenoid Hot Short Circuit
code Failure
L01 DW7BKY
Due to hot short circuit in radiator fan reverse solenoid system, abnormal current flows through circuit when
Detail of failure
controller stops driving radiator fan reverse solenoid.
q Disables fan reverse function.
Action of
controller
OFF position.
Problem on q Fan does not rotate in normal direction.
machine q Radiator may overheat.
Related 03705)

1. Turn the starting switch to OFF position
to OFF position.
Hot short circuit in wiring battery negative (-) terminal.)
1 harness (contact with 24 3. Disconnect connector RT6 and connect T-adapter to female side.
V circuit) 4. Turn the battery disconnect switch to ON position.
Voltage Between RT6 (female) (1) and (2) Max. 4.5 V
2. Disconnect connectors TM41 and RT6, and connect T-adapter to female side of TM41.
Continuity Between TM41 (female) (28) and each pin other than (28) No continuity
Since connector R1 has no T-adapter, check the short circuit at R1 according to the
to OFF position.
harness
3. Disconnect connectors TM39, TM40, TM41, and RT6, and connect Tadapter to female
side of TM41.
REMARK
Connectors TM39, TM40, and TM41 are the connector of transmission controller, and they
use R1 connector as an intermediate connector.
Between TM41 (female) (28) and each pin of TM39 No continuity
Continuity
Between TM41 (female) (28) and each pin of TM40 No continuity
3
GD535-5 40-365
(01)
Failure code [DW7BKY] Rad Fan R Sol Shrt Cir 40 Troubleshooting
Circuit diagram related to radiator fan reverse rotation solenoid
40-366 GD535-5
(01)
40 Troubleshooting Failure code [DX16KA] Rad Fan Pump EPC Sol Opn Cir
Failure code [DX16KA] Rad Fan Pump EPC Sol Opn Cir 1
Action
Failure code Radiator Fan Pump EPC Solenoid Open Circuit
code Failure
L01 DX16KA
Due to open circuit in fan motor EPC solenoid system, no current flows through circuit when controller
Detail of failure
drives fan motor EPC solenoid circuit.
q Stops driving fan motor EPC solenoid.
Action of
controller
OFF position.
Problem on
machine
q Command current value output to fan motor EPC solenoid can be checked with monitoring function.

Defective radiator fan 2. Disconnect connector RT7, and connect T-adapter to male side.
1
pump EPC solenoid
Resistance Between RT7 (male) (1) and (2) 2 to 12 Ω
Open circuit, short circuit, 2. Disconnect connector RT7, and connect T-adapter to female side.
2 circuit in wiring harness, 4. Shake the wiring harness by hand while measuring the voltage. If the voltage becomes
or defective transmission 0 V while shaking, wiring harness has open circuit at around this point.
controller
to OFF position.
3
wiring harness REMARK
If resistance value is 1 MΩ and above, wiring harness has open circuit. If it is 1 Ω and
below, wiring harness has short circuit.
Between TM41 (female) (13) and (37)
Resistance
Coil resistance of solenoid 2 to 12 Ω
If no failure is found by checks on open and short circuit of wiring harness, this check is not
required.
Open circuit in wiring to OFF position.
4 harness (wire breakage (When the battery disconnect switch is not installed, disconnect the cable from the
or defective contact) battery negative (-) terminal.)
3. Disconnect connectors TM41 and RT7, and connect T-adapter to each female side.
Resistance
5
GD535-5 40-367
(01)
Failure code [DX16KA] Rad Fan Pump EPC Sol Opn Cir 40 Troubleshooting
Circuit diagram related to radiator fan pump EPC solenoid
40-368 GD535-5
(01)
40 Troubleshooting Failure code [DX16KB] Rad Fan Pump EPC Sol Gnd Flt
Failure code [DX16KB] Rad Fan Pump EPC Sol Gnd Flt 1
Action
Failure code Radiator Fan Pump EPC Solenoid Ground Fault
code Failure
L01 DX16KB
Due to ground fault in fan motor EPC solenoid system, abnormal current flows through circuit when
Detail of failure
controller drives fan motor EPC solenoid.
Action of
controller
OFF position.
Problem on
machine

1
pump EPC solenoid Between RT7 (male) (1) and (2) 2 to 12 Ω
Resistance
to OFF position.
ground circuit) 3. Disconnect connectors TM41 and RT7, and connect T-adapter to either female side.
Between ground and TM41 (female) (13) or RT7 (female)
(1)
to OFF position.
harness
3. Disconnect connectors TM41 and RT7, and connect T-adapter to either female side.
Between TM41 (female) (13) and (37), or between RT7
4
GD535-5 40-369
(01)
Failure code [DX16KB] Rad Fan Pump EPC Sol Gnd Flt 40 Troubleshooting
40-370 GD535-5
(01)
40 Troubleshooting Failure code [DX16KY] Rad Fan Pmp EPC Sol Shrt Cir
Failure code [DX16KY] Rad Fan Pmp EPC Sol Shrt Cir 1
Action
Failure code Radiator Fan Pump EPC Solenoid Hot Short Circuit
code Failure
L01 DX16KY
Detail of failure When controller stops driving radiator fan pump EPC solenoid, current flows through circuit.
controller q If cause of failure is eliminated, machine becomes normal by itself.
Problem on
machine

Hot short circuit in wiring 2. Disconnect connector RT7, and connect T-adapter to female side.
1 harness (contact with 24 3. Turn the starting switch to ON position.
V circuit)
Voltage Between RT7 (female) (1) and (2) Max. 4.5 V
to OFF position.
3. Disconnect connectors TM41 and RT7, and connect T-adapter to female side of TM41.
Continuity Between TM41 (female) (37) and each pin other than (37) Min. 1 MΩ
Since connector R1 has no T-adapter, check the short circuit at R1 according to the
harness
to OFF position.
3. Disconnect connectors TM39, TM40, TM41, and RT7, and connect Tadapter to female
side of TM39, TM40, and TM41.
REMARK
Connectors TM39, TM40, and TM41 are the connector of transmission controller, and they
use R1 connector as an intermediate connector.
Continuity
3
GD535-5 40-371
(01)
Failure code [DX16KY] Rad Fan Pmp EPC Sol Shrt Cir 40 Troubleshooting
40-372 GD535-5
(01)
40 Troubleshooting Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup)
Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup) 1
Action
Failure code Disconnection of ECMV solenoid output (Lockup clutch)
code Failure
L03 DXH1KA
Detail of failure No current flows during output to lockup clutch ECMV solenoid.
OFF position.
q Even if the direct mode is selected by the transmission mode selector switch, the AUTO mode (Torque
Problem on
Converter mode) is always selected.
machine
q The clutch lockup is released.
information played.
Procedure: Turn starting switch to ON position. + Operate the transmission mode selector switch (DI-
RECT mode).

1 Failure of lockup solenoid 2. Disconnect connector TM16, and connect T-adapter to male side.
to OFF position.
2
If resistance is 1 Mz or higher, wiring harness has open circuit. If it is 1 z or below, wiring
Between TM41 (female) (38) and (13) Resistance 5 to 15 z
to OFF position.
harness
4
GD535-5 40-373
(01)
Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup) 40 Troubleshooting
Circuit diagram related to lockup solenoid
40-374 GD535-5
(01)
40 Troubleshooting Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup)
Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup) 1
Action
Failure code Ground fault of ECMV solenoid output (Lockup clutch)
code Failure
L03 DXH1KB
Detail of failure Abnormal current flowed during output to lockup clutch ECMV solenoid.
OFF position.
Problem on Even if the DIRECT mode (Mode 1) is selected by the transmission mode selector switch, the Torque
machine Converter mode (Mode 2) is always selected.
information played.
Procedure: Turn starting switch to ON position. + Operate the transmission mode selector switch (DI-
RECT mode).

1 Failure of lockup solenoid
to OFF position.
harness
3. Disconnect connectors TM41 and TM16, and connect T-adapter to either female side.
ground
to OFF position.
harness
Between TM41 (female) (38) and (13), or between TM16
4
GD535-5 40-375
(01)
Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup) 40 Troubleshooting
40-376 GD535-5
(01)
40 Troubleshooting Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup)
Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup) 1
Action
Failure code Hot short of ECMV solenoid output (Lockup clutch)
code Failure
L03 DXH1KY
As a hot short occurs in the lockup ECMV solenoid system, abnormal voltage is detected when lockup
Detail of failure
ECMV solenoid output is OFF.
Action of
controller
OFF position.
q The lockup clutch is always engaged.
Problem on
q The engine may stop.
machine
q The solenoid may be burnt out.
Related
information
played.

1 Failure of lockup solenoid
harness
Between TM41 (female) (38) and each pin other than pin No conductivity
3 to OFF position.
harness
3. Disconnect connectors TM39 to TM41 and TM16, and connect T-adapters to female
side of TM39 to TM41.
No conductivity
Between TM41 (female) (38) and each pin of TM39 (female)
No conductivity
4
GD535-5 40-377
(01)
Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup) 40 Troubleshooting
40-378 GD535-5
(01)
40 Troubleshooting Failure code [DXH2KA] Disconnection of ECMV Solenoid (High)
Failure code [DXH2KA] Disconnection of ECMV Solenoid (High) 1
Action
Failure code Open circuit of ECMV solenoid output (H-clutch)
code Failure
L03 DXH2KA
Detail of failure No current flows during output to FH-clutch ECMV solenoid.
OFF position.
Problem on
The FH-clutch is not engaged.
machine
Related
information
played.

Failure of FH-clutch 2. Disconnect connector TM2, and connect T-adapter to male side.
1
ECMV solenoid
to OFF position.
2
If resistance is 1 Mz or higher, wiring harness has open circuit. If it is 1 zor below, wiring
to OFF position.
harness
4
GD535-5 40-379
(01)
Failure code [DXH2KA] Disconnection of ECMV Solenoid (High) 40 Troubleshooting
40-380 GD535-5
(01)
40 Troubleshooting Failure code [DXH2KB] Ground Fault of ECMV Solenoid (High)
Failure code [DXH2KB] Ground Fault of ECMV Solenoid (High) 1
Action
Failure code Ground fault of ECMV solenoid output (H-clutch)
code Failure
L03 DXH2KB
Detail of failure Abnormal current flows during output to FH-clutch ECMV solenoid.
OFF position.
Problem on
The FH-clutch is not engaged.
machine
Related
information
played.

1
ECMV solenoid Between TM2 (male) (1) and (2) Resistance 5 to 15 z
to OFF position.
harness
ground
to OFF position.
harness
4
GD535-5 40-381
(01)
Failure code [DXH2KB] Ground Fault of ECMV Solenoid (High) 40 Troubleshooting
40-382 GD535-5
(01)
40 Troubleshooting Failure code [DXH2KY] Hot Short of ECMV Solenoid (High)
Failure code [DXH2KY] Hot Short of ECMV Solenoid (High) 1
Action
Failure code Hot short of ECMV solenoid output (H-clutch)
code Failure
L03 DXH2KY
As a hot short occurs in the FH-clutch ECMV solenoid system, abnormal voltage is detected when FH-
Detail of failure
clutch ECMV solenoid output is OFF.
Action of
controller
OFF position.
Problem on q The FH-clutch is always engaged.
machine q If failure code [1500L0] is detected, the gear is shifted to Neutral position.
Related
information
played.

1
solenoid Between TM2 (male) (1) and (2) Resistance 5 to 15 z
harness
to OFF position.
harness
to OFF position.
3. Disconnect connectors TM39 to TM41 and TM2, and connect T-adapter to female side
of TM39 to TM41.
No conductivity
No conductivity
4
GD535-5 40-383
(01)
Failure code [DXH2KY] Hot Short of ECMV Solenoid (High) 40 Troubleshooting
Circuit diagram related to FH-clutch solenoid
40-384 GD535-5
(01)
40 Troubleshooting Failure code [DXH3KA] Disconnection of ECMV Solenoid (Low)
Failure code [DXH3KA] Disconnection of ECMV Solenoid (Low) 1
Action
Failure code Open circuit of ECMV solenoid output (L-clutch)
code Failure
L03 DXH3KA
Detail of failure No current flows during output to FL-clutch ECMV solenoid.
OFF position.
Problem on
The FL-clutch is not engaged.
machine
tion. (Code: 31607)
Related
information
played.

Failure of FL-clutch 2. Disconnect connector TM4, and connect T-adapter to male side.
1
ECMV solenoid
to OFF position.
2
to OFF position.
harness
4
GD535-5 40-385
(01)
Failure code [DXH3KA] Disconnection of ECMV Solenoid (Low) 40 Troubleshooting
40-386 GD535-5
(01)
40 Troubleshooting Failure code [DXH3KB] Ground Fault of ECMV Solenoid (Low)
Failure code [DXH3KB] Ground Fault of ECMV Solenoid (Low) 1
Action
Failure code Ground fault of ECMV solenoid output (L-clutch)
code Failure
L03 DXH3KB
Detail of failure Abnormal current flows during output to FL-clutch ECMV solenoid.
OFF position.
Problem on
The FL-clutch is not engaged.
machine
tion. (Code: 31607)
Related
information
played.
Procedure: Start engine. + Shift the lever (any of F1, F3, F5, F7 positions).

1
to OFF position.
harness
ground
to OFF position.
harness
4
GD535-5 40-387
(01)
Failure code [DXH3KB] Ground Fault of ECMV Solenoid (Low) 40 Troubleshooting
40-388 GD535-5
(01)
40 Troubleshooting Failure code [DXH3KY] Hot Short of ECMV Solenoid (Low)
Failure code [DXH3KY] Hot Short of ECMV Solenoid (Low) 1
Action
Failure code Hot short of ECMV solenoid output (L-clutch)
code Failure
L03 DXH3KY
As a hot short occurs in the FL-clutch ECMV solenoid system, abnormal voltage is detected when FL-clutch
Detail of failure
Action of
controller
OFF position.
Problem on q The FL-clutch is always engaged.
tion. (Code: 31607)
Related
information
played.

1
to OFF position.
Hot short circuit in wiring
2
harness Since T-adapter is not available for connector R1, perform troubleshooting for short circuit
to OFF position.
3. Disconnect connectors TM39 to TM41 and TM4, and connect T-adapters to female side
of TM39 to TM41.
No conductivity
No conductivity
3
GD535-5 40-389
(01)
Failure code [DXH3KY] Hot Short of ECMV Solenoid (Low) 40 Troubleshooting
Circuit diagram related to FL-clutch solenoid
40-390 GD535-5
(01)
40 Troubleshooting Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st)
Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st) 1
Action
Failure code Open circuit of ECMV solenoid output (1st clutch)
code Failure
L03 DXH4KA
Detail of failure No current flows during output to 1st clutch ECMV solenoid.
OFF position.
Problem on
The 1st clutch is not engaged.
machine
Related
information
played.

Failure of 1st clutch 2. Disconnect connector TM11, and connect T-adapter to male side.
1
ECMV solenoid
to OFF position.
2
to OFF position.
harness
4
GD535-5 40-391
(01)
Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st) 40 Troubleshooting
Circuit diagram related to clutch ECMV
40-392 GD535-5
(01)
40 Troubleshooting Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st)
Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st) 1
Action
Failure code Ground fault of ECMV solenoid output (1st clutch)
code Failure
L03 DXH4KB
Detail of failure Abnormal current flows during output to the 1st clutch ECMV solenoid.
OFF position.
Problem on
The 1st clutch is not engaged.
machine
Related
information
played.

Disconnect connector TM11, and connect T-adapter to male side.
1
to OFF position.
harness
ground
to OFF position.
harness
4
GD535-5 40-393
(01)
Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st) 40 Troubleshooting
40-394 GD535-5
(01)
40 Troubleshooting Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st)
Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st) 1
Action
Failure code Hot short of ECMV solenoid output (1st clutch)
code Failure
L03 DXH4KY
As a hot short occurs in the 1st clutch ECMV solenoid system, abnormal voltage is detected when 1st clutch
Detail of failure
Action of
controller
OFF position.
Problem on q The 1st clutch is always engaged.
Related
information
played.

1
harness
to OFF position.
No conductivity
Between TM41 (female) (5) and each pin other than pin (5)
harness
to OFF position.
No conductivity
No conductivity
4
GD535-5 40-395
(01)
Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st) 40 Troubleshooting
Circuit diagram related to 1st clutch solenoid
40-396 GD535-5
(01)
40 Troubleshooting Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd)
Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd) 1
Action
Failure code Open circuit of ECMV solenoid output (2nd clutch)
code Failure
L03 DXH5KA
Detail of failure No current flows during output to 2nd clutch ECMV solenoid.
OFF position.
Problem on
The 2nd clutch is not engaged.
machine
Related
information
played.

Failure of 2nd clutch 2. Disconnect connector TM6, and connect T-adapter to male side.
1
ECMV solenoid
to OFF position.
2
to OFF position.
harness
4
GD535-5 40-397
(01)
Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd) 40 Troubleshooting
Circuit diagram relating to 2nd clutch ECMV solenoid
40-398 GD535-5
(01)
40 Troubleshooting Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd)
Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd) 1
Action
Failure code Ground fault of ECMV solenoid output (2nd clutch)
code Failure
L03 DXH5KB
Detail of failure Abnormal current flows during output to 2nd clutch ECMV solenoid.
OFF position.
Problem on
The 2nd clutch is not engaged.
machine
Related
information
played.

1
to OFF position.
harness
ground
to OFF position.
harness
4
GD535-5 40-399
(01)
Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd) 40 Troubleshooting
Circuit diagram relating to 2nd clutch ECMV solenoid
40-400 GD535-5
(01)
40 Troubleshooting Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd)
Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd) 1
Action
Failure code Hot short of ECMV solenoid output (2nd clutch)
code Failure
L03 DXH5KY
As a hot short occurs in the 2nd clutch ECMV solenoid system, abnormal voltage is detected when 2nd
Detail of failure
Action of
controller
OFF position.
Problem on q The 2nd clutch is always engaged.
Related
information
played.

1
harness
to OFF position.
harness
to OFF position.
of TM39 to TM41.
No conductivity
No conductivity
4
GD535-5 40-401
(01)
Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd) 40 Troubleshooting
Circuit diagram related to 2nd clutch solenoid
40-402 GD535-5
(01)
40 Troubleshooting Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd)
Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd) 1
Action
Failure code Open circuit of ECMV solenoid output (3rd clutch)
code Failure
L03 DXH6KA
Detail of failure No current flows during output to 3rd clutch ECMV solenoid.
OFF position.
Problem on
The 3rd clutch is not engaged.
machine
Related
information
played.

Failure of 3rd clutch 2. Disconnect connector TM8, and connect T-adapter to male side.
1
ECMV solenoid
to OFF position.
2
to OFF position.
harness
4
GD535-5 40-403
(01)
Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd) 40 Troubleshooting
Circuit diagram relating to 3rd clutch ECMV solenoid
40-404 GD535-5
(01)
40 Troubleshooting Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd)
Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd) 1
Action
Failure code Ground fault of ECMV solenoid output (3rd clutch)
code Failure
L03 DXH6KB
Detail of failure Abnormal current flows during output to 3rd clutch ECMV solenoid.
OFF position.
Problem on
The 3rd clutch is not engaged.
machine
Related
information
played.

1
to OFF position.
harness
ground
to OFF position.
harness
4
GD535-5 40-405
(01)
Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd) 40 Troubleshooting
Circuit diagram relating to 3rd clutch ECMV solenoid
40-406 GD535-5
(01)
40 Troubleshooting Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd)
Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd) 1
Action
Failure code Hot short of ECMV solenoid output (3rd clutch)
code Failure
L03 DXH6KY
As a hot short occurs in the 3rd clutch ECMV solenoid system, abnormal voltage is detected when 3rd
Detail of failure
Action of
controller
OFF position.
Problem on q The 3rd clutch is always engaged.
played. Procedure: Turn starting switch to ON position.

1
harness
to OFF position.
3 1. Turn starting switch to OFF position.
harness
to OFF position.
of TM39 to TM41.
No conductivity
No conductivity
4
GD535-5 40-407
(01)
Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd) 40 Troubleshooting
Circuit diagram related to 3rd clutch solenoid
40-408 GD535-5
(01)
40 Troubleshooting Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse)
Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse) 1
Action
Failure code Open circuit of ECMV solenoid output (Reverse clutch)
code Failure
L03 DXH7KA
Detail of failure No current flows during output to clutch ECMV solenoid.
OFF position.
Problem on
The R clutch is not engaged.
machine
q The output current command value to the R-clutch ECMV solenoid can be checked with monitoring
Related
information
played.

Failure of R clutch ECMV 2. Disconnect connector TM13, and connect T-adapter to male side.
1
solenoid
to OFF position.
2
If resistance is 1 Mzor higher, wiring harness has open circuit. If it is 1 z or below, wiring
to OFF position.
harness
4
GD535-5 40-409
(01)
Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse) 40 Troubleshooting
Circuit diagram related to R clutch ECMV
40-410 GD535-5
(01)
40 Troubleshooting Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse)
Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse) 1
Action
Failure code Ground fault of ECMV solenoid output (Reverse clutch)
code Failure
L03 DXH7KB
Detail of failure Abnormal current flows during output to R clutch ECMV solenoid.
OFF position.
Problem on
The R clutch is not engaged.
machine
tion. (Code: 31606)
Related
information
played.

Failure of R clutch ECMV
1
to OFF position.
harness
ground
to OFF position.
harness
4
GD535-5 40-411
(01)
Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse) 40 Troubleshooting
Circuit diagram related to R clutch ECMV
40-412 GD535-5
(01)
40 Troubleshooting Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse)
Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse) 1
Action
Failure code Hot short of ECMV solenoid output (Reverse clutch)
code Failure
L03 DXH7KY
As a hot short occurs in the R clutch ECMV solenoid system, abnormal voltage is detected when R clutch
Detail of failure
Action of
controller
OFF position.
Problem on q The R clutch is always engaged.
tion. (Code: 31606)
Related
information
played.

Failure of R clutch
1
harness
to OFF position.
harness
to OFF position.
No conductivity
No conductivity
4
GD535-5 40-413
(01)
Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse) 40 Troubleshooting
Circuit diagram related to R clutch solenoid
40-414 GD535-5
(01)
40 Troubleshooting Failure code [DXHHKA] Disconnection of ECMV Solenoid (4th)
Failure code [DXHHKA] Disconnection of ECMV Solenoid (4th) 1
Action
Failure code Open circuit of ECMV solenoid output (4th clutch)
code Failure
L03 DXHHKA
Detail of failure No current flows during output to 4th clutch ECMV solenoid.
OFF position.
Problem on
The 4th clutch is not engaged.
machine
Related
information
played.

Failure of 4th clutch 2. Disconnect connector TM15, and connect T-adapter to male side.
1
to OFF position.
2
to OFF position.
harness
4
GD535-5 40-415
(01)
Failure code [DXHHKA] Disconnection of ECMV Solenoid (4th) 40 Troubleshooting
Circuit diagram relating to 4th clutch ECMV solenoid
40-416 GD535-5
(01)
40 Troubleshooting Failure code [DXHHKB] Ground Fault of ECMV Solenoid (4th)
Failure code [DXHHKB] Ground Fault of ECMV Solenoid (4th) 1
Action
Failure code Ground fault of ECMV solenoid output (4th clutch)
code Failure
L03 DXHHKB
Detail of failure Abnormal current flows during output to 4th clutch ECMV solenoid.
OFF position.
Problem on
The 4th clutch is not engaged.
machine
Related
information
played.

to OFF position.
ECMV solenoid system 3. Disconnect connector TM15, and connect T-adapter to male side.
to OFF position.
harness
ground
to OFF position.
harness
4
GD535-5 40-417
(01)
Failure code [DXHHKB] Ground Fault of ECMV Solenoid (4th) 40 Troubleshooting
Circuit diagram relating to 4th clutch ECMV solenoid
40-418 GD535-5
(01)
40 Troubleshooting Failure code [DXHHKY] Hot Short of ECMV Solenoid (4th)
Failure code [DXHHKY] Hot Short of ECMV Solenoid (4th) 1
Action
Failure code Ground fault of ECMV solenoid output (4th clutch)
code Failure
L03 DXHHKY
As a hot short occurs in the 4th clutch ECMV solenoid system, abnormal voltage is detected when 4th
Detail of failure
Action of
controller
OFF position.
Problem on q The 4th clutch is always engaged.
Related
information
played.

1
solenoid system Between TM15 (male) (1) and (2) Resistance 5 to 15 z
harness
to OFF position.
harness
to OFF position.
No conductivity
No conductivity
4
GD535-5 40-419
(01)
Failure code [DXHHKY] Hot Short of ECMV Solenoid (4th) 40 Troubleshooting
Circuit diagram related to 4th clutch solenoid
40-420 GD535-5
(01)
40 Troubleshooting E-1 Engine does not start (Starting motor does not rotate).
Troubleshooting of electrical system (E-mode) 1
E-1 Engine does not start (Starting motor does not rotate). 1
Failure Starting motor does not rotate, and engine does not start.
q Since the engine start circuit has the neutral safety function, the engine does not start unless the gear
shift lever is in Parking position.
q Before performing troubleshooting, check that no related failure code is displayed.
(If failure code [DDB6L4], [DF10KA] or [DF10L4] is also displayed, perform troubleshooting for it first.)
q If failure symptom is "Battery relay operation sound is not heard" when starting switch is turned to ON
position, perform troubleshooting for E-1 as well.
q Flow of safety circuit by the shift lever (Parking position detection)
Output of shift lever (P) output (Parking position: 24 V; Other than P position: 0 V)
---> Diode SP35
Related
---> Between safety relay SP17 (15) C input and (3) 24V output:
information
ON (Parking position) / OFF (Other than parking position)
q Flow of starting switch C signal
C signal (ST8 terminal) ---> Safety relay: SP17(5) input, (3) output --->
Engine cut relay SP32 (6) input, (3) output --->
---> Diode R28 or R29
---> Safety relay E01
---> Turn ON input E20 terminal and output E19 terminal.
---> Flow current (from slow-blow fuse E31 terminal) to the starting motor C terminal (E21 terminal).
q Check the diode before checking the shift lever.

Blown slow-blow fuse
If slow-blow fuse has blown, the circuit may be shorted to ground. In this case, perform
1 (Holder 2 120A, 120A,
check on cause 14 first.
Holder 1 30A)
Blown fuse FB1 (2) (11) or If fuse No. 2, No. 11 or No. 15 of FB1 fuse box is blown, the circuit may be shorted to
2
(15) ground. In this case, perform check on cause 14 first.
Loose terminal or open
3 Check the battery relay, alternator, starting motor, each GND (FT11, FT13) terminal and
circuit in terminal
others.
Insufficient battery Battery voltage Min. 24 V

4
capacity Specific gravity of battery Min. 1.26
2. Replace safety relay SP17 with another relay (for example, stop lamp relay SP16)
5 Defective safety relay 3. Start engine.
If engine starts, original safety relay SP17 is defective.
2. Replace engine cut relay SP32 with another relay (for example, stop lamp relay SP16)
6 Failure of engine cut relay 3. Start engine.
If engine starts, original cut relay SP32 is defective.

2. Disconnect connectors R28, R29, R18 and R19, and connect T-adapters to each
diode.
7 Defective diode Measure in the diode range of multimeter.
Between each diode (male) (1) (+) and (2) (-) No continuity
Between each diode (male) (2) (-) and (1) (-) Conductive
GD535-5 40-421
(01)
E-1 Engine does not start (Starting motor does not rotate). 40 Troubleshooting

8 Failure of gear shift lever
"P" is displayed on machine Lever position: FREE Other than "P"
monitor. P position "P" display
to OFF position.
3. Disconnect terminals ST6 to 9. (Put an identification mark at the destination point.)
4. Turn starting switch to OFF, ON and START positions, and perform troubleshooting.
9 Defective starting switch OFF Resistance Min. 1 Mz

Between terminals ST6 and ST7
ON Resistance Max. 1 z
OFF Resistance Min. 1 Mz
ON Resistance Max. 1 z
OFF Resistance Min. 1 Mz
START Resistance Max. 1 z
10 Defective alternator
Between terminal R and ground Voltage Max. 1 V
2. Insert T-adapter into connector E01.
3. Turn starting switch to ON and START positions, and perform troubleshooting.
Power supply: Between terminal E30 (B)
ON Voltage 20 to 30 V
and ground
11 Defective starting motor Power supply: Between terminal E01 (2) (R)
ON Voltage Max. 1 V
and ground
Power supply: Between terminal E21 (C)
START Voltage 20 to 30 V
and ground
If voltage of power supply, charging, and starting devices is normal but starting motor
does not rotate, the starting motor is defective.
Battery relay
Between terminal ET76 and ground Resistance Max. 1 z
Battery relay
Open circuit in wiring Check the 24V line and locate the open circuit.
12
harness
Between terminal ST7 and ground Voltage 20 to 30 V
Between terminal ET75 and ground Voltage 20 to 30 V
Between secondary input terminal of battery relay and
Voltage 20 to 30 V
ground
Between secondary output terminal of battery relay and
Voltage 20 to 30 V
ground
40-422 GD535-5
(01)
40 Troubleshooting E-1 Engine does not start (Starting motor does not rotate).

Alternator, starting motor
to OFF position.
3. Insert T-adapters into connectors SP17, SP32, E01 and R28.
5. Make sure that shift lever is in "P" position.
6. Turn starting switch to START positions, and perform troubleshooting.
Check the 24V line and locate the open circuit.
Between terminal ST8 and ground Voltage 20 to 30 V
12
harness Between SP17 (1) and ground Voltage 20 to 30 V
Between SP32 (6) and ground Voltage 20 to 30 V
Between R28 (2) and ground Voltage 20 to 30 V
Between E01 (1) and ground Voltage 20 to 30 V
Between alternator B terminal and ground Voltage 20 to 30 V
Between terminal E30 and ground Voltage 20 to 30 V
Primary circuit of relay SP17
2. Insert T-adapter into connector SP17.
Check ground terminal FT11 for looseness and rusting.
Between SP17 (2) and ground Resistance Max. 1 z
When checking the battery relay for cause 12 and if only the voltage is abnormal at
13 Defective battery relay
secondary output terminal of battery relay, the battery relay is defective.
2. Disconnect the battery ground, battery relay terminal ET75, and battery relay
Ground fault in wiring secondary output terminal.
14
harness Between ST7 and ground Resistance Min. 1 Mz
Between ST8 and ground Resistance Min. 1 Mz
Between ET75 (wiring harness side) and ground Resistance Min. 1 Mz
2. Disconnect connector E01, and connect T-adapter to female side.
Hot short circuit in wiring 3. Disconnect cable from R terminal of alternator.
harness
If a hot short occurs, the charge lamp lights when starting switch is turned to ON position.
Between E01 (female) (2) and ground Voltage Max. 1 V
to OFF position.
Failure of transmission 3. Disconnect connector TM41.
16
controller 4. Turn the battery disconnect switch to ON position.
5. Turn the starting switch to START position.
If the starting motor rotates, the transmission controller is defective.
GD535-5 40-423
(01)
E-1 Engine does not start (Starting motor does not rotate). 40 Troubleshooting
Circuit diagram related to engine starting system
40-424 GD535-5
(01)
40 Troubleshooting E-2 Manual preheating system does not work
E-2 Manual preheating system does not work 1
Failure 1) Manual preheating system does not work.

q This troubleshooting describes procedures to be followed when manual preheating does not function to
heat the intake air heater mounting section.
q This machine has "Automatic preheating" and "Manual preheating" functions. When either preheating
works, preheating monitor lights up.
q (When only preheating monitor does not light up, perform troubleshooting for "3) While preheating is
Related working, preheating monitor does not light up").
information q If failure symptom "Machine monitor displays nothing" or "Battery relay does not make operating sound"
appears when starting switch is turned to ON position, main electric power supply system may be defec-
tive. In these cases, perform troubleshooting for E-3 and E-1 respectively.
q Before performing troubleshooting, check that no related failure code is displayed.
(If failure code [CA153], [CA154] or [CA2555] or [CA2556] is also displayed, perform troubleshooting for
it first.)

Loose terminal or open 1. Turn the starting switch to OFF position.

2
circuit in terminal Check terminals of heater relay, battery relay ground ET77, etc.
2. Disconnect connectors R31, and connect T-adapter to the diode.
Measure in the diode range of multimeter.
3 Defective diode
Between R31 (male) (1) (+) and (2) (-) No continuity
Between R31 (male) (2) (+) and (1) (-) Conductive
2. Disconnect terminal E07.
4 Defective intake air heater
Between E07 terminal (electrical intake air heater side) and
Conductive
ground
to OFF position.
5 Defective starting switch battery negative (-) terminal.)
3. Turn starting switch to OFF and the HEAT positions to perform troubleshooting.
Between terminal ST6 and terminal ST10 OFF Resistance Min. 1 Mz

both at switch side) HEAT Resistance Max. 1 z
Between terminal ST10 and ground Conductive
Open circuit or ground Between heater relay terminal A and ground Voltage 20 to 30 V
6
fault in wiring harness 1. Turn the starting switch to OFF position.
2. Disconnect terminal ET54.
To prevent current from flowing through heater when starting switch is turned to HEAT
position
3. Turn starting switch to HEAT position (R1 connection).
Between terminal ET82 and ground Voltage 20 to 30 V
GD535-5 40-425
(01)
E-2 Manual preheating system does not work 40 Troubleshooting

Ground fault in wiring 2. Disconnect connectors TM39 and R31 and terminals ET82 and E31.
7
harness
Between heater relay terminal A and ground Resistance Min. 1 Mz
Between terminal ET82 (wiring harness side) and ground Resistance Min. 1 Mz
If no failure is found by check on cause 6 and if heater relay operation sound is not heard,
8 Defective heater relay
heater relay is defective.
Circuit diagram related to engine preheat system
40-426 GD535-5
(01)
Failure 2) Automatic preheating system does not work.

q Automatic preheating starts when charge temperature is below -4°C
q The charge temperature can be checked by using the monitoring code (Code: 18500).
Related
q If automatic preheating function does not work, make sure that the manual preheating function works.
information
q Engine controller checks primary (coil) side of preheat relay SP40 by reading failure code [CA2555] and
[CA2556].

1 Blown fuse
2. Replace preheat relay SP40 with stop lamp relay SP16.
2 Defective preheat relay 3. Turn starting switch to ON position.
If automatic preheating functions when charge temperature is below -4°C, original
preheat relay SP40 is defective.
Open circuit or ground q If resistance is 1 Mz or higher, wiring harness has open circuit. If it is below 1 z, wiring
q Resistance of preheat relay coil
Between EC2 (female) (40) and ground Resistance 200 to 400 z
2. Disconnect connectors SP40 and TM39, and connect T-adapter to female side of
SP40.
Open circuit in wiring 3. Remove fuse No. 4 of FB2 fuse box.
4
harness
Between SP40 (female) (5) and ground Continuity
Between SP40 (female) (3) and FB2 (4) Resistance Max. 1 z
Ground fault in wiring 2. Disconnect connector SP40, and connect T-adapter to female side.
5
harness 3. Remove fuse No. 4 of FB2 fuse box.
Between SP40 (female) (3) and ground Resistance Min. 1 Mz
GD535-5 40-427
(01)
40-428 GD535-5
(01)
Failure 3) While preheating is working, preheating monitor does not light up.
q This machine has "Automatic preheating" and "Manual preheating" functions. When either preheating
works, preheating monitor lights up.
Related
q The preheating information of transmission controller is transmitted to machine monitor through CAN
information
communication.
q For the related circuit diagram, see the previous page.

2. Disconnect connectors SP40 and TM39, and connect T-adapter to each female side.
1
harness Between SP40 (female) (5) and TM39 (female) (5) Resistance Max. 1 z
Between terminal ST10 and TM39 (female) (5) Resistance Max. 1 z
Ground fault in wiring 2. Disconnect connector TM39 and terminal ET82, and connect T-adapter to female side
2 of TM39.
harness
If no failure is found by above checks, transmission controller is defective. (Since this is
an internal defect, troubleshooting cannot be performed.)
Reference
3 3. Disconnect terminal ET54.
controller
a To prevent current from flowing through heater when starting switch is turned to HEAT
position
4. Turn starting switch to HEAT position.
GD535-5 40-429
(01)
40-430 GD535-5
(01)
40 Troubleshooting E-3 When starting switch is turned ON, machine monitor displays nothing.
E-3 When starting switch is turned ON, machine monitor displays nothing.1
Failure When starting switch is turned to ON position, machine monitor displays nothing.
q When starting switch is turned to ON position, machine monitor displays KOMATSU logo, screen to input
password (if set), and standard screen in that order.
Related
q When engine is started, the battery voltage may quickly drop according to the temperature and battery
information
conditions. In such case, the display on the machine monitor may disappear temporarily, but this is not
a problem.

1 Blown slow-blow fuse
If fuses No. 1 and No. 2 of FB1 fuse box are blown, the circuit may be shorted to ground.
2 Blown fuse
In this case, perform check on cause 8 first.
Loose terminal or open 1. Turn the starting switch to OFF position.

3
circuit in terminal Check terminals of battery relay, battery, etc.
Insufficient battery
4 Battery voltage (2 cells) Min. 24 V
capacity
Specific gravity of battery Min. 1.26
to OFF position.
Open circuit or ground 4. Turn the battery disconnect switch to ON position.
5 fault of wiring harness, or (When the battery disconnect switch is not installed, connect the cable to the battery
defective starting switch negative (-) terminal.)
If voltage is 0 V, it has open-circuit or ground fault.
Between FP1 (female) (6) and (2) Voltage 20 to 30 V
Starting switch ON (ACC connection)
Between FP1 (female) (3) and (2) Voltage 20 to 30 V
to OFF position.
6 Defective starting switch
3. Disconnect terminals ST6 and ST9.
4. Turn starting switch to ON and OFF positions, and perform troubleshooting.
Between terminals ST6 and ST9 OFF Resistance Min. 1 Mz

(Starting switch side) ON Resistance Max. 1 z
GD535-5 40-431
(01)
E-3 When starting switch is turned ON, machine monitor displays nothing. 40 Troubleshooting

to OFF position.
3. If fuse is blown, replace it in advance.
7 Between FP1 (female) (2) or (7) and ground
harness
Resistance Max. 1 z
Check terminal ET89 for looseness and rusting.
Between FP1 (female) (1) and battery positive (+) terminal Resistance Max. 1 z
5. Turn starting switch to ON position. (Disconnect cable from negative (-) battery
terminal, and connect ACC.)
Between FP1 (female) (3) and battery positive (+) terminal Resistance Max. 1 z
to OFF position.
Ground fault in wiring 3. If fuse is blown, replace it in advance.
8
harness 4. Disconnect connector FP1, and connect T-adapter to female side.
5. Perform troubleshooting with the starting switch ON and OFF positions (with the
battery disconnect switch kept OFF).
(When the battery disconnect switch is not installed, perform troubleshooting with the
cable disconnected from battery negative (-) terminal.)
Between FP1 (female) (3) and ground Resistance Min. 1 Mz
If no failure is found by above checks, the machine monitor is defective. (Since this is an
9 Defective machine monitor
40-432 GD535-5
(01)
40 Troubleshooting E-3 When starting switch is turned ON, machine monitor displays nothing.
Circuit diagram related to Machine monitor
GD535-5 40-433
(01)
E-4 LCD panel backlight of machine monitor fails (goes out or flickers). 40 Troubleshooting
E-4 LCD panel backlight of machine monitor fails (goes out or flickers). 1
Failure The LCD panel backlight of machine monitor fails (goes out or flickers).
Related
information

Machine monitor may be defective. (Since this is an internal defect, troubleshooting
cannot be performed.)
40-434 GD535-5
(01)
40 Troubleshooting E-5 LCD display failure of machine monitor
E-5 LCD display failure of machine monitor 1
Failure LCD display failure of machine monitor

Related
information

GD535-5 40-435
(01)
E-6 The switch of machine monitor switch panel does not work. 40 Troubleshooting
E-6 The switch of machine monitor switch panel does not work. 1
Failure The switch of machine monitor switch panel does not work.
Related
information

40-436 GD535-5
(01)
40 Troubleshooting E-7 Two-switch operation of switch panel on machine monitor does not function.
E-7 Two-switch operation of switch panel on machine monitor does not

function. 1
Failure 2 switches operation of switch panel on machine monitor does not function
Related
information

GD535-5 40-437
(01)
E-8 Machine monitor buzzer does not sound. 40 Troubleshooting
E-8 Machine monitor buzzer does not sound. 1
Failure The machine monitor buzzer does not sound, or it continues to sound.
Related
information

40-438 GD535-5
(01)
40 Troubleshooting E-9 Some gauges or caution lamps of machine monitor do not work normally.
E-9 Some gauges or caution lamps of machine monitor do not work

normally. 1
Failure Some gauges or lamps do not work normally.

Related
Check to see that failure code relating to the machine is not displayed.
information

Some sensors or switches
1 Troubleshoot sensors or switches by referring to the failure code.
have failed.
Failure of CAN
2 Perform troubleshooting by referring to the CAN communication failure code.
communication circuit
GD535-5 40-439
(01)
E-10 Rearview monitor does not light up or backlight flickers. 40 Troubleshooting
E-10 Rearview monitor does not light up or backlight flickers. 1
Failure Rearview monitor does not light up or backlight flickers.

Related
information

If fuse No.1 in fuse box FB1 is blown out, the circuit probably has ground fault. Perform
1 Defective fuse
troubleshooting for “ground fault in wiring harness” first.
to OFF position.
Defective wiring harness 3. Visually check connector (RVM1, RVM2) connected to rearview monitor, and repeat
2 connection and disconnection of connector.
connector
If normal state is restored, cause of failure is defective contact of connector.
to OFF position.
3. Disconnect connector RVM1, and connect T-adapter to female side.
Open circuit in wiring Between RVM1 (female) (1) and (2) 20 to 30 V
3 harness (wire breakage or Voltage
defective contact) Between RVM1 (female) (12) and (2) 20 to 30 V
to OFF position.
3. Disconnect connector RVM1 and connect T-adapter to female side.
4. Remove fuse No.1 in fuse box FB1.
Between RVM1 (female) (1) and FB1-1 Max. 1 Ω
Resistance
Between RVM1 (female) (2) and ground Max. 1 Ω
to OFF position.
ground circuit) 3. Disconnect connector RVM1, and connect T-adapter to female side.
Resistance Between ground and RVM1 (female) (1) or FB1-1 Min. 1 MΩ
5 Defective rearview monitor If no failure is found by preceding checks, rearview monitor is defective.
40-440 GD535-5
(01)
40 Troubleshooting E-10 Rearview monitor does not light up or backlight flickers.
Circuit diagram related to rearview monitor power supply
GD535-5 40-441
(01)
E-11 Rearview monitor images are not displayed clearly 40 Troubleshooting
E-11 Rearview monitor images are not displayed clearly 1
Failure Rearview monitor images are not displayed clearly.

Related Since T-adapter for monitor controller connector is “socket-type box”, operating voltage cannot be
information measured at monitor controller connector.

to OFF position.
connector
to OFF position.
Open circuit in wiring Between RVM1 (female) (1) and (2) 20 to 30 V
2 harness (wire breakage or Voltage
defective contact) Between RVM1 (female) (12) and (2) 20 to 30 V
to OFF position.
3. Disconnect connector RVM1 and connect T-adapter to female side.
Between RVM1 (female) (1) and FB1-1 Max. 1 Ω
Resistance
Between RVM1 (female) (2) and ground Max. 1 Ω
to OFF position.
3. Insert T-adapter into connector RVM1.
4. Disconnect connector RVM2, and connect T-adapter to male side.
3 Defective rearview monitor 5. Turn the battery disconnect switch to ON position.
Between RVM2 (male) (1) and RVM1 (2) 8 ± 0.8 V
Voltage Between RVM2 (male) (5) and RVM1 (2) Max. 0.2 V
Between RVM2 (male) (8) and RVM1 (2) Max. 0.2 V
40-442 GD535-5
(01)
40 Troubleshooting E-11 Rearview monitor images are not displayed clearly

2. Disconnect connector RL11, and connect T-adapter to female side.
Voltage Between RL11 (female) (1) and (4) 8 ± 0.8 V
Open circuit in wiring 1. Turn the starting switch to OFF position.

4 harness (wire breakage or 2. Disconnect connectors RL11 and RVM2, and connect T-adapter to each female side.
defective contact) 3. Turn the starting switch to ON position.
Between RL11 (female) (1) and RVM2 (female) (1) Max. 1 Ω
Resistance
Between RL11 (female) (2) and RVM2 (female) (2) Max. 1 Ω
Between RL11 (female) (4) and each of RVM2 (female) (5)
and (8) Max. 1 Ω
5 Defective rearview camera If no failure is found by preceding checks, rearview camera may be defective.
6 Defective rearview monitor If no failure is found by preceding checks, rearview monitor may be defective.
GD535-5 40-443
(01)
E-12 Rearview monitor brightness cannot be adjusted 40 Troubleshooting
E-12 Rearview monitor brightness cannot be adjusted 1
Failure Rearview monitor brightness cannot be adjusted.

Related
information

If fuse No.12 in fuse box FB2 is blown out, the circuit probably has ground fault.
1 Defective fuse
Perform troubleshooting for “ground fault in wiring harness” first.
to OFF position.
3. Visually check connector (RVM1, RVM2) connected to rearview monitor, and repeat
connection and disconnection of connector.
Defective wiring harness If normal state is restored, cause of failure is defective contact of connector.
2
connector 1. Turn the starting switch to OFF position.
to OFF position.
3. Visually check connector C33 connected to brightness switch, and repeat connection
and disconnection of connector.
If normal state is restored, cause of failure is defective contact of connector
40-444 GD535-5
(01)
40 Troubleshooting E-12 Rearview monitor brightness cannot be adjusted

to OFF position.
Between RVM1 (female) (5) Brightness adjustment
Max. 0.2 V
and (2) switch (+): OFF
20 to 30 V
and (2) switch (+): ON
3 harness (wire breakage or Between RVM1 (female) (6) Brightness adjustment
Max. 0.2 V
defective contact) and (2) switch (-): OFF
20 to 30 V
and (2) switch (-): ON
If no failure is found by preceding checks, this check is not required.
to OFF position.
3. Disconnect connectors RVM1 and C33, and connect T-adapter to each female side.
Between C33 (female) (5) and FB2-12 Max. 1 Ω
Resistance Between C33 (female) (4) and RVM1 (female) (6) Max. 1 Ω
Between C33 (female) (6) and RVM1 (female) (5) Max. 1 Ω
4 Defective rearview monitor If no failure is found by preceding checks, rearview monitor is defective.
to OFF position.
Ground fault in wiring 3. Disconnect connectors RVM1 and C33, and connect T-adapter to female side of
5 harness (contact with connector C33.
ground circuit) 4. Remove fuse No.12 in fuse box FB2.
Between ground and C33 (female) (5) or FB2-12 Min. 1 MΩ
Resistance Between C33 (female) (4) and ground Min. 1 MΩ
Between C33 (female) (6) and ground Min. 1 MΩ
2. Disconnect connector C33, and insert T-adapter.
Brightness adjustment
Between C33 (5) and (4) Min. 1 MΩ
switch (+): OFF
Defective brightness Brightness adjustment
6
adjustment switch
Between C33 (5) and (4)
switch (+): ON Max. 1 Ω
Resistance
Between C33 (5) and (6) Min. 1 MΩ
switch (-): OFF
switch (-): ON Max. 1 Ω
GD535-5 40-445
(01)
E-12 Rearview monitor brightness cannot be adjusted 40 Troubleshooting
Circuit diagram related to brightness adjustment switch of rearview monitor
40-446 GD535-5
(01)
40 Troubleshooting E-13 Night lighting lamp of rearview monitor is abnormal
E-13 Night lighting lamp of rearview monitor is abnormal 1
Failure Night lighting lamp of rearview monitor is abnormal.

q Night lighting lamp of rearview monitor lights up only when clearance lamp is turned on while monitor
Related
brightness selector switch is at the night mode.
information
q Check if night lighting lamp of meter unit of machine monitor is abnormal.

to OFF position.
connector
If night lighting lamp of meter unit lights up, this check is not required.
2. Disconnect connector RVS2, and connect T-adapter to female side.
Defective monitor
2 brightness selector (night Between RVS2 (female) (5) Turn the brightness selector
lighting) switch and (4) switch to OFF position Min. 1 MΩ
Resistance
Between RVS2 (female) (5) Turn the brightness selector
and (4) switch to ON position Max. 1 Ω

to OFF position.
6. Clearance lamp lights up.
Between RVM1 (8) and (2) Night lighting switch: OFF Max. 0.2 V
3 harness (wire breakage or Between RVM1 (8) and (2) Night lighting switch: ON 20 to 30 V
defective contact)
If no failure is found by preceding checks, this check is not required.
to OFF position.
3. Disconnect connectors RVM1, RVS2, and SP42, and connect T-adapter to each
female side.
Between RVS2 (female) (4) and RVM1 (female) (8) Max. 1 Ω
Resistance Between SP42 (female) (5) and RVS2 (female) (5) Max. 1 Ω
Between SP42 (female) (1) and SP22 (female) (4) Max. 1 Ω
GD535-5 40-447
(01)
E-13 Night lighting lamp of rearview monitor is abnormal 40 Troubleshooting

4 Defective rearview monitor 2. Turn the starting switch to ON position.
3. Turn on night lighting switch.
If night lighting display of LCD unit, LED unit, and switch panel of machine monitor
are normal, rearview monitor is defective.
Circuit diagram related to night lighting switch of rearview monitor
40-448 GD535-5
(01)
40 Troubleshooting E-14 Speedometer or engine speed display is abnormal.
E-14 Speedometer or engine speed display is abnormal. 1
Failure 1) Speedometer display is abnormal.

Related The source information of the speedometer (the signal of transmission output shaft speed sensor) is
information received from transmission controller through CAN communication.

An error occurred in the
1 transmission output shaft If failure code [DLT3KA] is displayed, perform troubleshooting for it first.
speed sensor system.
If failure code [15K0MW], [15L0MW], [15M0MW] or [15N0MW] is displayed, perform
2 Clutch slipping
troubleshooting for it first.
If no failure is found by check on cause 1, machine monitor may be defective. (Since this
is an internal defect, troubleshooting cannot be performed.)
Failure of transmission If no failure is found by checks on cause 1, transmission controller may be defective.
4
Failure 2) Speedometer display pilot lamp does not work normally.

q The signal of speedometer display pilot lamp is processed in the machine monitor.
Related
q The speedometer display pilot lamp lights during "km/h" display mode, and the speed step is displayed
information
during "MPH" display mode.

Failure 3) Engine speed display is abnormal.

q The engine speed information (the signal of engine Ne speed sensor) is received by machine monitor
Related through CAN communication from engine controller.
information q Engine speed can be checked with monitoring function.
(Code: 01002)

An error occurred in
1 engine Ne speed sensor If failure code [CA238] is displayed, perform troubleshooting for it first.
system
If no failure is found by checks on cause 1, engine controller may be defective. (Since this
3 Defective engine controller
GD535-5 40-449
(01)
E-15 Engine coolant temperature is displayed abnormally. 40 Troubleshooting
E-15 Engine coolant temperature is displayed abnormally. 1
1) While coolant temperature is rising normally, it does not rise from white range (C).
Failure
2) While coolant temperature is stabilized normally, it rises to red range (H).
q Signal voltage of coolant temperature sensor is input to engine controller, and then it is transmitted to
Related machine monitor through CAN communication system.
information q Coolant temperature can be checked with monitoring function.
(Code: 04107)

Defective engine coolant
Coolant temperature sensor system may be defective. Perform troubleshooting for failure
codes [CA144] and [CA145].
system
If no failure is found by check on Cause 1, machine monitor may be defective.
(Since this is an internal defect, troubleshooting cannot be performed.)
3) Coolant temperature is different from indication of engine coolant temperature gauge.

Failure 4) Indication of engine coolant temperature gauge is different from indication of coolant temperature
monitor.
q Signal voltage of coolant temperature sensor is input to engine controller, and then it is transmitted to
Related machine monitor through CAN communication system.
information q Coolant temperature can be checked with monitoring function.
(Code: 04107)

Turn starting switch to ON position or start engine, and perform troubleshooting.
Coolant temperature gauge Coolant temperature gauge
Engine coolant temperature
level color
Min. 135.0°C 10 or less is lit.

Red (R)
102.0 to 134.9°C 9 or less is lit.
1 Defective machine monitor 89.0 to 95.9°C 7 or less is lit.

Green (G)

White (W)
Max. 49.9°C Only 1 is lit.
40-450 GD535-5
(01)
40 Troubleshooting E-15 Engine coolant temperature is displayed abnormally.
Engine coolant temperature gauge and coolant temperature monitor
GD535-5 40-451
(01)
E-16 Articulated meter display is abnormal. 40 Troubleshooting
E-16 Articulated meter display is abnormal. 1
Failure 1) Articulated meter display is abnormal.

q If an error occurs in articulated angle sensor system, failure code [DKD0KX] may be displayed and re-
corded.
Related
q The articulated meter information (articulated angle sensor signal) is received by transmission controller
information
through CAN communication.
q Input voltage from articulated angle sensor can be checked with monitoring function. (Code: 43900)

1 articulated angle sensor Perform troubleshooting for failure code [DKD0KX].
system.
40-452 GD535-5
(01)
40 Troubleshooting E-16 Articulated meter display is abnormal.
Failure 2) Articulated meter display is incorrect.

Related
information

Zero-point adjustment Perform zero-point adjustment of articulated meter by referring to Testing and adjusting,
1
failure "Tuning " of "Special function of machine monitor".
Start engine, change the articulated angle, and diagnose the articulated (body) angle.
Articulated level Articulated angle sensor
Articulated (body) angle
(Pointer position) (Output voltage)
- Min. 3.75 V -25° and above (Abnormal)
7 Min. 3.7 V -23° and above
6 2.6 to 2.8 V -5° to -8°
5 2.5 to 2.6 V -2° to -5°
4 2.2 to 2.5 V ± 2°
3 2.0 to 2.2 V 2° to 5°
2 1.9 to 2.0 V 5° to 8°
1 Max. 2 V 23° and above
- Max. 1.1 V -25° and above (Abnormal)
Articulated level meter
GD535-5 40-453
(01)
E-17 Torque converter oil temperature is displayed abnormally. 40 Troubleshooting
E-17 Torque converter oil temperature is displayed abnormally. 1
1) While torque converter oil temperature is rising normally, it does not rise from white range (C).
Failure
2) While torque converter oil temperature is stabilized normally, it rises to red range (H).
q If an error occurs in torque converter oil sensor system, failure code [DGT1KX] may be displayed and
recorded.
q Information of torque converter oil temperature gauge (signal of torque converter oil temperature sensor)
Related
is received by machine monitor through CAN communication from transmission controller.
information
q The input voltage sent from torque converter oil temperature sensor can be checked by the monitoring
function.
(Code: 30101)

torque converter oil
1 Perform troubleshooting for failure code [DGT1KX].
temperature sensor
system.
Failure of transmission If no failure is found by checks on cause 1, transmission controller may be defective.
3
3) Display of torque converter oil temperature and torque converter oil temperature gauge does not match.
Failure 4) Display of torque converter oil temperature gauge and torque converter oil temperature caution lamp
does not match.
Related
The torque converter oil temperature caution lamp lights at 120°C or more.
information

Turn starting switch to ON position or start engine, and perform troubleshooting.
Torque converter oil Torque converter oil
Oil temperature gauge color
temperature gauge level temperature
10 or less is lit. Min. 135.0°C
Red (R)
9 or less is lit. 120.0 to 134.9°C
1 Defective machine monitor 7 or less is lit. 102.0 to 110.9°C

Green (G)
White (W)
Only 1 is lit. Max. 19.9°C
40-454 GD535-5
(01)
40 Troubleshooting E-17 Torque converter oil temperature is displayed abnormally.
Torque converter oil temperature gauge
GD535-5 40-455
(01)
E-18 Fuel gauge is displayed abnormally. 40 Troubleshooting
E-18 Fuel gauge is displayed abnormally. 1
Failure 1) Fuel gauge is displayed abnormally.

q If an error occurs in fuel level sensor system, failure code [DJF1KA] may be displayed and recorded.
Related
q The input resistance and voltage from the fuel level sensor can be checked with monitoring function.
information
(Code: 04201, 04200)

An error occurred in fuel
1 Perform troubleshooting for failure code [DJF1KA].
level sensor system.
Ground fault in wiring 2. Disconnect connectors TM39 and ET39, and connect T-adapter to either female side.
2
harness Between TM39 (female) (19) or ET39 (female) (1) and
ground
2. Disconnect connectors TM39 and ET39, and connect T-adapter to female side of
Short circuit in wiring TM39.
harness
Between TM39 (female) (19) and each pin other than pin No continuity
Circuit diagram related to fuel level sensor
40-456 GD535-5
(01)
40 Troubleshooting E-18 Fuel gauge is displayed abnormally.
Failure 2) Indication of fuel gauge is different from actual fuel level.

Related q The resistance of fuel sensor can be measured between machine monitor's connectors FP2 (female)
information (10) and FP1 (female) (3)

a Turn starting switch to ON position or start engine, and perform troubleshooting.
Fuel gauge
Fuel level Fuel gauge level Resistance
color
FULL 210 l 6 or less is lit. 11.3 z
3/4 197 l 5 or less is lit. 16.1 z
1 Defective machine monitor Green (G)
1/2 144 l 4 or less is lit. 35.1 z
1/4 84 l 3 or less is lit. 68.7 z
EMPTY 76 l 2 or less is lit. 79.0 z
Red (R)
1 seg. Max. 73 l Only 1 is lit. Min. 83.3 z
Fuel level gauge and fuel monitor
GD535-5 40-457
(01)
E-19 Centralized warning lamps do not light or do not go out. 40 Troubleshooting
E-19 Centralized warning lamps do not light or do not go out. 1
Failure Centralized warning lamps do not light up or go out.

q Centralized warning lamps light when:
1) An emergency stop event occurs.
Related 2) Action code [L02] or [L03] is displayed on the machine monitor.
information 3) Two seconds after starting switch turning ON.
q When centralized warning lamps light, warning buzzer sounds intermittently.
q If a machine overrun occurs, only the warning buzzer sounds.

1 Lamp bulb has burnt out. Check the centralized warning lamps for burn-out or poor contact.
Defective lamp assembly
2 Check the lamp assembly for internal failure (open circuit or short circuit).
(Internal failure)
Open circuit in wiring 2. Disconnect connectors TM40 and FP3, and connect T-adapteras to each female side.
3
harness
Between FP3 (female) (11) and TM40 (female) (19) Resistance Max. 1 z
Ground fault in wiring 2. Disconnect connectors TM40 and FP3, and connect T-adapter to either female side.
4
harness Between FP3 (female) (11) or FP1 (female) (19) and
Resistance Max. 1 z
ground
For approximately 2
5 seconds after starting switch Voltage Max. 1 V
controller
Between TM40 (19) and is turned to ON position
ground When 2 seconds have
passed after starting switch Voltage 20 to 30 V
turned ON
40-458 GD535-5
(01)
40 Troubleshooting E-20 Alarm buzzer does not sound or does not stop sounding.
E-20 Alarm buzzer does not sound or does not stop sounding. 1
Failure Alarm buzzer does not sound or does not stop sounding.
Related q If an error occurs in warning buzzer system, failure code [DV00KB] may be displayed and recorded.
information q If a machine overrun occurs, only the warning buzzer sounds.

Failure of alarm buzzer
1 Perform troubleshooting for failure code [DV00KB].
system
2. Disconnect connectors FP1 and FP4, and insert T-adapters into each female side.
2
harness Between terminal ST9 and FP4 (female) (1) Resistance Max. 1 z
Between FP4 (female) (2) and FP1 (female) (5) Resistance Max. 1 z
Ground fault in wiring 2. Disconnect connectors FP1 and FP4, and insert T-adapters into each female side.
3
harness
Between FP4 (female) (1) or FP1 (female) (3) and ground Resistance Min. 1 Mz
2. Insert T-adapter into connector FP4.
For approximately 2
4 Failure of alarm buzzer seconds after starting switch Voltage Max. 3 V
is turned to ON position
Between FP4 (1) and (2)
When 2 seconds have
turned ON
2. Insert T-adapter into connector FP1.
For approximately 2
5 Defective machine monitor seconds after starting switch Voltage Max. 3 V
Between FP1 (5) and is turned to ON position
ground When 2 seconds have
turned ON
GD535-5 40-459
(01)
E-20 Alarm buzzer does not sound or does not stop sounding. 40 Troubleshooting
Circuit diagram related to the warning buzzer
40-460 GD535-5
(01)
40 Troubleshooting E-21 Transmission mode cannot be switched.
E-21 Transmission mode cannot be switched. 1
Failure Transmission mode cannot be switched.

q Manual mode: Direct power shift (Hydroshift) mode
Related Auto mode: Torque converter mode
information q Input condition (ON/OFF) from transmission mode selector switch can be checked with monitoring func-
tion. (Code: 02214)

2. Disconnect connector TM30, and connect T-adapters to male side.
1
mode selector switch Between TM30 (male) (5) Switch ON (Manual mode) Resistance Max. 1 z
and (6) Switch OFF (Auto mode) Resistance Min. 1 Mz
Open circuit in wiring 3. Remove fuse No. 11 of the FB1 fuse box.
2
harness
Between FB1-11 and TM30 (female) (5) Resistance Max. 1 z
3
ground
harness
Reference
5
4. Perform troubleshooting by operating the transmission mode selector switch.
Switch ON (Manual mode) Voltage 20 to 30 V
Switch OFF (Auto mode) Voltage Max. 1 V
GD535-5 40-461
(01)
E-21 Transmission mode cannot be switched. 40 Troubleshooting
Circuit diagram related to transmission switch
40-462 GD535-5
(01)
40 Troubleshooting E-22 Engine mode cannot be switched.
E-22 Engine mode cannot be switched. 1
Failure Engine mode cannot be switched.

q P-mode (Power mode): Switch ON
Related E-mode (Economy mode): Switch OFF
information q Input condition (ON/OFF) from engine mode selector switch can be checked with monitoring function.
(Code: 02218)

2. Disconnect connector TM45, and connect T-adapters to male side.
Failure of engine mode
1
selector switch Between TM45 (male) (5) Switch ON (P-mode) Resistance Max. 1 z
and (6) Switch OFF (E-mode) Resistance Min. 1 Mz
Open circuit in wiring 3. Remove fuse No. 11 of the FB1 fuse box.
2
harness
3
ground
harness
Reference
5
4. Perform troubleshooting by operating the engine mode selector switch.
Switch ON (P-mode) Voltage 20 to 30 V
Switch OFF (E-mode) Voltage Max. 1 V
GD535-5 40-463
(01)
E-22 Engine mode cannot be switched. 40 Troubleshooting
Circuit diagram related to engine mode switch
40-464 GD535-5
(01)
40 Troubleshooting E-23 Differential gear lock function does not operate or is not canceled (for differential gear lock model).
E-23 Differential gear lock function does not operate or is not canceled (for
differential gear lock model). 1
Failure Differential gear lock function does not operate or is not canceled.
q The coil circuit (primary side circuit) of differential gear lock relay is monitored by the transmission con-
troller. If an open or short circuit occurs, failure code [D19KKZ] is displayed.
Related q Input state (ON/OFF) from differential gear lock switch can be checked with monitoring function. (Code:
information 02218)
q Drive state (ON/OFF) of differential gear lock relay can be checked with monitoring function. (Code:
03705)

1 Blown fuse
causes 4 and 6.)
2. Disconnect connector FP12, and connect T-adapter to male side.
2
lock switch Between FP12 (male) (5) Switch: OFF Resistance Min. 1 Mz
and (6) Switch: ON Resistance Max. 1 z
3 Perform troubleshooting for failure code [D19KKZ].
lock relay
4
lock solenoid valve Between R9 (male) (1) and (2) Resistance Approx. 25 z
Between R9 (male) (1) and ground Resistance Min. 1 Mz
4. Turn ON the differential gear lock switch.
Between TM43 (female) (6) and ground
Resistance Approx. 25 z
(Resistance of differential gear lock solenoid valve coils)
5
harness If no failure is found by above checks, this check is not required.
2. Disconnect connectors TM40, TM43, FP12 and R9, and connect T-adapters to each
female side.
Between TM40 (female) (12) and FP12 (female) (6) Resistance Max. 1 z
Between FP12 (female) (5) and ground Resistance Max. 1 z
2. Disconnect connectors TM40, TM43, FP12 and R9, and connect T-adapters to each
female side.
Ground fault and short 4. Turn ON the differential gear lock switch.
6
circuit in wiring harness
Between FP12 (female) (5) and (6) Resistance Min. 1 Mz
GD535-5 40-465
(01)
E-23 Differential gear lock function does not operate or is not canceled (for differential gear lock model). 40 Troubleshooting

harness
Reference
8
4. Perform troubleshooting by operating the differential gear lock switch.
Between TM40 (12) and Switch: OFF Voltage Max. 1 V

ground Switch: ON Voltage 7 to 12 V
Circuit diagram related to differential gear lock switch and differential gear lock solenoid valve
40-466 GD535-5
(01)
40 Troubleshooting E-24 Cannot be locked or canceled by the lifter lock pin.
E-24 Cannot be locked or canceled by the lifter lock pin. 1
Failure 1) Cannot be locked or canceled by the lifter lock pin.

Related The lifter lock switch turns ON (the pin is released) when it is pressed. It turns OFF when pushed back (the
information pin is locked).

1 Blown fuse
causes 3 and 5.)
2 Failure of lifter lock switch
Between SP28 (male) (1) Switch: OFF Resistance Min. 1 Mz
and (2) Switch: ON Resistance Max. 1 z
Failure of lifter lock
3
solenoid valve Between R10 (male) (1) and (2) Resistance 2 to 100 z
Between R10 (male) (1) and ground Resistance Min. 1 Mz
2. Disconnect connectors SP28 and R10, and connect T-adapters to each female side.
4
harness Between R10 (female) (1) and SP28 (2) Resistance Max. 1 z
Between FB1-7 and SP28 (female) (3) Resistance Max. 1 z
2. Disconnect connectors FP3 and R10, and connect T-adapter to female side of R10.
Ground fault and short 3. Remove fuse No. 7 of the FB1 fuse box.
5
circuit in wiring harness 4. Lifter lock switch ON
Hot short circuit in wiring 2. Disconnect connector R10, and connect T-adapter to female side.
harness
Between R10 (female) (1) and (2) Voltage Max. 1 V
GD535-5 40-467
(01)
E-24 Cannot be locked or canceled by the lifter lock pin. 40 Troubleshooting
Failure 2) Only the display of lifter lock pin pilot lamp is abnormal (the function operates and releases normally).
q When lifter lock pin is locked: Pilot lamp goes out.
Related
q When lifter lock pin is released: Pilot lamp lights.
information
q If the wiring harness is shorted to ground or if it is hot shorted, the function fails.

1 Lamp bulb has burnt out. Check the lamp bulb of lifter lock pin pilot lamp for burn-out or poor contact.
2 Defective lamp assembly Check the lamp assembly for internal failure (open circuit or short circuit).
2. Disconnect connectors FP3 and SP28, and connect T-adapters to each female side.
3
harness Between FP3 (female) (9) and SP28 (2) Resistance Max. 1 z
Circuit diagram related to lifter lock switch and lifter lock solenoid valve
40-468 GD535-5
(01)
40 Troubleshooting E-25 Horn does not sound or does not stop sounding.
E-25 Horn does not sound or does not stop sounding. 1
Failure 1) Horn does not sound.

Related
information

If fuses No. 14 of FB1 fuse box is blown, the circuit may be shorted to ground. In this
1 Blown fuse
case, perform check on cause 7 first.
2. Replace horn relay SP27 with another relay (for example, headlight relay SP13)
2 Failure of horn relay 3. Turn starting switch to ON position.
4. Sound the horn.
If horn sounds, original horn relay is defective.
3 Failure of horn RH.
Between FL7 (male) (1) and (2) Continuity
Between FL7 (male) (2) and ground Resistance Min. 1 Mz
4 Failure of horn LH
Between FL8 (male) (1) and (2) Conductive
Between FL8 (male) (2) and ground Resistance Min. 1 Mz
5 Failure of horn switch
Between FP9 (male) (1) and Switch: ON Resistance Max. 1 z
ground Switch: OFF Resistance Min. 1 Mz
2. Disconnect connectors SP27, FP9 and FL8, and connect T-adapters to each female
side.
3. Remove fuse No. 14 of FB1 fuse box.
Between FP9 (female) (1) and SP27 (female) (6) Resistance Max. 1 z
6 Between FB1-14 and SP27 (female) (5) Resistance Max. 1 z
harness
Between SP27 (female) (2) and FL7 (female) (2) Resistance Max. 1 z
Between FL7 (female) (1) and ground Resistance Max. 1 z
2. Disconnect connectors FL7, FL8 and SP27, and connect T-adapters to each female
side.
Ground fault and short
7 3. Remove fuse No. 14 of FB1 fuse box.
Between FL7 (female) (1) and (2) Resistance Min. 1 Mz
GD535-5 40-469
(01)
E-25 Horn does not sound or does not stop sounding. 40 Troubleshooting
Failure 2) Horn does not stop sounding.

Related
information

2. Remove horn relay SP27.
1 Failure of horn relay 3. Turn starting switch to ON position.
If horn stops sounding, original horn relay SP27 is defective.
2. Disconnect connector FP9.
2 Failure of horn switch 3. Turn starting switch to ON position.
If horn stops sounding, the horn switch is defective.
Ground fault and short 2. Disconnect connector SP27, and connect T-adapter to female side.
3
Hot short circuit in wiring 2. Disconnect connector SP27, and connect T-adapter to female side.
harness
Between SP27 (female) (2) and ground Voltage Max. 1 V
Circuit diagram related to horn
40-470 GD535-5
(01)
40 Troubleshooting E-26 Backup alarm does not sound or does not stop sounding.
E-26 Backup alarm does not sound or does not stop sounding. 1
Failure 1) Backup alarm does not sound.

q If the gear lever is shifted to "R" and if the backup lamp lights, the fuses are OK, relay harness is not
shorted to ground, and harness is not hot shorted. Check the operations.
Related
q If a fuse blows, the stop lamp also does not light.
information
q If the backup lamp relay is turned ON by transmission controller, it can be checked with monitoring func-
tion. (Code: 03705)

1 Blown fuse
2. Replace the backup lamp relay TM42 with another relay (for example, stop lamp relay
Defective backup lamp SP16).
2 3. Start engine.
relay
4. Depress the brake pedal, and shift the lever to "R" position.
If the back alarm sounds, original backup lamp relay TM42 is defective.
2. Disconnect connector BZ, and connect T-adapter to male side.
3 Failure of back alarm
Between BZ (male) (1) and (2) Conductive
Between BZ (male) (1) and ground Resistance Min. 1 Mz
Primary circuit side of backup lamp relay
a Coil resistance of backup lamp relay
Secondary circuit side of backup lamp relay
3. Disconnect connector RL1 (in order to disconnect the back lamp circuit).
Open circuit in wiring Between TM42 (female) (3) and FB1-13 Resistance Max. 1 z
4
harness Between TM42 (female) (5) and ground Conductive
2. Disconnect connectors TM40, TM42 and BZ, and connect T-adapter to each female side.
3. Disconnect connector RL1 (in order to disconnect the backup lamp circuit).
Between TM42 (female) (5) and BZ (female) (1) Resistance Max. 1 z
Between BZ (male) (2) and ground Resistance Max. 1 z
2. Disconnect connectors TM40, TM42 and BZ, and connect T-adapter to female side of
TM42.
Ground fault and short 3. Remove fuse (14) of FB1 fuse box.
5
circuit in wiring harness Between TM42 (female) (1) and (2) Resistance Min. 1 Mz
GD535-5 40-471
(01)
E-26 Backup alarm does not sound or does not stop sounding. 40 Troubleshooting

3. Start engine.
If the input voltage is normal with shift lever at "R" position, and if the relay output voltage
6 is abnormal, the transmission controller is defective.
controller
Voltage 20 to 30 V
(Input voltage when lever is in "R" position)
Voltage 20 to 30 V
(Relay output voltage)
Failure 2) Backup alarm does not stop sounding.

Related
information

Defective backup lamp 2. Remove backup lamp relay TM42.
relay
If the back alarm stops sounding, original backup lamp relay TM42 is defective.
2
harness
3. Start engine.
controller
Voltage 20 to 30 V
Voltage 20 to 30 V
40-472 GD535-5
(01)
40 Troubleshooting E-26 Backup alarm does not sound or does not stop sounding.
Circuit diagram related to back alarm device
GD535-5 40-473
(01)
E-27 Headlamps, clearance lamps, and tail lamps do not light up or go out. 40 Troubleshooting
E-27 Headlamps, clearance lamps, and tail lamps do not light up or go out.1
Failure 1) All of headlamps, clearance lamps, and tail lamps do not light up or do not go out.
q If fuse No. 12 of FB1 blows, all of headlamps, clearance lamps, and tail lamps do not light.
Related
q If the small lamp relay fails or if fuse No. 9 of FB2 blows, the headlamps light. But all of clearance lamps,
information
tail lamps, and machine monitor night lamp do not light.

1 Blown fuse
Between SP22 (male) (5) Switch: Headlamps ON Resistance Max. 1 z

Defective headlamp
2 and (6)
switch Switch: OFF Resistance Min. 1 Mz
Between SP22 (male) (4) Switch: Clearance lamps ON Resistance Max. 1 z

and (5) Switch: OFF Resistance Min. 1 Mz
2. Disconnect connectors SP22 and SP13, and connect T-adapter to female side.
Open circuit in wiring Between SP13 (female) (6) and ground Resistance Max. 1 z
3
harness
2. Disconnect connectors SP22 and SP13, and connect T-adapter to female side of
SP13.
4 3. Remove fuse No. 12 of FB1 fuse box.
Between SP13 (female) (1) and (2) Resistance Min. 1 Mz
40-474 GD535-5
(01)
40 Troubleshooting E-27 Headlamps, clearance lamps, and tail lamps do not light up or go out.
Circuit diagram related to headlamps, clearance lamps, tail lamps, and front work lamps
GD535-5 40-475
(01)
Failure 2) Head lamps do not light up nor go out.

q If headlamps or clearance lamps do not light, check the directional lamp and emergency lamp. If all front
Related
lamps do not light, check the ground circuits (FLG2) (the tail lamps light).
information
q Dimmer relay SP11 switches between Hi beam and Low beam.

If only each lamp does not light up, burned-out bulb and defective contact are suspected.
1 Lamp bulb has burnt out.
So check it.
2. Replace headlamp relay SP13 with another relay (for example, horn relay SP27)
2 Defective headlamp relay 3. Turn starting switch to ON position.
4. Light up the headlamps.
If the headlamps light, original headlamp relay SP13 is defective.
2. Replace dimmer relay SP11 with another relay (for example, stop lamp relay SP16)
3 Defective dimmer relay 3. Turn starting switch to ON position.
4. Light up the headlamps.
If headlamps light, original dimmer relay is defective.
Defective headlamp
4
switch Between SP22 (male) (5) Switch: Headlamps ON Resistance Max. 1 z
Defective headlamp relay (primary circuit side)
2. Disconnect connector SP22, and connect T-adapter to female side.
a Resistance of headlamp relay coils
Between SP22 (female) (6) and ground Resistance 200 to 400 z
Defective headlamp relay (secondary circuit side)
Make sure that dimmer (Hi beam) switch turns OFF.
a A single lamp has approx. 8 z parallel resistance (8/2=4).
Between SP13 (female) (2) and (6) Resistance Approx. 4 z
Open circuit in wiring If no failure is found by above checks, this check is not required.
5
harness 1. Turn the starting switch to OFF position.
2. Disconnect connectors SP11, SP13, SP22, FL1 and FL2, and connect T-adapters to
each female side.
Between SP22 (female) (6) and SP13 (female) (5) Resistance Max. 1 z
40-476 GD535-5
(01)

2. Disconnect connectors SP11, SP13, SP22, FL1 and FL2, and connect T-adapter to
female side of SP13.
Ground fault and short Between SP13 (female) (2) and (6) Resistance Min. 1 Mz
6
GD535-5 40-477
(01)
Failure 3) The headlamps cannot be switched between Hi and Low beams.

Related
q The Hi and Low beams are switched by the dimmer switch and dimmer relay (SP11).
information

So check it.
2. Replace dimmer relay SP11 with another relay (for example, stop lamp relay SP16)
2 Defective dimmer relay 3. Turn starting switch to ON position.
4. Light up headlamps, and turn the dimmer switch ON and OFF.
If the Hi and Low beams are switched, original dimmer relay SP11 is defective.
3 Defective dimmer switch
Between FP7 (male) (5) and Switch: ON Resistance Max. 1 z
(6) Switch: OFF Resistance Min. 1 Mz
Dimmer relay (primary circuit side)
2. Disconnect connectors SP11 and SP13, and connect T-adapter to each female side.
3. Turn the dimmer (Hi beam) switch ON.
Dimmer relay (secondary circuit side)
a A single lamp has approx. 8 z parallel resistance (8/2=4).
Open circuit in wiring Between SP11 (female) (5) and (2) Resistance Approx. 4 z
4
harness
Between SP11 (female) (6) and (2) Resistance Approx. 4 z
2. Disconnect connectors SP11, SP13, FP7, FL1 and FL2, and connect T-adapters to
each female side.
Between SP13 (female) (2) and FP7 (female) (6) Resistance Max. 1 z
Between SP11 (female) (1) and FP7 (female) (5) Resistance Max. 1 z
2. Disconnect connectors SP11, SP13, FL1 and FL2, and connect T-adapter to female
side of SP11.
Make sure that dimmer (Hi beam) switch turns OFF.
5 Between SP11 (female) (1) and (2) Resistance Min. 1 Mz
40-478 GD535-5
(01)
Failure 4) Headlamp Hi-beam pilot lamp does not light or does not go out.
Related If the wiring harness is shorted to ground or hot shorted, the headlamps cannot be switched between Hi
information and Low beams.

1 Lamp bulb has burnt out. Check the headlamp Hi-beam pilot lamp for bulb burn-out or poor contact.
2. Disconnect connectors FP3 and SP11, and connect T-adapters to each female side.
3
harness Between FP3 (female) (3) and SP11 (female) (1) Resistance Max. 1 z
Failure 5) Clearance lamps and tail lamps do not light up or do not go out.
q If the small lamp relay fails or if fuse (9) of FB2 blows, the headlamps light. But all of clearance lamps
and tail lamps do not light.
Related q If tail lamps light but clearance lamps do not light, check the headlamps, directional lamps and emergen-
information cy lamp. If all front lamps do not light, check the ground circuits (FLG2)
q If clearance lamps light but tail lamps do not light, check the headlamps, directional lamps, emergency
lamp, stop lamps, and backup lamps. If all rear lamps do not light, check the ground circuits (ET77)
44

So check it.
2 Blown fuse
Defective headlamp
3
switch Between SP22 (male) (4) Switch: Headlamps ON Resistance Max. 1 z
GD535-5 40-479
(01)

2. Disconnect connectors SP22, SP12 and SP13, and connect T-adapter to each female
side.
Between SP12 (5) and (2)
Open circuit in wiring A single lamp has approx. 125 z (four) parallel resistance Resistance Approx. 30 z
4
harness (125 / 4 = 31).
If no failure is found by above checks, this check is not
required.
1. Turn the starting switch to OFF position. Resistance Max. 1 z
2. Disconnect connectors SP42, FL1, FL2, RL2 and RL3,
and connect T-adapter to each female side.
Between SP42 (female) (5) and RL2 (female) (6) Resistance Max. 1 z
SP12.
40-480 GD535-5
(01)
GD535-5 40-481
(01)
E-28 Working lamps do not light up or go out. 40 Troubleshooting
E-28 Working lamps do not light up or go out. 1
Failure 1) Front working lamps do not light up or do not go out.

Related The front working lamps have the circuit that is completely separated from the circuit of headlamps,
information clearance lamps and tail lamps. The circuit has its own fuses and ground leads.

So check it.
2 Blown fuse
2. Replace front work lamp relay SP14 with another relay (for example, horn relay SP27)
Failure of front working 3. Turn starting switch to ON position.
3
lamp relay 4. Front working lamps ON
If the front working lamps light, original front working lamp relay SP14 is defective.
Failure of front working
4
lamp switch Between SP23 (male) (5) Switch: ON Resistance Max. 1 z
4. Front working lamp switch ON
a * A single lamp has approx. 8 z resistance.
5
Open circuit in wiring Between SP14 (female) (6) and ground Resistance Max. 1 z
harness
Between SP14 (female) (1) and (5) Resistance Max. 1 z
Between SP14 (female) (2) and (6) Resistance * Approx. 8 z
Between SP14 (female) (4) and (6) Resistance * Approx. 8 z
2. Disconnect connectors SP23, SP14, FL9 and FL10, and connect T-adapter to each
female side.
Open circuit in wiring Between SP23 (female) (6) and SP14 (female) (5) Resistance Max. 1 z
6
harness Between SP14 (female) (1) and (3) Resistance Max. 1 z
40-482 GD535-5
(01)
40 Troubleshooting E-28 Working lamps do not light up or go out.

2. Disconnect connectors SP14, FP3, FL9 and FL10, and connect T-adapter to female
side of SP14.
7
circuit in wiring harness Between SP14 (female) (1) and (5) Resistance Min. 1 Mz
Failure 2) The working pilot lamp does not light or does not go out.
Related
If the wiring harness is shorted to ground or hot shorted, the front working lamps do not operate normally.
information

1 Lamp bulb has burnt out. Check the working pilot lamp for bulb burn-out or poor contact.
Disconnect connectors FP3 and SP14, and connect T-adapters to each female side.
3
harness Between FP3 (female) (5) and SP14 (female) (5) Resistance Max. 1 z
GD535-5 40-483
(01)
Circuit diagram related to headlamps, clearance lamps, tail lamps, front working lamps, cab
working lamps
40-484 GD535-5
(01)
40 Troubleshooting E-28 Working lamps do not light up or go out.
Failure 3) The rear working lamps do not light up or go out.

q The rear working lamp relay uses the primary circuit power supply (and fuses) that are common to the
Related front working lamps. Check the front working lamps for abnormal operation.
information q If tail lamps do not light, it may be shorted to ground. See "Headlamps, clearance lamps, and tail lamps
do not light up or go out."

So check it.
2 Blown fuse
2. Replace rear working lamp relay SP15 with another relay (for example, stop lamp relay
Failure of rear working SP16)
3
lamp relay 3. Turn ON the rear working lamp switch.
If the rear working lamps light, original rear working lamp relay SP15 is defective.
Failure of rear working
4
lamp switch Between SP24 (male) (5) Switch: ON Resistance Max. 1 z
2. Disconnect connectors SP14 and SP15, and connect T-adapter to female side.
3. Remove fuses No. 9 and No. 10 of FB1 fuse box.
4. Turn ON the rear working lamp switch.
a * A single lamp has approx. 8 z parallel resistance (8/2=4).
Between SP15 (female) (5) and ground Resistance * Approx. 4 z
5 2. Disconnect connectors SP15, SP24, SP14, RL4 and RL5, and connect T-adapter to
harness
each female side.
Between SP14 (4) and SP24 (female) (5) Resistance Max. 1 z
Between RL4 (female) (2) and ground Resistance Max. 1 z
Between RL5 (female) (2) and ground Resistance Max. 1 z
GD535-5 40-485
(01)

2. Disconnect connectors SP15, SP24, RL4 and RL5, and connect T-adapter to female
side of SP15.
6
Circuit diagram related to rear working lamps
40-486 GD535-5
(01)
40 Troubleshooting E-29 Turn indicator light or emergency flashing light does not flash.
E-29 Turn indicator light or emergency flashing light does not flash. 1
Failure 1) Turn indicator light or emergency flashing light does not flash.
q Hazard lamp relay 2 (SP19) switches the power supply of flasher (SP26). (Different fuses are used for
directional indicators and emergency flashing lights.)
q Flasher (SP26) uses the circuit that is common to both turn indicator light and emergency flashing light.
Related q If the flasher fails, any turn indicator light may not flash but turn ON even when the right or left turn indi-
information cator light is turned ON or even when the emergency flashing light is turned ON.
q When troubleshooting the flasher failure, if only front or rear lights do not flash after diagnosis of wiring
harnesses, the circuit may be shorted to ground. See "Headlamps, clearance lamps, and tail lamps do
not light up or go out."

2. Replace hazard lamp relay 2 (SP19) with another relay (for example, stop lamp relay
Failure of hazard lamp SP16).
1
relay 2 3. Turn the Hazard switch ON.
If the emergency flashing light flashes, original hazard lamp relay 2 (SP19) is defective.
2. Disconnect connectors SP26, SP18 and SP19, and connect T-adapters to each female
side.
2
harness Between SP26 (female) (1) and ground Resistance Max. 1 z
2. Insert T-adapter into connector SP26.
4 Defective flasher
Between SP26 (3) and (1) Power supply Voltage 20 to 30 V
20 to 30V and 1V or less
Between SP26 (4) and (1) Output Voltage
pulses
GD535-5 40-487
(01)
E-29 Turn indicator light or emergency flashing light does not flash. 40 Troubleshooting
Circuit diagram related to turn indicator light and emergency flashing light
40-488 GD535-5
(01)
Failure 2) Turn indicator light does not flash.

q Check that the emergency flashing light operates normally.
q Hazard lamp relay 2 (SP19) switches the power supply of flasher (SP26).
Related
q If only the right or left turn indicator light does not flash, the wiring harness is defective.
information
q If only front or rear lamps do not flash, it may be a ground fault. See "E-23 Headlamps, clearance lamps,
and tail lamps do not light up or go out."

So check it.
2 Blown fuse
Between FP8 (male) (A) and Lever: Left turn (upper side) Resistance Max. 1 z
Failure of turn indicator (B)
3 Lever: Neutral Resistance Min. 1 Mz
light lever
Lever: Right turn (bottom
Between FP8 (male) (A) and side) Resistance Max. 1 z
(C)
Lever: Neutral Resistance Min. 1 Mz
2. Disconnect connectors SP18, SP19, FP8, FL1, FL2, RL2 and RL3, and connect T-
adapters to each female side.
Between FB1 (6) and SP19 (female) (6) Resistance Max. 1 z
Open circuit in wiring Between SP18 (female) (1) and (3) Resistance Max. 1 z
4
harness Between SP18 (female) (1) and FP8 (female) (A) Resistance Max. 1 z
Between FP8 (female) (B) and FL2 (female) (5) Resistance Max. 1 z
Between FP8 (female) (B) and RL3 (female) (1) Resistance Max. 1 z
Between FP8 (female) (C) and FL1 (female) (5) Resistance Max. 1 z
Between FP8 (female) (C) and RL2 (female) (1) Resistance Max. 1 z
2. Disconnect connectors SP18, SP19, SP26, FP8, FL1, FL2, RL2 and RL3, and connect
T-adapters to female side of SP19 and FP8.
5
Between FP8 (female) (B) and ground Resistance Min. 1 Mz
Between FP8 (female) (C) and ground Resistance Min. 1 Mz
GD535-5 40-489
(01)
40-490 GD535-5
(01)
Failure 3) Emergency flashing light does not flash.

q Check that the turn indicator light operates normally.
q Hazard lamp relay 2 (SP19) switches the power supply of flasher (SP26).
Related
q If the emergency flashing light flashes when starting switch is turned to ON position, hazard lamp relay
information
2 (SP19) is defective.
q For the related circuit diagrams, see cause of failure 1) or 2).

So check it.
2 Blown fuse
2. Replace hazard lamp relay 2 (SP19) with another relay (for example, stop lamp relay
Failure of hazard lamp SP16).
3
relay 2 3. Turn ON the hazard lamp switch.
Failure of hazard lamp 2. Replace hazard lamp relay 1 (SP18) with another relay (for example, horn relay SP27).
4 3. Turn ON the hazard lamp switch.
relay 1
Failure of hazard lamp
5
switch Between SP25 (male) (5) Switch: ON Resistance Max. 1 z
2. Disconnect connectors SP18, SP19, SP26, FL1, FL2, RL2 and RL3, and connect T-
adapters to each female side.
4. Turn ON the hazard lamp switch.
6
harness Between FB1-4 and SP19 (female) (1) Resistance Max. 1 z
Between SP18 (female) (1) and (3) Resistance Max. 1 z
GD535-5 40-491
(01)

2. Disconnect connectors SP18, SP19 and SP25, and connect T-adapters to each female
side.
7
Open circuit in wiring Between FB1-4 and SP25 (female) (5) Resistance Max. 1 z
harness
SP18.
Turn OFF the hazard lamp switch.
8
40-492 GD535-5
(01)
GD535-5 40-493
(01)
Failure 4) Turn signal pilot lamp does not flash.

Related
If the wiring harness is shorted to ground or hot shorted, the turn indicator light does not flash.
information

If the turn indicator pilot lamp does not light, its bulb may be burnt out or poor contact.
Check them.
2. Disconnect connectors FP3 and FP8, and connect T-adapters to each female side.
3
Open circuit in wiring Between FP3 (female) (4) and FP8 (female) (B) Resistance Max. 1 z
harness
Between FP3 (female) (2) and FP8 (female) (C) Resistance Max. 1 z
40-494 GD535-5
(01)
GD535-5 40-495
(01)
E-30 Stop lamp does not light up or does not go out. 40 Troubleshooting
E-30 Stop lamp does not light up or does not go out. 1
Failure The stop lamp does not light or does not go out.
Related If tail lamps and back lamps do not light, ground ET77 failure or blown fuse No. 13 of FB1 fuse box is to be
information considered.

So check it.
2 Blown fuse
2. Replace stop lamp relay SP16 with another relay (for example, small lamp relay SP12).
3 Defective stop lamp relay 3. Turn starting switch to ON position.
4. Depress the brake pedal.
If the stop lamp lights, original stop lamp relay SP16 is defective.
Failure of brake lamp
4
switch Between B13 (male) (1) and Depress the brake pedal. Resistance Max. 1 z
(2) Release the brake. Resistance Min. 1 Mz
2. Disconnect connector B13, and connect T-adapter to female side.
a * Coil resistance of stop lamp relay
* 200 to 400
Between B13 (female) (2) and ground Resistance
z
Between FB1-13 and B13 (female) (1) Resistance Max. 1 z
a * A single lamp has approx. 24 z parallel resistance.
Open circuit in wiring Between FB1-13 and SP16 (female) (3) Resistance Max. 1 z
5
harness
* Approx. 12
Between SP16 (female) (5) and (2) Resistance
z
2. Disconnect connectors B13, SP16, RL2 and RL3, and connect T-adapters to each
female side.
Between B13 (female) (2) and SP16 (female) (1) Resistance Max. 1 z
40-496 GD535-5
(01)
40 Troubleshooting E-30 Stop lamp does not light up or does not go out.

2. Disconnect connectors B13, SP16, RL2 and RL3, and connect T-adapter to female
side of SP16.
6
Circuit diagram related to the stop lamp
GD535-5 40-497
(01)
E-31 Backup lamp does not light up or does not go out 40 Troubleshooting
E-31 Backup lamp does not light up or does not go out 1
Failure Backup lamp does not light up or does not go out.

q If the gear shift lever is shifted to "R" and if the backup alarm sounds, none of blown fuse, relay failure,
harness grounding, and harness hot short have occurred. Check the operations.
q If a fuse blows, the stop lamp also does not light.
Related
q If tail lamps and stop lamp do not light, ground fault (ET77) is to be considered.
information
q For the back alarm troubleshooting, see E-22.
q If the backup lamp relay is turned ON by transmission controller, it can be checked with monitoring func-
tion. (Code: 03705)

So check it.
2 Blown fuse
2. Replace backup lamp relay TM42 with another relay (for example, small lamp relay
Defective backup lamp SP12).
3 3. Start engine.
relay
If the backup lamp lights, original backup lamp relay TM42 is defective.
a Coil resistance of backup lamp relay
a * A single lamp has approx. 50 z parallel resistance.
4 * Approx. 25
harness Between TM42 (female) (5) and (2) Resistance
z
2. Disconnect connectors TM40, TM42, RL2 and RL3, and connect T-adapters to each
female side.
Between TM42 (female) (5) and RL2 (female) (2) Resistance Max. 1 z
Between TM42 (female) (5) and RL3 (female) (2) Resistance Max. 1 z
40-498 GD535-5
(01)
40 Troubleshooting E-31 Backup lamp does not light up or does not go out

2. Disconnect connectors TM40, TM42, RL2 and RL3, and connect T-adapter to female
side of TM42.
Ground fault and short Between TM42 (female) (1) and (2) Resistance Min. 1 Mz
5
circuit in wiring harness Between TM42 (female) (2) and (3) Resistance Min. 1 Mz
3. Start engine.
controller
Voltage 20 to 30 V
Voltage 20 to 30 V
Circuit diagram related to backup lamp
GD535-5 40-499
(01)
E-32 All wipers do not operate 40 Troubleshooting
E-32 All wipers do not operate 1
Failure No wiper operates continuously or intermittently
Related If any of wipers operates, see each of “FRONT WIPER DOES NOT OPERATE”, “REAR WIPER DOES
NOT OPERATE”, “RIGHT DOOR WIPER DOES NOT OPERATE”, and “LEFT DOOR WIPER DOES NOT
information OPERATE” in E mode.

If fuse is blown out, the circuit probably has ground fault. Perform troubleshooting for
“ground fault in wiring harness” first.
REMARK
1 Defective fuse
If following fuse is blown out, each symptom occurs.
q If fuse No.15 in fuse box FB2 is blown out, all the wipers do not work.
q If fuse No.14 in fuse box FB2 is blown out, door wipers do not work.
2. Disconnect connector L21, and connect T-adapter to male side.
3. Turn on and off wiper switch to perform troubleshooting.
Between L21 (male) (7) and Front intermittent ON Max. 1 Ω

(2) Front intermittent OFF Min. 1 MΩ
Defective wiper Between L21 (male) (7) and Front Hi/ON Max. 1 Ω
2
intermittent switch (4) Front Hi/OFF Min. 1 MΩ
Resistance
Between L21 (male) (7) and Front Lo/ON Max. 1 Ω
(5) Front Lo/OFF Min. 1 MΩ
Between L21 (male) (7) and Rear ON Max. 1 Ω

(9) Rear OFF Min. 1 MΩ
Open circuit in wiring 2. Check that fuse No.15 in fuse box FB2 is not blown out.
3 harness (wire breakage or 3. Disconnect connector L21, and connect T-adapter to female side.
defective contact) 4. Turn the starting switch to ON position.
Voltage Between L21 (female) (7) and ground 20 to 30 V
If no failure is found by checks on “open circuit in wiring harness”, this check is not
required.
4 harness (contact with 2. Disconnect connectors L21, L48, C15, C16, and C53, and connect Tadapter to female
ground circuit) side of L21.
Resistance Between L21 (female) (7) and ground Min. 1 MΩ
40-500 GD535-5
(01)
40 Troubleshooting E-32 All wipers do not operate
Circuit diagram related to wiper
GD535-5 40-501
(01)
E-33 Front wiper does not operate 40 Troubleshooting
E-33 Front wiper does not operate 1
Failure Front wiper does not operate.

q If all the wipers do not operate, see “NO WIPER OPERATES CONTINUOUSLY OR INTERMITTENTLY”
in E mode.
q By using combination of front Hi wiper relay and front Lo wiper relay, and front wiper intermittent unit, Hi/
Lo/Intermittent are switched as follows.
q When 24 V power is supplied to pin 3 and pin 4 of wiper intermittent unit (front: L48), wiper operates
intermittently.
Related
q Front Hi wiper relay (C14) switches 24 V power supply (pin 1: Hi, pin 2: Lo, INT) of wiper motor (front:
information
C15).
q "SW OFF" terminal of wiper motor is output of wiper motor which shows wiper is in end position. With
this signal, wiper intermittent unit stops temporarily supplying 24 V power to wiper motor (makes out-
put of L48 pin 5 to pulse state).
q Front Lo wiper relay switches pulse output voltage from wiper intermittent unit at intermittent opera-
tion and constant voltage from C14 at Lo operation.

1 Defective fuse Perform troubleshooting for “ground fault in wiring harness” first.
q If fuse No.15 in fuse box FB2 is blown out, front and rear wipers do not work.
Defective front wiper 2. Disconnect connector C15, and connect T-adapter to male side.
2 motor (internal open
Between C15 (male) (1) and (3) Continuity
circuit) Continuity
Between C15 (male) (2) and (3) Continuity
2. Disconnect connector C14, and replace it with TM42 (backup lamp relay).
Defective front Hi wiper 3. Turn the starting switch to ON position.
3
relay 4. Turn on and off front Hi of wiper switch to perform troubleshooting.
If front wiper Hi operation is normal, original front Hi wiper relay is defective.
Defective front Lo wiper 3. Turn the starting switch to ON position.
4 4. Turn on and off front Lo of wiper switch to perform troubleshooting.
relay
If front wiper Lo and intermittent operation are normal, original front Lo wiper relay is
defective.
2. Replace connector L48 with new one.
Defective front wiper 3. Turn the starting switch to ON position.
5 4. Turn on and off Intermittent of wiper switch to perform troubleshooting.
intermittent unit
If front wiper intermittent operation is normal, original front wiper intermittent unit is
defective.
40-502 GD535-5
(01)
40 Troubleshooting E-33 Front wiper does not operate

Voltage Between FB2-14 and ground 20 to 30 V
2. Disconnect connector C12, and connect T-adapter to female side.
4. Turn on and off front Lo of wiper switch to perform troubleshooting.
Between C12 (female) (1)
Front Lo 20 to 30 V
and (2)
Front OFF 0V
Voltage and (2)
Pulse of 20
Front Intermittent to 30 V and
and (2)
0V
3. Turn on and off front Hi of wiper switch to perform troubleshooting.
6 harness (wire breakage or Front Hi 20 to 30 V
and (2)
defective contact)
Voltage Between C14 (female) (1)
Front OFF 0V
and (2)
Between C14 (female) (3) and (2) 20 to 30 V
q Wiper motor
4. Turn on and off front Hi/Lo/Intermittent of wiper switch to perform troubleshooting.
Front Lo 20 to 30 V
and (3)
Voltage Pulse of 20
Front Intermittent to 30 V and
and (3)
0V
Front Hi 20 to 30 V
and (3)
GD535-5 40-503
(01)
E-33 Front wiper does not operate 40 Troubleshooting

2. Disconnect connectors L21, L48, C11, C12, C13, C14, C16, C51, C53, and C54, and
connect T-adapter to female side of L21, C12, and C14.
3. Remove fuse No.14 and 15 in fuse box FB2.
Between L21 (female) (2) and ground Min. 1 MΩ
Resistance
ground circuit) Between C14 (female) (3) and ground Min. 1 MΩ
If no failure is found for “wiper motor” by checks on “open circuit in wiring harness”,
this check is not required.
2. Disconnect connectors C12, C14, and C15, and connect T-adapter to female side of
C15.
40-504 GD535-5
(01)
40 Troubleshooting E-33 Front wiper does not operate
GD535-5 40-505
(01)
E-34 Rear wiper does not operate 40 Troubleshooting
E-34 Rear wiper does not operate 1
Failure Rear wiper does not operate.

in E mode.
q If front wiper also does not operate, see “FRONT WIPER DOES NOT OPERATE” in E mode.
q With/without intermittent operation of rear wiper is switched by rear wiper intermittent relay through in-
termittent signal of front wiper switch.
q The rear wiper motor is driven by the power supplied from rear wiper intermittent unit C53 even during
continuous operation.
q When rear wiper motor detects stop position, it converts input voltage (24 V) of pin 2 to pulse signal, and
output it to pin 3.
Related q The rear wiper motor is driven by 24 V voltage pulse delivered between rear wiper intermittent unit C53
information and rear wiper motor during intermittent operation.
q Pins which are associated with this failure in wiper intermittent unit C53 are as follows.
q (1): GND 1
q (2): Output 1 (power supply 1 to wiper motor)
q (3): Continuous input (24 V)
q (4): Intermittent input (24 V)
q (6): 24 V common input
q (8): 24 V pulse input 1 from wiper motor
q Although T-adapter is not available for wiper intermittent unit C53, check the wiring harness of each pin
of wiper intermittent unit C53 for open circuit.

Defective rear wiper motor 2. Disconnect connector C16, and connect T-adapter to male side.
1
(internal open circuit)
Continuity Between C16 (2) and (4) Continuity
Defective rear wiper 3. Turn the starting switch to ON position.
2 4. Turn on rear wiper switch, and turn on and off intermittent of front wiper switch to
intermittent relay
perform troubleshooting.
If rear wiper operates normally, original rear wiper intermittent relay is defective.
2. Disconnect connectors C53 and C54, and interchange intermittent units with each
other.
Defective rear wiper 3. Turn the starting switch to ON position.
3
intermittent unit 4. Turn on rear wiper switch, and turn on and off intermittent of front wiper switch to
perform troubleshooting.
If rear wiper operates normally, original rear wiper intermittent unit is defective.
40-506 GD535-5
(01)
40 Troubleshooting E-34 Rear wiper does not operate

3. Insert T-adapter into connector C51.
5. Turn on and off intermittent of rear and front wiper switches to perform troubleshooting.
q Check the wiring harness
connected to pin 2 and 6
of C53 for open circuit. Rear ON 20 to 30 V
and (4)
Voltage
Rear OFF 0V
and (4)
Between C51 (1) and (2) Rear intermittent 20 to 30 V
Between C51 (3) and (2) Rear ON 20 to 30 V
Open circuit in wiring Between C51 (3) and (2) Rear OFF 0V
4 harness (wire breakage or q Description hereafter is check of wiring harness of wiper intermittent unit for open cir-
defective contact) cuit.
q Check pin 2 and pin 8 of C53 for open circuit.
Resistance Between C16 (female) (2) and (3) Max. 1 Ω
REMARK
q Since there are many diodes in internal circuit, take care about polarity of multimeter.
q If "OFF" is not displayed for resistance value in multimeter, this means that open circuit
does not occur.
q Check the wiring harness connected to pin 1 and 3 of
C53 for open circuit. 1 to 50 MΩ
Between C51 (female) (6) (+) and (2) (-)
Resistance
C53 for open circuit. 1 to 50 MΩ
Between C51 (female) (5) (+) and (2) (-)
2. Disconnect connectors L21, C16, C51, and C53, and connect T-adapter to female side
of C16 and C51.
Ground fault in wiring Between C51 (female) (3) and ground Min. 1 MΩ
ground circuit) Between C51 (female) (5) and ground Min. 1 MΩ
GD535-5 40-507
(01)
E-34 Rear wiper does not operate 40 Troubleshooting
40-508 GD535-5
(01)
40 Troubleshooting E-35 Left and right door wiper does not operate
E-35 Left and right door wiper does not operate 1
Failure Right and left door wipers do not operate.

in E mode.
q If either one of right and left door wipers does not operate, see “LEFT DOOR WIPER DOES NOT
OPERATE” or “RIGHT DOOR WIPER DOES NOT OPERATE” in E mode.
q With/without intermittent operation is switched by door wiper intermittent unit through intermittent signal
of front wiper switch.
q Power is supplied from wiper intermittent unit C54 even in continuous operation, and each door wiper
motor on right and left operates.
q When each door wiper motor on right and left detects stop position, it converts input voltage (24 V) of 1
pin to pulse signal, and output it to 3 pins.
q While intermittent operation, door wiper intermittent unit C54 and each door wiper motor on right and left
Related
receive/deliver 24 V voltage pulse, and each door wiper motor on right and left operates.
information
q Door wiper intermittent unit C54 has 2 wiper intermittent circuits.
q (1): GND 1
q (3): Continuous input (24 V)
q (4): Intermittent input (24 V)
q (6): 24 V common input
q (9): GND2
q Although T-adapter is not available for wiper intermittent unit C54, check the wiring harness of each pin
of wiper intermittent unit C54 for open circuit.

1 Defective fuse Perform troubleshooting for “ground fault in wiring harness” first.
q If fuse No.14 in fuse box FB2 is blown out, door wipers do not work.
REMARK
If door wiper does not work at Intermittent, check following.
Defective door wiper other.
2
intermittent unit 3. Turn the starting switch to ON position.
4. Turn on and off Intermittent of wiper switch to perform troubleshooting.
If right and left door wipers operate normally at Lo and Intermittent, original door wiper
intermittent unit is defective.
q Set the front wiper switch to Hi, and if right and left door wiper do not operate, perform
this check.
Defective diode (internal 2. Disconnect connector SP36, and connect T-adapter to male side.
3
defect)
Between SP36 (male) (1) (+) and (2) (-) No continuity
Continuity
Between SP36 (male) (2) (+) and (1) (-) Continuity
GD535-5 40-509
(01)
E-35 Left and right door wiper does not operate 40 Troubleshooting

q Description hereafter is check of wiring harness of wiper intermittent unit for open cir-
cuit.
2. Disconnect connectors L21, L48, C51, C12, and SP36, and connect Tadapter to
female side of L21.
REMARK
q There are many diodes in internal circuit. Pay attention to polarity of multimeter.
q If "OFF" is not displayed for resistance value in multimeter, this means that open circuit
does not occur.
q Check wiring harness connected 1 and 3 pin, 9 and 3
pin of C54 for open circuit. 1 to 50 MΩ
Between L21 (female) (5) (+) and ground
Open circuit in wiring Resistance
4 harness (wire breakage or q Check wiring harness connected 1 and 3 pin, 9 and 3
defective contact) pin of C54 for open circuit. 1 to 50 MΩ
Between L21 (female) (2) (+) and ground
2. Insert T-adapter into connectors C11 and C13.
4. Turn the front wiper switch to Lo position.
C54 for open circuit. 20 to 30 V
Voltage
C54 for open circuit. 20 to 30 V
If front wiper works at Lo, this check is not required.
Ground fault in wiring 2. Disconnect connectors C11, C13, C14, and C54, and connect T-adapter to female side
5 harness (contact with of C13.
ground circuit) 3. Remove fuse No.14 in fuse box FB2.
40-510 GD535-5
(01)
40 Troubleshooting E-35 Left and right door wiper does not operate
GD535-5 40-511
(01)
E-36 Left door wiper does not operate 40 Troubleshooting
E-36 Left door wiper does not operate 1
Failure Left door wiper does not operate.

in E mode.
q If right and left wipers do not operate, see “RIGHT AND LEFT DOOR WIPERS DO NOT OPERATE”
Related
in E mode.
information
q With/without intermittent operation of door wiper is switched by door wiper intermittent relay through in-
termittent signal of front wiper switch.
q Although T-adapter is not available for wiper intermittent unit C54, check the wiring harness of wiper in-
termittent unit C54 for open circuit.

Defective left door wiper 2. Disconnect connector C11, and connect T-adapter to male side.
1
motor
Continuity Between C11 (male) (2) and (4) Continuity
REMARK
Check that rear wiper operates normally.
2
4. Perform troubleshooting with front wiper switch at Lo and Intermittent.
If left door wiper operates normally at Lo and Intermittent, original door wiper intermittent
unit is defective.
q Wiper motor
4. Turn on and off Lo wiper switch to perform troubleshooting.
harness (wire breakage or Between C11 (female) (2)
3 Front Lo 20 to 30 V
defective contact of Voltage and (4)
connector) Between C11 (female) (2)
Front OFF 0V
and (4)
q Check pin 5 and pin 7 of C54.
q If no failure is found for wiper motor by checks on open circuit of wiring harness, this
check is not required.
4 harness (contact with 2. Disconnect connectors C11 and C54, and connect T-adapter to female side of C11.
ground circuit)
Resistance
40-512 GD535-5
(01)
40 Troubleshooting E-36 Left door wiper does not operate
GD535-5 40-513
(01)
E-37 Right door wiper does not operate 40 Troubleshooting
E-37 Right door wiper does not operate 1
Failure Right door wiper does not operate.

in E mode.
q If right and left wipers do not operate, see “RIGHT AND LEFT DOOR WIPERS DO NOT OPERATE”
Related
in E mode.
information
q With/without intermittent operation is switched by door wiper intermittent unit through intermittent signal
of front wiper switch.
q Although T-adapter is not available for wiper intermittent unit C54, check the wiring harness of wiper in-
termittent unit C54 for open circuit.

Defective right door wiper 2. Disconnect connector C13, and connect T-adapter to male side.
1
motor
Continuity Between C13 (2) and (4) Continuity
REMARK
Check that rear wiper operates normally.
2
4. Perform troubleshooting with front wiper switch at Lo and Intermittent.
If right door wiper operates normally at Lo and Intermittent, original door wiper intermittent
unit is defective.
q Wiper motor
4. Turn on and off Lo of wiper switch to perform troubleshooting.
Open circuit in wiring Between C13 (female) (2)
3 harness (wire breakage or Front Lo 20 to 30 V
Voltage and (4)
defective contact)
Front OFF 0V
and (4)
q Check pin 2 and pin 8 of C54.
q If no failure is found for "wiper motor" by checks on open circuit in wiring harness, this
check is not required.
4 harness (contact with 2. Disconnect connectors C13 and C54, and connect T-adapter to female side of C13.
ground circuit)
Resistance
40-514 GD535-5
(01)
40 Troubleshooting E-37 Right door wiper does not operate
GD535-5 40-515
(01)
E-38 Front or door washer does not operate 40 Troubleshooting
E-38 Front or door washer does not operate 1
Failure Front washer or door washer does not operate.

Related
in E mode.
information
q T-adapter is not provided to the connector of a washer motor (check without a T-adapter).

2. Disconnect connector L21, and connect T-adapter to male side.
Defective front wiper 3. Turn on and off wiper switch to perform troubleshooting.
1
switch (internal defect)
Between L21 (male) (7) and Front washer switch: ON Max. 1 Ω
Resistance
(6) Front washer switch: OFF Min. 1 MΩ
q If front washer operates, this check is not required.
Defective front washer 1. Turn the starting switch to OFF position.
2 motor (internal open 2. Disconnect connector B16, and connect T-adapter to male side.
circuit)
Continuity Between B16 (male) (1) and (2) Continuity
q When door washer works, this check is not required.
Defective door washer 1. Turn the starting switch to OFF position.
3 2. Disconnect connector B15, and connect T-adapter to male side.
motor
Continuity Between B15 (male) (1) and (2) Continuity
q Perform the following troubleshooting when both front washer and door washer do not
operate.
2. Disconnect connectors B20 and B21, and connect T-adapter to each male side.
Defective diode (internal
4 Between B20 (male) (1) (+) and (2) (-) No continuity
defect)
Between B20 (male) (2) (+) and (1) (-) Continuity
Continuity
Between B21 (male) (1) (+) and (2) (-) No continuity
q Front washer system
2. Disconnect connectors L21, B15, B20, and B21, and connect T-adapter to female side
of L21.
Open circuit in wiring Continuity Between L21 (female) (6) and ground Continuity
5 harness (wire breakage or
defective contact) q Door washer system
2. Disconnect connectors L21, B16, B20, and B21, and connect T-adapter to female side
of L21.
Continuity Between L21 (female) (6) and ground Continuity
q Perform the following troubleshooting when both front washer and door washer do not
operate.
6 harness (contact with 2. Disconnect connectors L21, B15, B16, B20, and B21, and connect Tadapter to female
ground circuit) side of L21.
Resistance Between L21 (female) (6) and ground Min. 1 MΩ
40-516 GD535-5
(01)
40 Troubleshooting E-38 Front or door washer does not operate
Circuit diagram related to windshield washer
GD535-5 40-517
(01)
E-39 Rear washer does not operate 40 Troubleshooting
E-39 Rear washer does not operate 1
Failure Rear washer does not operate.

q If wiper also do not operate, see “NO WIPER OPERATES CONTINUOUSLY OR INTERMITTENTLY”
Related
or “REAR WIPER DOES NOT OPERATE” in E mode.
information
q T-adapter is not provided to the connector of a washer motor (check without a T-adapter).

to OFF position.
Defective rear wiper 3. Disconnect connector L21, and connect T-adapter to male side.
1
switch 4. Turn on and off rear wiper switch to perform troubleshooting.
Between L21 (male) (7) and
(10)
Rear washer switch: ON Max. 1 Ω
Resistance
Between L21 (male) (7) and
Rear washer switch: OFF Min. 1 MΩ
(10)
Defective rear washer 1. Turn the starting switch to OFF position.

2 motor (internal open 2. Disconnect connector B17, and connect T-adapter to male side.
circuit) Continuity Between B17 (male) (1) and (2) Continuity
Defective diode (internal
3
defect) Between B22 (male) (1) (+) and (2) (-) No continuity
Continuity

4 harness (wire breakage or 2. Disconnect connectors B22 and L21, and connect T-adapter to female side of L21.
defective contact) Continuity Between L21 (female) (10) and ground Continuity

5 harness (contact with 2. Disconnect connectors L21, B17, B22, and connect T-adapter to female side of L21.
ground circuit) Resistance Between L21 (female) (10) and ground Min. 1 MΩ
40-518 GD535-5
(01)
40 Troubleshooting E-39 Rear washer does not operate
Circuit diagram related to windshield washer
GD535-5 40-519
(01)
E-40 KOMTRAX system does not operate normally. 40 Troubleshooting
E-40 KOMTRAX system does not operate normally. 1
Failure KOMTRAX system does not operate normally.

q Perform following troubleshooting if administrator of KOMTRAX system requests to check whether fail-
ure occurs in system on machine.
q Even when KOMTRAX system is defective, no problem appears on machine.
Related q All troubleshooting can be checked on the service menu of the machine monitor.
information q For checking the terminal settings, see Testing and adjusting "Checking the KOMTRAX setting display
(terminal setting status)".
q For checking the GPS and communication status, see Testing and adjusting "Checking the KOMTRAX
setting display (GPS and communication status)".

2. Display the "Terminal Setting Status" screen.
1 Transmitting error 1
Check item: Radio station
Monitoring display Established
establishment state
2. Display the "GPS & Communication Status" screen.
N ###.##.## (Latitude)
2 Defective GPS positioning Monitoring display Check item: Positioning E ###.##.## (Longitude)
Positioning in Progress
If the latitude and longitude are not displayed within 5 minutes in an open-sky area, call
the KOMTRAX service hot-line for advice.
Communication reception
Defective communication range level 1 to
3 Monitoring display Check item: Communication
environment communication reception
range level 3
Contact KOMTRAX Service hot-line if Communication reception range is not within level 1
to 3.
4 Transmitting error 2
Check item: Number of
Monitoring display 0 to 100 (normally 0)
message(s) not yet sent
40-520 GD535-5
(01)
40 Troubleshooting E-40 KOMTRAX system does not operate normally.
GD535-5 40-521
(01)
How to use troubleshooting table 40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-mode) 1
How to use troubleshooting table 1
This troubleshooting chart indicates the location where the problem occurring on the machine and categorizes the
problem under one of the main components, such as the steering system or work equipment hydraulic system.
Use the following procedure to perform accurate troubleshooting swiftly.
Step 1. Ask operator questions Step 3. How to read matrix

q The questions to ask the operator are given under 1. Operate the machine and perform troubleshooting
the problem. If the answer to the question introduced in the Diagnosis column. If any prob-
matches the description given, the cause given lems occur as the result of the troubleshooting, put
after "o" is the probable cause. Keeping the a check in the corresponding box.
description of the questions in mind, read the
a Perform troubleshooting for easier items first. It
matrix and proceed with Step 2 and Step 3 to pin-
is not necessary to follow the number order.
point the correct cause.
(Example)
Example: Machine does not turn Remedy
Ask the operator and check the following points. No
Diagnosis
q Did the problem suddenly start?
-> Broken device related to steering 1 Machine turns neither right nor left
q Was the steering wheel operation heavy before?
2 Machine turns only right or left
-> Worn part or defective seal in device related to
steering Steering wheel operation is heavy in both
3
right and left directions
Step 2. Checks before troubleshooting Steering wheel is too heavy to turn in either
q Before measuring the oil pressure or starting the 4
right or left direction
troubleshooting, perform the checks before start-
ing, check for oil leakage, or for loose bolts. This 5 Work equipment operates.
will prevent wasting time when troubleshooting.
The items given under Checks before trouble-
shooting are checks that must be performed with 2. Find the corresponding cause in the cause column.
special care taking the condition of the machine If a problem is found, the Q marks on the same
into consideration before starting the actual trou- line for the troubleshooting item are the causes.
bleshooting. (In Diagnosis item 2 in the diagram below, the
cause is c or e.)
Example: Check before starting troubleshooting [Where there is 1 Q mark]
q Is oil level and type of oil in hydraulic tank correct? Perform troubleshooting for the other items
q Is there any oil leakage from steering valve or marked with Q in the same column for the cause
demand valve? to check if the problem occurs, then make repairs.
q Is steering linkage adjusted properly? [Where there are 2 or more Q marks]
Go to step 3 to narrow down the cause.
40-522 GD535-5
(01)
40 Troubleshooting How to use troubleshooting table
3. Operate the machine and perform troubleshooting 6. Repeat the operation in Step 3 to 5 until the cause
for the items not checked in step 2, and if any is narrowed down to 1 item (1 common item).
problem occurs, put a check in the corresponding If cause items are 2 or more, continue until num-
line. ber of items becomes minimum.
(In troubleshooting item 5 in the figure below, the
problem was re-produced.) 7. Remedy
After narrowing down the common causes, taken
4. Find the corresponding cause in the cause column. the action given in the remedy line.
If a problem is found, the Q marks on the same [Symbols in remedy column and their meanings]
line for the troubleshooting item are the causes. x=Replace; E=Repair; A=Adjust; C=Clean
(In Diagnosis item 5 in the figure below, the cause
is "b" or "e".)
5. Narrow down the causes.

Of the causes found in Step 2 and Step 5, there is
a common cause (Q marks on the line for each
troubleshooting item and in the common cause
column for both) is a cause common to the prob-
lem items found in the troubleshooting in Step 2
and Step 3.
a The items that are not common (items that do
not have Q marks in the same cause column)
are probably not the cause, so they can be
eliminated. (The causes for troubleshooting
item 2 in the figure below are "c" or "e", and the
causes in troubleshooting item 5 are "b" or "e",
so cause e is a common cause.)
GD535-5 40-523
(01)
40-524 GD535-5
(01)
GD535-5 40-525
(01)
40-526 GD535-5
(01)
GD535-5 40-527
(01)
H-1 Engine speed drops significantly or engine stalls 40 Troubleshooting
H-1 Engine speed drops significantly or engine stalls 1
Checks before troubleshooting Cause

q Check the hydraulic oil tank level. a b c
Malfunction of main pump (servo piston)

Internal failure of main pump
Engine failure
Remedy
EEE
No.
Diagnosis X X X
1 Main pump assembly is abnormal. Q

2 Main pump is abnormal. Q
3 Basic engine may be defective. Q
* Perform troubleshooting of engine (S-mode).
40-528 GD535-5
(01)
40 Troubleshooting H-2 Machine does not move off.
H-2 Machine does not move off. 1

q Check that transmission case oil level is normal. a b c d e f g h i
q Check the oil pressure while torque converter oil temperature gauge is in opera-
Defective connection of power train pump (drive system)

tor range.
Air sucked into suction circuit of power train pump
Malfunction of torque converter main relief valve

Clogged transmission case suction strainer
Malfunction of power train main relief valve

Internal defect of power train pump
Internal defect of torque converter

Internal defect of transmission
Internal defect of PTO
Remedy
EEEEEEEEE
No.
Diagnosis X X C X X X X X X
1 Machine does not move off in any gear position. Q Q Q Q Q Q Q Q Q

2 Machine does not move off in specific gear position. Q
When transmission oil temperature is low, noise is generated in the strainer or
3 Q Q
transmission filter.
4 Oil pressure of power train main relief valve is abnormal. Q
5 Torque converter inlet pressure is low. Q
6 Torque converter outlet pressure is abnormal. Q
7 The transmission system is abnormal. Q
GD535-5 40-529
(01)
H-3 Gear speed does not shift. 40 Troubleshooting
H-3 Gear speed does not shift. 1

q Check that transmission case oil level is normal. a b c
q Check the oil pressure while torque converter oil temperature gauge is in operator range.
Move gear shift lever to each gear speed and check that gear cannot be shifted only for forward
or reverse travel. Then, perform troubleshooting.
Wear or damage of transmission clutch disc or plate

Malfunction of transmission clutch valve (ECMV)
Defective sealing of transmission clutch piston
Remedy
EEE
No.
Diagnosis X X X
1 Machine does not travel forward or reverse. Q Q Q

2 Gear is not shifted up or down. Q Q Q
3 Defective sealing of transmission clutch piston Q
4 Wear or damage of transmission clutch disc or plate Q
40-530 GD535-5
(01)
40 Troubleshooting H-4 Travel speed or power is low.
H-4 Travel speed or power is low. 1

q Check that transmission case oil level is normal. a b c d e f g h i j
q Check the oil pressure while torque converter oil temperature gauge is in
Wear or damage of corresponding clutch disc or plate

operator range.
Malfunction of corresponding clutch valve (ECMV)

q Check that wheel brake and parking brake are not dragging, and then per-
Internal defect of power train pump (pump body)
Malfunction of torque converter main relief valve
Defective sealing of corresponding clutch piston

form troubleshooting.
Clogged transmission case suction strainer

Internal defect of final drive
Remedy
C EEEEE
No. X * * *
Diagnosis X X X X X X
Metal powder (such as aluminum, copper and iron powder) is adhered to

1 Q Q Q
transmission filter and strainer.
When transmission oil temperature is low, noise is generated in the pump or
2 Q Q
transmission filter.
3 Overheat of torque converter oil temperature Q Q Q Q Q Q
4 Abnormal main relief pressure of power train Q Q
5 Low oil pressure of ECMV output (clutch) Q Q Q Q Q Q
6 Defective seal of torque converter lockup clutch piston Q
7 Wear or damage of torque converter lockup clutch disc or plate Q
8 Defective sealing of transmission clutch piston Q
10 Torque converter main relief inlet pressure is low. Q Q
11 Abnormal final drive Q
* Go to "Locating the failure clutch and ECMV (Check by remodeling code)".
GD535-5 40-531
(01)
H-4 Travel speed or power is low. 40 Troubleshooting
* Locating the failure clutch and ECMV (Check by failure code) (H-4)
a For checking the failure code display, see Testing and adjusting "Special functions of machine monitor ".
a If replacing the ECMV for troubleshooting, remove mud and dust, and clean the ECMV. Then, tighten mounting
bolts with the specified torque.
a Start the engine, select the Manual mode, and perform the following troubleshooting.
Cause
ECMV operation table
a b c d e f g
No.
2nd
3rd
4th
FH
1st
FL
R
SPEED RANGE
F1 W W
F2 W W
F3 W W
Operation failure of 2nd clutch ECMV (fill switch)

Operation failure of 3rd clutch ECMV (fill switch)
Operation failure of 4th clutch ECMV (fill switch)
Operation failure of FH-clutch ECMV (fill switch)
Operation failure of 1st clutch ECMV (fill switch)

Operation failure of FL-clutch ECMV (fill switch)
W W
Operation failure of R-clutch ECMV (fill switch)

F4
F5 W W
F6 W W
F7 W W
F8 W W
N
R1 W W
R2 W W
R3 W W
R4 W W
a When the lever is in N position in Manual mode, the clutch of the gear (Q mark)
selected by the lever is ON.
a When the lever is in N position, the clutch is not switched.
Remedy
Failure
No. X X X X X X X
Diagnosis Code
Failure code "15SDL1" is not displayed in F1, F3, F5 and F7 positions. It is displayed in R1
(1) 15SDL1 Q
to R4, F2, F4, F6 and F8 positions.
1
After Step (1), failure code 15SDL1 is not displayed if F1 fill switch connector (T36) is
(2) 15SDMA
disconnected. Failure code 15SDMA is not displayed if ECMV (other than F) is replaced.
Failure code "15SCL1" is not displayed in F2, F4, F6 and F8 positions. It is displayed in R1
(1) 15SCL1 Q
2
After Step (1), failure code 15SCL1 is not displayed if FH fill switch connector (T37) is
(2) 15SCMA
disconnected. Failure code 15SCMA is not displayed if ECMV (other than FH) is replaced.
Failure code "15SBL1" is not displayed in R1 to R4 positions, but displayed in F1 to F8
(1) 15SBL1 Q
positions.
3
After Step (1), failure code 15SBL1 is not displayed if R fill switch connector (T38) is
(2) 15SBMA
disconnected. Failure code 15SBMA is not displayed if ECMV (other than R) is replaced.
Failure code "15SEL1" is not displayed in F1 and F2 positions. It is displayed in F3 to F8
(1) 15SEL1 Q
and R1 to R4 positions.
4
After Step (1), failure code 15SEL1 is not displayed if 1st fill switch connector (T39) is
(2) 15SEMA
disconnected. Failure code 15SEMA is not displayed if ECMV (other than 1st) is replaced.
Failure code "15SFL1" is not displayed in F3 and F4 positions. It is displayed in F1, F2, F5
(1) 15SFL1 Q
to F8 and R1 to R4 positions.
5
After Step (1), failure code 15SFL1 is not displayed if 2nd fill switch connector (T40) is
(2) 15SFMA
disconnected. Failure code 15SFMA is not displayed if ECMV (other than 2nd) is replaced.
Failure code "15SGL1" is not displayed in F5 and F6 positions. It is displayed in F1 to F4,
(1) 15SGL1 Q
F7, F8, and R1 to R4 positions.
6
Step (1), failure code 15SGL1 is not displayed if 3rd fill switch connector (T41) is
(2) 15SGMA
disconnected. Failure code 15SGMA is not displayed if ECMV (other than 3rd) is replaced.
Failure code "15SHL1" is not displayed in F7 and F8 positions. It is displayed in F1 to F6
(1) 15SHL1 Q
7
After Step (1), failure code 15SHL1 is not displayed if 4th fill switch connector (T42) is
(2) 15SHMA
disconnected. Failure code 15SHMA is not displayed if ECMV (other than 4th) is replaced.
40-532 GD535-5
(01)
40 Troubleshooting H-4 Travel speed or power is low.
* Locating the failure ECMV (Check by failure code)

a For checking the failure code display, see Testing and adjusting "Special functions of machine monitor".
Cause
h i j k l m n
No.
2nd
3rd
4th
FH
1st
FL
R
SPEED RANGE
F1 W W
Wear or seizure of 2nd clutch disc, or wear of piston seal

Wear or seizure of 3rd clutch disc, or wear of piston seal
Wear or seizure of 4th clutch disc, or wear of piston seal
Wear or seizure of FH clutch disc, or wear of piston seal
Wear or seizure of 1st clutch disc, or wear of piston seal

Wear or seizure of FL clutch disc, or wear of piston seal
Wear or seizure of R clutch disc, or wear of piston seal

F2 W W
F3 W W
F4 W W
F5 W W
F6 W W
F7 W W
F8 W W
N
R1 W W
R2 W W
R3 W W
R4 W W
a When the lever is in N position in Manual mode, the clutch of the gear (Q
mark) selected by the lever is ON.
Remedy
Failure
No. X X X X X X X
Diagnosis code
Failure code 15G0MW is not displayed in F1 to F8 positions, but displayed in R1 to R4

(1)
positions.
1 15G0MW Q
See the Testing and adjusting, "Testing power train oil pressure", and make sure that R-
(2)
clutch oil pressure is normal.
Failure code15H0MW is not displayed in F1, 3, 5, 7 and R1 to R4 positions, but displayed
(1)
in F2, 4, 6 and 8 positions.
2 15H0MW Q
See the Testing and adjusting, "Testing power train oil pressure", and make sure that FH-
(2)
Failure code15J0MW is not displayed in F2, 4, 6, 8 and R1 to R4 positions, but displayed
(1)
in F1, 3, 5 and 7 positions.
3 15J0MW Q
See the Testing and adjusting, "Testing power train oil pressure", and make sure that FL-
(2)
Failure code 15K0MW is not displayed in F3 to F8 and R2 to R4 positions, but displayed
(1)
in F1 to F2 and R1 positions.
4 15K0MW Q
See the Testing and adjusting, "Testing power train oil pressure", and make sure that 1st
(2)
Failure code 15L0MW is not displayed in F1 to F2, F5 to F8, and R1, 3 and 4 positions,
(1)
but displayed in F3, F4 and R2 positions.
5 15L0MW Q
See the Testing and adjusting, "Testing power train oil pressure", and make sure that 2nd
(2)
Failure code 15M0MW is not displayed in F1 to F4, F7 to F8, and R1, 2 and 4 positions,
(1)
but displayed in F5, F6 and R3 positions.
6 15M0MW Q
See the Testing and adjusting, "Testing power train oil pressure", and make sure that 3rd
(2)
Failure code 15N0MW is not displayed in F1 to F6 and R1 to R3 positions, but displayed
(1)
in F7, F8 and R4 positions.
7 15N0MW Q
See the Testing and adjusting, "Testing power train oil pressure", and make sure that 4th
(2)
GD535-5 40-533
(01)
H-5 Torque converter lockup does not operate or is not canceled. 40 Troubleshooting
H-5 Torque converter lockup does not operate or is not canceled. 1

q Because the lockup clutch (L/C) of the torque converter is not engaged, the torque converter is
in the torque converter mode regardless of the selection of the transmission mode selector
switch.
Wear or damage of lockup clutch disc or plate

Failure of lockup clutch ECMV operation
Defective seal of lockup clutch piston
Remedy
No. X X X
Diagnosis
1 Lockup oil pressure is low or zero. Q Q

2 Lockup oil pressure is zero, but not turned OFF. Q
40-534 GD535-5
(01)
40 Troubleshooting H-6 Machine starts or gear speed shifts with long time lag.
H-6 Machine starts or gear speed shifts with long time lag. 1

q Move gear shift lever to each gear speed and check gear speed or forward/reverse travel caus-
ing long time lag. Then, perform troubleshooting.
q Check that travel speed is normal before performing troubleshooting.

(If it is not normal, perform troubleshooting for "H-4 Travel speed or power is low" first.)

Malfunction of corresponding ECMV
Remedy
No. * * *
Diagnosis
1 Time lag is large in specific gears. Q Q

2 ECMV output (clutch) oil pressure is low in specific gears. Q Q
* Go to "Locating the failure clutch and ECMV (Check by remodeling code)".
GD535-5 40-535
(01)
H-6 Machine starts or gear speed shifts with long time lag. 40 Troubleshooting
* Locating the failure clutch and ECMV (Check by failure code)

Cause
a b c d e f g
No.
2nd
3rd
4th
1st
FH
FL
R
SPEED RANGE
F1 W W
F2 W W
F3 W W


W W

F4
F5 W W
F6 W W
F7 W W
F8 W W
N
R1 W W
R2 W W
R3 W W
R4 W W
Remedy
Failure
No. X X X X X X X
Diagnosis Code
(1) 15SDL1 Q
1
After Step (1), failure code 15SDL1 is not displayed if FL fill switch connector (T36) is
(2) 15SDMA
(1) 15SCL1 Q
2
(2) 15SCMA
(1) 15SBL1 Q
positions.
3
(2) 15SBMA
(1) 15SEL1 Q
4
(2) 15SEMA
(1) 15SFL1 Q
5
(2) 15SFMA
(1) 15SGL1 Q
6
After Step (1), failure code 15SGL1 is not displayed if 3rd fill switch connector (T41) is
(2) 15SGMA
(1) 15SHL1 Q
7
(2) 15SHMA
40-536 GD535-5
(01)
40 Troubleshooting H-6 Machine starts or gear speed shifts with long time lag.

a For checking the failure code display, see Inspection and adjusting "Special functions of machine monitor
(EMMS)".
ECMV operation table Cause
No. h i j k l m n
2nd
3rd
4th
FH
1st
FL
R
SPEED RANGE

W W


F1

F2 W W
F3 W W
F4 W W
F5 W W
F6 W W
F7 W W
F8 W W
N
R1 W W
R2 W W
R3 W W
R4 W W
Remedy
Failure
No. X X X X X X X
Diagnosis Code
Failure code "15SDL1" is not displayed in F1, F3, F5 and F7 positions. It is displayed in
(1) 15SDL1 Q
R1 to R4, F2, F4, F6 and F8 positions.
1
After Step (1), failure code 15SDL1 is not displayed if F fill switch connector (T36) is
(2) 15SDMA Q
unplugged. Failure code 15SDMA is not displayed if ECMV (other than F) is replaced.
Failure code "15SCL1" is not displayed in F2, F4, F6 and F8 positions. It is displayed in
(1) 15SCL1 Q
R1 to R4, F1, F3, F5 and F7 positions.
2 After Step (1), failure code 15SCL1 is not displayed if FH fill switch connector (T37) is
(2) unplugged. ***No Translation*** Failure code 15SCMA is not displayed if ECMV (other 15SCMA Q
than FH) is replaced.
(1) 15SBL1 Q
positions.
3
(2) 15SBMA Q
unplugged. Failure code 15SBMA is not displayed if ECMV (other than R) is replaced.
(1) 15SEL1 Q
4
(2) 15SEMA Q
unplugged. Failure code 15SEMA is not displayed if ECMV (other than 1st) is replaced.
Failure code "15SFL1" is not displayed in F3 and F4 positions. It is displayed in F1, F2,
(1) 15SFL1 Q
F5 to F8 and R1 to R4 positions.
5
(2) 15SFMA Q
unplugged. Failure code 15SFMA is not displayed if ECMV (other than 2nd) is replaced.
(1) 15SGL1 Q
6
(2) 15SGMA Q
unplugged. Failure code 15SGMA is not displayed if ECMV (other than 3rd) is replaced.
(1) 15SHL1 Q
7
(2) 15SHMA Q
unplugged. Failure code 15SHMA is not displayed if ECMV (other than 4th) is replaced.
GD535-5 40-537
(01)
H-7 Torque converter oil temperature is high. 40 Troubleshooting
H-7 Torque converter oil temperature is high. 1

q Check that transmission case oil level is normal. a b c d e f g h i j
q Check the oil pressure while torque converter oil temperature gauge is in
operator range.
q Check that wheel brake and parking brake are not dragging, and then per-
form troubleshooting.
Wear or damage of torque converter lockup clutch disc or plate

Malfunction of torque converter lockup clutch valve (ECMV)
Defective seal of torque converter lockup clutch piston

Malfunction of torque converter relief valve
Malfunction of corresponding ECMV


Remedy
EE EEE E
No. X * * *
1 Insufficient travel speed, thrust and gradeability in all gears Q Q Q Q Q Q Q Q Q Q

2 Insufficient travel speed, thrust and gradeability in specific gears Q
3 Abnormal speed during engine low idle or during high idle Q Q
4 Torque converter stall speed is too high. Q Q Q Q Q Q Q Q Q Q
5 ECMV output (clutch) oil pressure is low in specific gears. Q
6 Torque converter main relief inlet pressure is low. Q Q
* Go to "Locating the failure clutch and ECMV (Check by failure code)".
40-538 GD535-5
(01)
40 Troubleshooting H-7 Torque converter oil temperature is high.
* Locating the failure clutch and ECMV (Check by failure code)

Cause
a b c d e f g
No.
2nd
3rd
4th
1st
FH
FL
R
SPEED RANGE
F1 W W
F2 W W
F3 W W



F4 W W
F5 W W
F6 W W
F7 W W
F8 W W
N
R1 W W
R2 W W
R3 W W
R4 W W
Remedy
Failure
No. X X X X X X X
Diagnosis Code
(1) 15SDL1 Q
1
After Step (1), failure code 15SDL1 is not displayed if FL fill switch connector (T36) is
(2) 15SDMA
(1) 15SCL1 Q
2
(2) 15SCMA
(1) 15SBL1 Q
positions.
3
(2) 15SBMA
(1) 15SEL1 Q
4
(2) 15SEMA
(1) 15SFL1 Q
5
(2) 15SFMA
(1) 15SGL1 Q
6
(2) 15SGMA
(1) 15SHL1 Q
7
(2) 15SHMA
GD535-5 40-539
(01)
H-7 Torque converter oil temperature is high. 40 Troubleshooting

ECMV operation table Cause
No. h i j k l m n
2nd
3rd
4th
FH
1st
FL
R
SPEED RANGE

W W

F1

F2 W W
F3 W W
F4 W W
F5 W W
F6 W W
F7 W W
F8 W W
N
R1 W W
R2 W W
R3 W W
R4 W W
Remedy
Failure
No. X X X X X X X
Diagnosis Code
(1) 15SDL1 Q
1
After Step (1), failure code 15SDL1 is not displayed if F fill switch connector (T36) is
(2) 15SDMA Q
(1) 15SCL1 Q
2
(2) 15SCMA Q
(1) 15SBL1 Q
positions.
3
(2) 15SBMA Q
(1) 15SEL1 Q
4
(2) 15SEMA Q
(1) 15SFL1 Q
5
(2) 15SFMA Q
(1) 15SGL1 Q
6
(2) 15SGMA Q
(1) 15SHL1 Q
7
(2) 15SHMA Q
40-540 GD535-5
(01)
40 Troubleshooting H-8 Differential gear lock function does not operate or is not canceled.
H-8 Differential gear lock function does not operate or is not canceled. 1

q Check that final drive case oil level is normal. a b c d e f g
q Check oil pressure when final drive case oil temperature is 60 to 80°C.
Malfunction and defective adjustment of differential lock valve

Defective connection of differential lock pump (drive system)
Wear or damage of differential lock clutch disc or plate

Air sucked into suction circuit of differential lock pump
Internal defect of differential lock pump (pump body)
Defective sealing of differential lock clutch piston

Clogged final drive case suction strainer
Remedy
EC EEE
No. E X
Diagnosis X X X X X
1 Differential lock pump does not rotate. Q Q Q Q Q Q Q

2 Noise is heard from strainer when final drive case oil temperature is low. Q Q Q
3 Differential lock (pump outlet or valve outlet) oil pressure is abnormal. Q
4 Differential lock caution lamp lights up and caution buzzer sounds. Q Q Q Q Q Q
GD535-5 40-541
(01)
H-9 Steering speed or power is insufficient. 40 Troubleshooting
H-9 Steering speed or power is insufficient. 1

q Check that the hydraulic oil tank level is normal. a b c
q Check oil pressure and oil leakage of cylinder when hydraulic oil temperature is 45 to 55°C.
q Check that the work equipment operates normally before performing troubleshooting.
q (If it is not normal, perform troubleshooting for "H-15 Travel speed or power is low" first.)
q Since steering valve (Orbitrol) is variable ratio type, steering speed varies depending on steer-
ing wheel speed.
Malfunction of priority valve (relief valve)
Defective sealing of steering cylinder

Malfunction of steering valve
Remedy
EEE
No.
Diagnosis X X X
1 Response is low in both right and left steering directions. Q Q Q

2 Steering wheel operation is heavy in both right and left directions. Q
3 Work equipment operates. Q Q Q
4 Steering relief oil pressure is low in both right and left directions. Q Q
40-542 GD535-5
(01)
40 Troubleshooting H-10 Steering wheel does not move
H-10 Steering wheel does not move 1

q Check that the hydraulic oil tank level is normal. a b c
Defective connection between steering wheel and steering valve

(If it is not normal, perform troubleshooting for "H-16 All work equipment do not operate" first.)
Malfunction of steering valve

Deformed steering cylinder
Remedy
EE
No. X
Diagnosis X X
1 Steering wheel idles. Q Q

2 Steering wheel operation is heavy in both right and left directions. Q Q
GD535-5 40-543
(01)
H-11 Wheel brakes do not work or are weak 40 Troubleshooting
H-11 Wheel brakes do not work or are weak 1

q Check that the hydraulic oil tank level is normal. a b c d e f g
q Check oil pressure and oil leakage of cylinder when hydraulic oil temperature is 45 to
55°C.
(If abnormal, perform troubleshooting for "H-15 Travel speed or power is low" or "H-
16 All work equipment do not operate" first.)
Malfunction of brake accumulator charge valve (pressure governor valve)

Malfunction of brake accumulator charge valve (LS relief valve)
Lowered gas pressure of brake accumulator
Insufficient bleeding air from brake circuit

Wear or damage of brake disc or plate
Defective brake piston seal
Remedy Defective brake valve
EEEEEE
No. E
1 No resistance when brake pedal is depressed Q Q Q Q Q

2 The brake pedal is heavy when depressed. Q
3 Need to depress too much to get the specified braking force. Q Q Q
4 Abnormal noise is heard from axle brake during braking. Q
5 Machine does not travel (due to insufficient traction). Q
6 Air flows during brake circuit air vent. Then machine operates normally. Q
7 Excessive leakage of brake oil from axle Q
8 Insufficient braking force although force and stroke of brake pedal are normal Q
9 Insufficient braking force when engine is stopped Q Q Q Q Q
10 Accumulator is not charged, and buzzer sounds. Q Q Q
11 Time lag occurs during braking. Q
40-544 GD535-5
(01)
40 Troubleshooting H-12 Wheel brakes are not released or drag
H-12 Wheel brakes are not released or drag 1

q Check that the brake pedal is returned completely.
Wheel brake
Brake valve
q Check that the parking brake is released completely.
Check of abnormality
q The brake is abnormally heated.
q Machine can coast on a flat place. a b c
Internal failure of brake valve (piston fixed)
Malfunction of brake piston in axle

Failure of brake disc in axle
Remedy
EEE
No.
Diagnosis X X X
1 Braking continues even when the brake pedal is released. Q Q Q

When brake pedal is released and when oil is removed from air vent breather, circuit pressure
2 Q
drops and brake is released.
Machine is jacked up, engine is stopped, and parking brake is released. Specific wheels are heavy
3 Q Q
when rotated by hand.
GD535-5 40-545
(01)
H-13 Parking brake does not work or it is weak 40 Troubleshooting
H-13 Parking brake does not work or it is weak 1
Ask the operator about the following: Cause

q Does the brakes fail suddenly? o Damage of related parts
Parking brake
q Is abnormal noise heard? Where is the noise generated?
Solenoid
q Does the braking capacity drop gradually? o Wear of related parts or damaged seal
Checks before troubleshooting

q Did you mechanically release the parking brake?
a b c d
Failure of parking brake solenoid valve
Malfunction of parking brake piston

Failure of parking brake spring
Wear of parking brake disc

Remedy
E
No. X X X
Diagnosis X
1 Parking brake does not work even when engine is stopped. Q Q Q

2 The thickness of parking brake disc is below standard. Q
Oil pressure is zero with parking brake switch
3 Q Q
When the parking brake inlet pressure is turned ON. (Normal)
measured Oil pressure is present with parking brake
4 Q Q
switch turned ON
Oil pressure is zero with parking brake switch
5 Q
When the parking brake solenoid valve output turned ON. (Normal)
pressure is measured Oil pressure is present with parking brake
6 Q
switch turned ON.
40-546 GD535-5
(01)
40 Troubleshooting H-14 Parking brake (including emergency release system) is not released or drags
H-14 Parking brake (including emergency release system) is not released

or drags 1

q Check that the hydraulic oil tank level is normal. a b c d e
55°C.
Malfunction of parking brake caliper, or poor adjustment of parking brake

q Check that the operating pressure of the wheel brake is normal before measurement.
(If abnormal, perform troubleshooting for failure of "H-11 Wheel brakes do not work or are
Malfunction of parking brake or bank valve (parking solenoid valve)

weak." in H mode.
Clogged parking brake or bank valve (filter)
Poor adjustment of parking brake

Clogged elbow filter
Remedy
EEE
No.
Diagnosis X X X
1 Parking brake does not work even when engine is stopped. Q Q Q Q Q

When parking brake switch is turned ON, the parking brake solenoid valve output pressure
2 Q
exists. (Normal)
3 Clogged elbow filter Q
4 Malfunction of parking brake caliper Q
GD535-5 40-547
(01)
H-15 All work equipment operates slowly or lacks power 40 Troubleshooting
H-15 All work equipment operates slowly or lacks power 1

q Check the hydraulic oil tank level. a b c d e f
q Check oil pressure when hydraulic oil temperature is 45 to 55°C.
Malfunction or poor adjustment of control valve (main relief valve)

Looseness of piston pump suction piping joint, or crack of hose
Malfunction and poor adjustment of main pump (PC valve)
Internal defect of main pump (pump body)

Clogged hydraulic tank suction strainer
Clogged main pump (orifice plug)

Remedy
C EE A E A
No.
1 Clogging of hydraulic tank strainer Q Q

2 Looseness of pipe joints between hydraulic tank and pump, or cracking of hose Q
3 Too much metal powder adhered to pump discharge side Q Q
No oil is output when main pump pressure measuring plug is removed and engine is
4 Q
cranked.
5 Abnormal relief pressure of main relief valve Q
40-548 GD535-5
(01)
40 Troubleshooting H-16 Work equipment does not operate.
H-16 Work equipment does not operate. 1

q Check the hydraulic oil tank level. a b c d
Malfunction or poor adjustment of control valve (main relief valve)

Incorrect connection of main pump (drive system)
Internal defect of main pump (pump body)
Internal defect of PTO
Remedy
EEE
No. A
Diagnosis X X X
1 No oil is output when main pump pressure measuring plug is removed and engine is cranked. Q Q
2 Main pump does not rotate. Q
3 Abnormal oil pressure after main relief valve has been adjusted Q
GD535-5 40-549
(01)
H-17 Unusual noise is heard from around hydraulic pump 40 Troubleshooting
H-17 Unusual noise is heard from around hydraulic pump 1
Cause
q Lowered hydraulic tank oil level
q Air mixed in hydraulic oil
q Clogged hydraulic oil tank cap
q Clogging of hydraulic tank strainer
q Internal failure of main pump
q Lowered transmission case oil level
q Air mixed in transmission oil
q Clogged transmission case strainer
q Internal defect of power train pump
If no failure is found in above causes, move the machine for a while to check whether symptom changes or not.
40-550 GD535-5
(01)
40 Troubleshooting H-18 Blade lift speed or power is low.
H-18 Blade lift speed or power is low. 1

q Check the hydraulic oil tank level. a b c d e
55°C.
Malfunction of blade lift control valve (check valve)

Insufficient stroke of blade lift control valve (spool)
Malfunction of pilot check valve (relief valve)

Defective sealing of blade lift cylinder
Deformed blade lift cylinder
Remedy A
EE
No. E X X
Diagnosis X X
X
1 Blade lifting speed is low. Q Q
2 Improper operation of check valve Q
3 Low relief valve oil pressure of work equipment valve Q Q Q
GD535-5 40-551
(01)
H-19 Hydraulic drift of lifted blade is large. 40 Troubleshooting
H-19 Hydraulic drift of lifted blade is large. 1

q Check that the hydraulic oil tank level is normal.
Cause
q Malfunction of pilot check valve (check valve)
q Malfunction of pilot check valve (relief valve)
q Defective sealing of blade lift cylinder
40-552 GD535-5
(01)
40 Troubleshooting H-20 Drawbar side shift speed or power is low
H-20 Drawbar side shift speed or power is low 1

Insufficient stroke of drawbar side shift control valve (spool)
Defective sealing of drawbar side shift cylinder.

Malfunction of pilot check valve (check valve)
Deformed drawbar side shift cylinder

Remedy A
E
No. E X X
Diagnosis X
X
1 Drawbar side shift speed is low. Q
3 Low relief valve oil pressure of work equipment valve Q Q
GD535-5 40-553
(01)
H-21 Blade side shift speed or power is low. 40 Troubleshooting
H-21 Blade side shift speed or power is low. 1

q Check the hydraulic oil tank level. a b c d e
Insufficient stroke of blade cross slide control valve (spool)

55°C.
Defective sealing of blade cross slide cylinder

Deformed blade cross slide cylinder

Defective sealing of swivel joint
Remedy A
EE
No. E X X
Diagnosis X X
X
1 Blade side shift speed is low. Q Q
3 Low relief valve oil pressure of work equipment valve Q Q Q
40-554 GD535-5
(01)
40 Troubleshooting H-22 Power tilt speed or power is low.
H-22 Power tilt speed or power is low. 1

q Check that the hydraulic oil tank level is normal. a b c d e f
55°C.
Insufficient stroke of power tilt control valve (spool)

Malfunction of pilot check valve (relief valve)
Defective sealing of power tilt cylinder

Defective sealing of swivel joint
Deformed power tilt cylinder

Remedy A
EE
No. E X X X
Diagnosis X X
X
1 Power tilt speed is low. Q Q
3 Low relief valve oil pressure of work equipment valve Q Q Q Q
GD535-5 40-555
(01)
H-23 Articulate speed or power is low. 40 Troubleshooting
H-23 Articulate speed or power is low. 1

Insufficient stroke of articulate control valve (spool)
Defective sealing of articulate cylinder

Malfunction of pilot check valve
Deformed articulate cylinder

Remedy A
E
No. E X X
Diagnosis X
X
1 Articulate speed is low. Q
40-556 GD535-5
(01)
40 Troubleshooting H-24 Leaning speed or power is insufficient.
H-24 Leaning speed or power is insufficient. 1

Insufficient stroke of leaning control valve (spool)
Defective sealing of leaning cylinder

Malfunction of pilot check valve
Deformed leaning cylinder

Remedy A
E
No. E X X
Diagnosis X
X
1 Leaning speed is low. Q
GD535-5 40-557
(01)
H-25 Hydraulic drift (tilting) of leaning is large. 40 Troubleshooting
H-25 Hydraulic drift (tilting) of leaning is large. 1

q Check that the hydraulic oil tank level is normal.
Cause
q Malfunction of pilot check valve
q Defective sealing of leaning cylinder
40-558 GD535-5
(01)
40 Troubleshooting H-26 Blade does not rotate.
H-26 Blade does not rotate. 1

q Check the hydraulic oil tank level. a b
q Check that oil level of circle rotation gear case is normal before performing troubleshooting.
Insufficient stroke of circle rotation control valve (spool)

Malfunction of blade rotator
Remedy A
No. E X
Diagnosis X
1 Blade does not rotate. Q
2 Low relief valve oil pressure of work equipment valve Q
GD535-5 40-559
(01)
H-27 Lifter lock pin is not locked or is not canceled. 40 Troubleshooting
H-27 Lifter lock pin is not locked or is not canceled. 1

q Check oil pressure and oil leakage of cylinder when hydraulic oil temperature is 45 to 55°C. a b c d
Malfunction of parking brake or bank valve (bank solenoid valve)

Malfunction or internal defect of lifter lock cylinder
Clogged parking brake or bank valve (filter)
Displacement of lifter and lock pin
Remedy A
EE
No. E X
Diagnosis X X
X
1 Lifter lock pin is not locked. Q Q Q Q
2 Displacement of lifter and lock pin Q
3 Clogging of parking brake valve filter Q
4 Cylinder head pressure or bottom pressure of bank solenoid valve is abnormal. Q
40-560 GD535-5
(01)
40 Troubleshooting H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats)
H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally large

or engine overheats) 1
Check the following with the operator. Cause

q Did the fan start making the abnormal sound sudden- Tank to Charge
Fan motor Others
ly? Pump valve
oDamage of the devices related to the fan and fan a b c d e f g h i j k
motor
q Did the engine overheat after the fan had started mak-
ing the abnormal sound?
oInternal wear of the devices related to the fan pump
and fan motor, lowering of sealing performance or
dirt
Clogging or sucked air on pump suction side

Check for abnormality
Measure the fan speed to check for abnormality.
Seized forward-reverse selector valve

heck before troubleshooting
Malfunction of suction safety valve

Seized brake circuit selector spool
Malfunction of EPC solenoid valve

q Check the level and type of the oil in the hydraulic tank.
Lowering of engine performance

Seized ON/OFF solenoid valve
q Check the hydraulic hoses, pump and motor for oil
leakage.
Malfunction of relief valve

q Check the fan for damage.
Malfunction of controller
Defective fan motor
Defective fan pump
(Note): If “Lowering of engine performance” is judged, go
to the troubleshooting for the engine system (S
mode).
Note
Remedy c E E E E E E
No. x x x
Troubleshooting E x x x x x x
1 Fan speed is low (in fan 100% mode) Q Q Q Q Q Q
2 Fan hunts Q Q Q Q Q
3 Fan does not revolve Q Q Q Q
4 Fan always revolves in reverse Q Q Q
5 Fan does not revolve in reverse Q Q Q
GD535-5 40-561
(01)
H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats) 40 Troubleshooting
40-562 GD535-5
(01)
40 Troubleshooting How to read matrix
Troubleshooting of engine (S-mode) 1
How to read matrix 1
The troubleshooting matrix consists of "Question"

"Checkpoints", "Cause" and "Diagnosis" blocks.
Answer to the "Question" and "Checkpoints" without

using troubleshooting devices. You can narrow down
the trouble by referring to the "Cause" block.
After you have narrowed the causes, locate the final
"Cause" by using troubleshooting devices or by direct
inspection.
"Question":
The user or operator is asked. This is parts A and
B as shown at right.
Questions A ask the basic items, and Questions B
are asked by user or operator.
"Checkpoints":
The service person briefly checks the points, and
this is part C at right.
"Cause":
The cause is narrowed by the Question and
Checkpoints.
The service person reads parts A, B and C, and
narrows the possible cause.
"Diagnosis":
The located cause is finally determined to be a
failure or not. The troubleshooting devices are
used, and direct inspection may be selected.
On the troubleshooting matrix, the items relating to the "Cause" are marked by "E", "Q or "W according to the
answer to "Question" and "Checkpoints".
E mark: The Cause can be referred to the Question or Checkpoints.
Q mark: The Cause is related to the Question or Checkpoints.
W mark: Among the above Q mark items, the possibility of Cause is high.
a When narrowing the "Cause", the priority of Q mark is higher than that of W mark.
E mark shows the item is not counted when narrowing the Cause. (However, if each level has no difference
and if you cannot narrow down the Cause without using this leveling, you can use the leveling.)
GD535-5 40-563
(01)
How to read matrix 40 Troubleshooting
<Troubleshooting example> Exhaust gas color is black.

If, for example, the "Exhaust gas color is black" is caused by the "Clogged air cleaner", three causes of failure,
such as "Exhaust color becomes gradually black", "Power is gradually lost" and "Air cleaner clogging caution lamp
flashes" can be considered.
40-564 GD535-5
(01)
40 Troubleshooting How to read matrix
From these 3 causes of failure, we can consider the 5 causes of failure.

The following explains how to narrow the highest probability of failure from these causes.
GD535-5 40-565
(01)
S-1 Engine startability is poor. 40 Troubleshooting
S-1 Engine startability is poor. 1
Generally, the poor startability is caused by: Cause
Leakage, clogging or air mixing in fuel piping

Incorrect matching of valve and valve sheet
q Abnormal electric system
Fixture or burn-out of supply pump plunger

q Insufficient fuel supply
Defective alternator (regulator portion)

Clogging of fuel tank cap air vent hole
q Insufficient intake air volume
q Incorrect selection of fuel
Defective intake air heater system
Defective alternator (generator)

q The common rail fuel injection system (CRI) controls the fuel injection timing
Wear of piston ring or cylinder
Defective or degraded battery

Clogged air cleaner element
electrically. When you start the engine, the injection does not start until
crankshaft rotates 2 times maximum. This is not a problem.
Clogging of fuel filter
Defective injector
Check the recent repair history.
Machine operation state Machines operated for a long period E E E
Gradually dropped. Q w w Q
Startability
Starts when weather is warm. w w
Q Q Q
Question
Unspecified fuel is used.

Filter is not replaced as specified by the Operating Manual. w w Q Q
Engine oil supply rate has increased. w
Preheat monitor display is abnormal during preheating or during low temperature (if w
the monitor is mounted).
The charge monitor display is abnormal during operation (if the monitor is
w w
mounted).
The dust indicator lights in red (if the indicator is mounted). w
Fuel tank cap air vent hole is clogged. w
Fuel leaks from the fuel pipe. w Q
The priming pump has no response during operation, or it is heavy to operate. w Q
When engine is rotated by starting motor, its speed is low.
No fuel is output when air vent plug of fuel filter w
Start the engine by cranking with
is removed.
the starting motor.
w
Checkpoints
Too much fuel is returned from injector.

Some cylinder is found to be cool when exhaust manifolds are touched by hand w
immediately after engine is started.
Engine does not pick-up smoothly, and combustion is unstable. Q Q w
Engine rotation is hunting (poor rotation). Q w Q
Too much blowby gas is output. w
Check the air cleaner. q
The compression pressure is low. q q
Air is output during air blow of fuel system. q
Check the fuel filter. q
Diagnosis
Troubleshoot for "Supply pump pressure low" according to the failure code (*1). q
When engine runs in cylinder cutout mode with some cylinder cut out, engine speed
q
does not change.
The intake air heater mounting section is not heated during preheating. q
Is voltage (20 to 30V) output between alternator B terminal and E Yes q
terminal during low idle? No q
The specific gravity and voltage of battery are low. q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Clean
Clean
Remedy
40-566 GD535-5
(01)
40 Troubleshooting S-2 Engine does not start.
S-2 Engine does not start. 1
a) Engine does not start. Cause
Generally, engine does not start if:
Defective harness of starting switch circuit

Defective starting motor (motor section)
q Inside of engine is burnt out.
Poor connection of battery terminals

o See "S-4 Engine stops during operation".
q Abnormal electric system

q Failure of power train
Damaged flywheel ring gear
Defective starting switch

Defective battery relay
Defective safety relay

Question
Machine operation
Machines operated for a long period EE
state
When starting switch Horn does not sound. Q Q w
is ON Sound is small. w
Insufficient battery fluid level w
Battery cables are loosely connected. w
When starting switch is ON, battery relay operation sound is not heard. Q w
When starting switch is turned to START position, the starter pinion is not output. Q Q w
Checkpoints
The starter pinion is output but speed is low. w

When starting switch
Scratchy noise is heard. w w
is turned to START
position Released in intermediate position w
Noise is heard, but not rotated. Q Q w
Check the flywheel ring gear. q

Perform troubleshooting in E-mode.
Voltage (20 to 30V) is not output between B terminal and
q
E terminal of battery relay.
When B terminal and C terminal of starting switch are
Diagnosis
Turn starting switch to connected, the engine starts. q

OFF position, connect
When B terminal and C terminal of safety relay output are
cords, turn switch ON, q
connected, the engine starts.
and perform
When B terminal and C terminal of safety relay output are
troubleshooting. q
connected, the engine does not start.
When the safety switch terminal and B terminal are
q
connected, the engine starts.
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Remedy
-
GD535-5 40-567
(01)
S-2 Engine does not start. 40 Troubleshooting
b) Engine rotates but smoke is not output. Cause
Burn-out or abnormal wearing of feed pump

Generally, the engine rotates but the smoke is not output if:
Defective common rail pressure limiter

q No fuel is supplied.
Malfunction of pressure relief valve

q Fuel supply is too few.
q Incorrect selection of fuel (especially in winter season)
Damaged supply pump shaft
Defective supply pump IMV

Inappropriate fuel is used.
Insufficient fuel in tank
Defective fuel injector

Question
Machine
Machines operated for a long period EE
operation state
Smoke was suddenly stopped to output (during restarting). w Q w w E
Unspecified fuel is used. w
Filter is not replaced as specified by the Operation Manual. w E Q
The fuel tank is empty. w
Fuel tank cap air vent hole is clogged. Q w
When fuel was drained, rusting and water are drained from fuel tank. Q E EE
When fuel filter is removed, no fuel is found in the filter. w
Fuel leaks from the fuel pipe. w
The priming pump has no response during operation, or it is heavy to
w Q
Checkpoints
operate.
Start the engine No fuel is output when air vent plug of fuel filter is Q Q w Q
by cranking with removed.
the starting When spill hose is disconnected from injector, the spill
Q w w w Q
motor. rate is low.

Check the fuel filter and strainer. q
Check the feed pump. q
Diagnosis
Troubleshoot for "Supply pump pressure low" according to the failure

q q
code (*1).
Troubleshoot for "Supply pump IMV error" according to the failure code
q
(*2).
Check the pressure relief valve. q
Fuel is output when pressure limiter return pipe is removed. q
Refilling with oil
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Clean
Remedy
*1: Failure codes [CA559] and [CA2249]

40-568 GD535-5
(01)
40 Troubleshooting S-2 Engine does not start.
c) Smoke comes out but engine does not start (fuel is injected). Cause
Wear of valve operating system (valve and rocker lever)

Generally, smoke comes out but engine does not start if:
Defective coolant sensor, or defective wiring harness

q The rotation power is insufficient due to defective electric system.
Leakage, clogging or air mixing in fuel system

q Fuel supply is too few.

q Intake air volume is insufficient.
Clogging or injection failure of injector
Defective intake air heater system


Inappropriate fuel is used.

Machine operation
Machines operated for a long period E E E
state
Machine was suddenly stopped to start. w w Q
Question
Unspecified fuel is used. Q Q

Filter is not replaced as specified by the Operation Manual. w w
Preheat monitor display is abnormal during preheating or during low
w
temperature (if the monitor is mounted).
Fuel tank cap air vent hole is clogged. Q
When fuel was drained, rusting and water are drained from fuel tank. w
The priming pump has no response during operation, or it is heavy to operate. w Q
When engine is rotated by starting motor, its speed is low. w
When engine is rotating, abnormal noise is generated around the cylinder
w
head.
When fuel filter air vent plug is removed, no fuel is output. Q w
Checkpoints
When engine is
cranked by When spill hose is disconnected from injector, the spill
starting motor w
rate is low.

Check the valve operating system. q
The compression pressure is low. q
Diagnosis

Troubleshoot for "Supply pump pressure low" according to the failure code
q
(*1).
Display of coolant temperature gauge is abnormal (if coolant temperature
q
gauge is mounted).
The intake air heater mounting section is not heated during preheating. q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Clean
Clean
Remedy
*1: See failure codes [CA559] and [CA2249].
GD535-5 40-569
(01)
S-3 Engine does not pick-up smoothly. 40 Troubleshooting
S-3 Engine does not pick-up smoothly. 1
Generally, engine does not pick-up smoothly if: Cause

q Fuel supply is insufficient.

q Fuel injection is abnormal.

Burn-out or interference of turbocharger

q This is controlled by the controller in Derate mode.

(If an electric system error occurs, the fuel injection (output) is con-
trolled.)

Incorrect valve clearance

Machine Machines operated for a long period EE E E
Question
Suddenly, engine does not pick-up smoothly. w Q Q Q

Unspecified fuel is used. w w w
Filter is not replaced as specified by the Opearation Manual. w w
When fuel was drained, rusting and water are drained from fuel tank. w
The priming pump has no response during operation, or it is heavy to w Q
Some cylinder is found to be cool when exhaust manifolds are touched by
Q w
hand immediately after engine is started.
It is blue under small load. w
Exhaust gas
It is black w Q w w
w
Checkpoints

When engine is rotated, interference noise is generated around the w
Although no-load and high idle speed is normal, the rotation speed
Q w
suddenly drops when loaded.
Engine rotation is hunting (poor rotation). Q Q Q
Check the valve clearance. q
Diagnosis
Turbocharger is heavy to rotate when tried by hand. q

Troubleshoot for "Supply pump pressure low" according to the failure code q
When a certain cylinder is cutout, engine speed does not change. q
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Adjust
Clean
Remedy
40-570 GD535-5
(01)
40 Troubleshooting S-4 Engine stops during operation.
S-4 Engine stops during operation. 1
Generally, engine stops during operation if: Cause
Damage or burn-out of piston and connecting rod
Damage of auxiliaries (pump and compressor)

q Inside of engine is burnt out.
Defective engine controller power cables

Overheating
Damage or burn-out of crankshaft metal

q

q Hydraulic pump has failed.
Damage of supply pump shaft spline

Damage of valve operating system
Clogging of feed pump gauze filter

Damage or burn-out of feed pump
Leakage or clogging of fuel piping
Damage or burn-out of gear train
Defective starting switch cables

Defective hydraulic pump
(valve and rocker lever)

Machine operation state Machines operated for a long period EE
It has noise and stopped suddenly. w w w w Q w Q w
It was overheated and stopped. w Q
Question
Engine
It stopped slowly. w Q Q Q Q
It was hunting and stopped. w Q Q Q Q Q Q
Unspecified fuel is used. Q Q Q Q
Filter is not replaced as specified by the Opeation Manual. w w
Fuel level monitor shows the dropped fuel level. w
Fuel leaks from the fuel pipe. w w
When fuel was drained, rusting and water are drained from fuel tank. Q Q
Metal powder is output when oil is drained to oil pan. w w
w w
Checkpoints
It does not rotate at all.

When the engine is It rotates in reverse direction. w
rotate by hand It moves for the backlash of gears. w w
The supply pump shaft does not rotate. w
Engine rotates, but it stops when loaded at the machine side. w

Perform troubleshooting in H-mode.
Check the piston and connecting rod. q

Check the crankshaft metal. q
Check the gear train. q
Check the fuel filter. q
Diagnosis
Check the feed pump gauze filter. q

Check the feed pump. q
q q
(*1).
Engine rotates if auxiliaries (pump and compressor) are removed. q
Check the controller power cables. q
Check the starting switch cables q
Refilling with oil
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair
Clean
Clean
Clean
Remedy
-
* 1: See failure codes [CA559] and [CA2249].
GD535-5 40-571
(01)
S-5 Engine runs rough or is unstable. 40 Troubleshooting
S-5 Engine runs rough or is unstable. 1
Generally, the engine runs rough if: Cause
Defective Bkup speed sensor, or defective wiring harness

q Air is inserted into fuel system.
Defective Ne speed sensor, or defective wiring harness

Clogging or injection failure of injector (dust clogging)
q The rotation sensor is abnormal (at the level where no error is displayed).
Leakage, clogging or air insertion in fuel piping


Machine operation state Machines operated for a long period E
Q Q
Question
It occurs in specific speed range.

It occurs during low idle. Q Q Q Q Q
Hunting
It occurs even when speed is increased. Q Q Q
It occurs on a slope. w
Filter is not replaced as specified by the Opeation Manual. w
Checkpoints
When fuel was drained, rusting and water are drained from fuel tank. Q
The priming pump has no response during operation, or it is heavy to
w Q
operate.
Diagnosis

Troubleshoot for "Ne speed sensor error" according to the failure code (*1). q
Troubleshoot for "Bkup speed sensor error" according to the failure code
q
(*2).
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Remedy
*1: Failure code [CA689]

*2: Failure code [CA778]
40-572 GD535-5
(01)
40 Troubleshooting S-6 Engine lacks power.
S-6 Engine lacks power. 1
Generally, engine lacks power if: Cause
Incorrect mounting of boost pressure sensor




Leakage or clogging of fuel piping
Defective boost pressure sensor,

Air leakage from air intake pipe

q Overheating
or defective wiring harness

(signal and solenoid valve)
See "S-14 Coolant temperature rises too high (overheating)".
Clogging of fuel spill pipe

Drive failure of injector

(If an electric system error occurs, the fuel injection (output) is con-
trolled.)
(dust clogging)
(air leakage)
Machine Machines operated for a long period E E E E
operation state
Q w Q Q Q Q
Question
It lacks power suddenly.

Engine
It lacks power gradually. Q Q Q Q Q Q
Unspecified fuel is used. Q Q Q
Filter is not replaced as specified by the Opeation Manual. w w
Engine oil supply rate has increased. Q Q
The dust indicator lights in red (if the indicator is mounted). w w
Fuel tank cap air vent hole is clogged. w w
Engine output is insufficient after short stop. w
It is black. w w
Exhaust gas
Some cylinder is found to be cool when exhaust manifolds are touched by
hand immediately after engine is started. w w
When engine is rotated, interference noise is generated around the
turbocharger. w
Checkpoints

head. w
High idle speed is high. Q
Although no-load and high idle speed is normal, the rotation speed
suddenly drops when loaded. Q w Q Q
Engine does not pick-up smoothly, and combustion is unstable. w w Q Q w
Engine rotation is hunting (poor rotation). Q Q Q Q Q
Too much blowby gas is output. w w

Check the air intake pipe. q
The boost pressure is low. q q q
Check the fuel pipe. q
Diagnosis

Check the spill port check valve. q
(*1). q
When a certain cylinder is cutout, engine speed does not change. q q
Check the mounting of boost pressure sensor. q
Troubleshoot for "Boost pressure sensor error" according to the failure
code (*2). q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair
Adjust

Clean
Clean
Remedy
GD535-5 40-573
(01)
S-7 Exhaust smoke is black (Incomplete combustion) 40 Troubleshooting
S-7 Exhaust smoke is black (Incomplete combustion) 1
Generally, exhaust smoke is black if: Cause

Air leakage between turbocharger and cylinder head

q Overheating

See "S-14 Coolant temperature rises too high (overheating)".
(If an electric system error occurs, the fuel injection (output) is controlled.)
Incorrect fuel injection pressure

Clogging or burn-out of injector
Incorrect fuel injection timing

Crush or clogging of muffler
Abnormal wear of injector

Machine operation state Machines operated for a long period E E E E
It becomes black suddenly. w w Q Q Q
Exhaust gas It becomes black gradually. w Q Q
Question

It lacks power suddenly. w Q Q Q
Engine
It lacks power gradually. Q Q Q Q
Muffler is crushed. w
Air leakage between turbocharger and cylinder head, or loosened clamps w
Machine is operated in Low Temperature mode although in normal temperature range. Q Q Q
Some cylinder is found to be cool when exhaust manifolds are touched by hand Q w
When engine is rotated, interference noise is generated around the turbocharger. w
Checkpoints
When engine is rotating, abnormal noise is generated around the cylinder head. w
Torque converter stalls or pump relief speed is high (excessive fuel injection). Q
Exhaust noise is abnormal. Q w Q
Engine does not pick-up smoothly, and combustion is unstable. Q Q Q Q Q w
Too much fuel is returned from injector. w
Turbocharger is heavy to rotate when tried by hands. q
Diagnosis
Exhaust noise becomes better if muffler is removed. q

Perform troubleshooting for "Supply pump pressure low error (*1)" according to the failure
q q
code.
When a certain cylinder is cut out, engine speed does not change in specific cylinder. q
Perform troubleshooting for "Coolant temperature sensor error (*2)" according to the failure
q
code.
Check it using the INSITE or monitoring function at the installed machine side. q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Adjust
Clean
Remedy

40-574 GD535-5
(01)
40 Troubleshooting S-8 Large oil consumption (or blue exhaust gas)
S-8 Large oil consumption (or blue exhaust gas) 1
Generally, the oil consumption becomes large if: Cause
q Oil is burned abnormally.

q Machine is operated in low idle or high idle state for a long time.
Wear or damage of valves (stem, guide, and seal)

(Unloaded machine operation exceeding 20 minutes or longer time is
Oil leakage from oil pan, cylinder head or others

not allowed.)
q Oil is leaking to the outside.
Turbocharger
q Lubrication system is worn.
Suction of dust from air intake system
Clogging of breather or breather hose
Wear or damage of rear oil seal

Oil leakage from oil drain plug

Wear of seal at turbine side
Wear of seal at blower side
Oil leakage from oil cooler
Oil leakage from oil pipe

Oil leakage from oil filter
Damaged piston ring
Defective oil cooler

Machine operation
EEE E
Question
Machines operated for a long period

state
Oil consumption has increased suddenly. w Q
Oil supply rate has increased. w Q
Oil becomes contaminated early. Q Q w
Engine surface is contaminated with oil. w w w w w
Pipe clamps of air intake system are loose. w
Inside of turbocharger intake air outlet pipe is contaminated with oil. w
Inside of turbocharger exhaust air outlet pipe is contaminated with oil. Q w
Checkpoints
Oil is mixed in the coolant. w

Oil of gear chamber has increased. w
Exhaust gas is blue under small load. Q w w
Excessive amount of gas is discharged. Q Q w w
Blowby gas
No gas is discharged. w
Dust enters if the intake air manifold is removed. q
Inside of intake air manifold is largely contaminated. q
Turbocharger shaft has a large play (looseness). q q
Diagnosis
Check the breather or breather hose. q

Check the rear oil seal. q
During pressure resistance test, oil leaks from oil cooler. q q
Oil leaks to the outside of engine. q q q q
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair
Repair
Repair
Repair
Repair
Clean
Remedy
GD535-5 40-575
(01)
S-9 Oil becomes contaminated early. 40 Troubleshooting
S-9 Oil becomes contaminated early. 1
Generally, the oil becomes contaminated if: Cause
q Exhaust gas is mixed in the oil due to internal wearing.
Clogging of turbocharger lubrication drain tube

q Lubrication path is clogged.
Damaged seal at turbocharger turbine side

q Unspecified fuel is used.
q Unspecified oil is used.
Clogging of breather or breather hose

q Machine is overloaded.
Damage of oil filter safety valve

Wear of valve or valve guide
Exhaust smoke color is bad.

Clogging of oil cooler
Clogging of oil filter
Question
Machine operation
Machines operated for a long period EEE
state
Metal powder is output when oil is drained from oil filter. Q Q w
Inside of exhaust pipe is contaminated with oil. w
Engine oil temperature increases rapidly. w
Checkpoints
Exhaust gas
It is black w
Excessive amount of gas is discharged. Q Q w Q
Blowby gas
No gas is discharged. w
Turbocharger shaft has a large play (looseness). q

q
Diagnosis
Check the breather or breather hose.

See S-7.
Check the oil cooler. q

Check the oil filter. q
It is hooked by the spring of oil filter safety valve, and broken. q
Check the turbocharger lubrication drain tube. q
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Remedy
-
40-576 GD535-5
(01)
40 Troubleshooting S-10 Fuel consumption is excessive.
S-10 Fuel consumption is excessive. 1
Generally, the fuel consumption becomes large if: Cause

q The fuel leaks.
q Fuel injection status (fuel pressure, injection timing) is abnormal.
q Fuel is injected too much.
Defective common rail injection pressure

Fuel leakage from fuel filter or piping
Fuel leakage inside of head cover
Defective fuel injection by injector

Defective supply pump plunger
Incorrect fuel injection timing

Defective feed pump oil seal
Malfunction of injector
Machine
Machines operated for a long period EE E
Question
operation state
It is higher than the same model. Q Q Q Q
Fuel consumption It increases gradually. Q Q
It increases suddenly. Q Q
Fuel leaks to the outside of engine. W
Engine combustion is unstable. W
Oil leaks more and diesel oil is smelled. W W
Some cylinder is found to be cool when exhaust manifolds are touched by hand
W
Checkpoints
Low idle speed is high. Q

Torque converter stalls or pump relief speed is high. Q
It becomes black Q Q Q Q
Exhaust gas
It becomes white Q
Remove the head cover and check it. q

Check the supply pump oil seal. q
Troubleshoot for "Supply pump pressure low" according to the failure code (*1). q
Diagnosis

Too much fuel is returned from injector. q
Troubleshoot for "Coolant temperature sensor error" according to the failure code
q
(*2).
Check it with the monitoring function of machine monitor. q q
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair
Remedy

GD535-5 40-577
(01)
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 40 Troubleshooting
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 1
Generally, oil is mixed in the coolant if: Cause
q Internal leak occurs in the lubrication system.

q Internal leak occurs in the cooling system.
Damage of hydraulic oil cooler or power train oil cooler

Damage of cylinder head or head gasket
Damage of oil cooler core or O-ring

Internal cracking of cylinder block
Perforation by pitching
Machine operation
Machines operated for a long period E E
Question
state
It increases rapidly. Q Q Q
Oil level
It increases gradually. Q Q
Hard water is used as the coolant. Q Q
Oil increases and becomes cloudy. Q Q w
Too much bubbles in the radiator, and coolant spurts back. w
Diagnosis Checkpoints
Hydraulic oil or power train oil becomes cloudy. w
Water is output when hydraulic oil or power train oil is drained. w
Oil leaks during pressure resistance test of cylinder head. q

Check the cylinder block. q q
Oil leaks during pressure resistance test of oil cooler. q
Replace
Replace
Replace
Replace
Replace
Remedy
40-578 GD535-5
(01)
40 Troubleshooting S-12 Oil pressure drops.
S-12 Oil pressure drops. 1
Generally, oil pressure drops if: Cause
Defective oil level sensor, or defective wiring harness

q Lubrication system has leaked, is clogged or worn.
Leakage, crushing or clogging of hydraulic piping

q Hydraulic pressure control is abnormal.
q The correct oil shown by the Opeartion Manual is not used in ambient tem-
Clogging or damage of pipe in engine oil pan

perature.
q Oil has degraded due to overheating.
Insufficient capacity in engine oil pan
Clogging of strainer in engine oil pan

Water and fuel mixing in the oil
Defective regulator valve

Clogging of oil filter
Worn metal journal
Defective oil pump

Machine
operation state
Question
The oil pressure monitor shows the dropped oil pressure (if the monitor is
Q w
mounted).
Unspecified oil is used. Q Q
Filter is not replaced as specified by the Opeartion Manual. w
It shows the dropped oil pressure during low idle. w
The oil pressure
It shows the dropped oil pressure during low idle and
monitor display Q w w w Q
high idle.
(when monitor is
mounted) Dropped oil pressure is shown on a slope. w
Dropped oil pressure is shown sometimes. w Q
The oil pressure monitor shows the dropped oil level (if the monitor is
w w
mounted).
Oil level is insufficient in engine oil pan. w
External hydraulic pipe leaks or it is crushed. w
Checkpoints
Oil becomes cloudy, or diesel oil is smelled. w

Metal powder is output when oil is drained from oil pan. w
Metal powder is output when oil is drained from oil filter. w Q
Metal powder is output from oil filter. q

Check the oil pan strainer and piping. q q
See S-13.
Diagnosis
Oil pump is heavy to rotate, or it has play. q

Regulator valve spring has settling or damage. q
Check the oil filter. q
Display of oil level monitor becomes normal after replacement of oil level
q
sensor.
Clean and replace
Refilling with oil
Replace
Replace
Replace
Replace
Repair
Adjust
Clean
Remedy
-
GD535-5 40-579
(01)
S-13 Oil amount increases (due to water or fuel mixing). 40 Troubleshooting
S-13 Oil amount increases (due to water or fuel mixing). 1
Generally, oil is mixed in the coolant if: Cause
q Coolant is mixed (and becomes cloudy).

q Fuel is mixed (diluted diesel oil is smelled).
q If oil is mixed in coolant, perform troubleshooting for "S-11 Oil is in coolant".
Defective inside of supply pump

Wear or damage of rear oil seal
Damage of oil cooler or O-ring
Damage of injector O-ring
Question
Machine
operation state
Fuel consumption is excessive. w w
Oil supply rate has increased. Q Q Q
Oil is mixed in the coolant. Q Q Q Q w
Oil leaks more and diesel oil is smelled. w w
Oil becomes cloudy. Q Q
Q
Checkpoints
When engine is started, water drops from the muffler.

If radiator cap is opened and engine is idled at low speed, bubbles may come out or
w Q
spurt back.
Exhaust smoke is white.
Oil of gear chamber has decreased. w
Oil of hydraulic oil tank has decreased.
Remove the injector, and check the O-ring. q
Diagnosis
Check the cylinder block. q q

Check the rear oil seal. q
Oil leaks during pressure resistance test of oil cooler. q
Remove the supply pump and check it. q
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Remedy
40-580 GD535-5
(01)
40 Troubleshooting S-14 Coolant temperature rises too high (overheating).
S-14 Coolant temperature rises too high (overheating). 1
Generally, the coolant temperature rises too high if: Cause
Defective radiator cap (pressure valve)

q Cooling airflow rate is low (due to deformed or damaged fans).
Increased power train oil temperature

Defective coolant temperature gauge
q Cooling efficiency has dropped.

q Cooling circulation system has failed.
Clogging or damage of oil cooler
Clogging or crush of radiator fin

Operation failure of thermostat
q Power train oil temperature has increased.
Clogging of radiator core

Insufficient coolant
Defective fans
Machine
Machines operated for a long period E E EE
operation state
It occurs suddenly. Q w
Question
Overheating
It tends to be in the overheating state most of the time. Q Q w w
Coolant It increases rapidly. Q Q w
temperature (if
temperature
It does not drop from the red range. w
gauge is
mounted)
The radiator level monitor shows the dropped coolant level (if the monitor
Q w
is mounted).
Engine oil increases and becomes cloudy. w w Q
The cloudy oil flows on the coolant. Q Q w w
Too much bubbles in the radiator, and coolant spurts back. w
When radiator core is illuminated by electric light, the illumination light
w
cannot be seen.
Checkpoints
Radiator shroud and under cover are clogged with dust and sand. w
Radiator hose is cracked or clamps are loosened, and coolant leaks. w
Coolant flows through radiator overflow hose. w
Pointer of power train oil temperature gauge enters the red range before
the engine coolant temperature gauge enters (if oil and coolant w
temperature gauges are mounted).
The compression pressure is low.
Perform troubleshooting in H-mode.
q
Check the cylinder.

q
q
Check the oil cooler.

q
Temperature difference is large between radiator top and bottom tanks.

q
Diagnosis
The thermostat does not open at the valve open temperature.

q
Temperature difference is small between radiator top and bottom tanks.

q
Check the radiator core.

q
When radiator cap operation is tested, the valve open pressure is low.
q
The coolant temperature is normal.

q
Refilling with oil
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair
Remedy
-
GD535-5 40-581
(01)
S-15 Unusual noise is heard. 40 Troubleshooting
S-15 Unusual noise is heard. 1
Generally, unusual noise is heard if: Cause
Incorrect fuel injection timing (coolant low-temperature sensor

q Some parts are defective.
Damage of valve operating system (valve and rocker lever)

q Abnormal combustion occurs.
q Air is taken from intake air system.
Air leakage between turbocharger and cylinder head

q Determine the noise location, and troubleshoot it.
Damage inside of muffler (dropped partition plate)

a If engine is not warmed enough, engine sound slightly increases for low-tempera-
ture operation. This is not a problem.
a When engine is accelerated, engine sound increases approx. 3 second MAX. This
error or boost temperature sensor error)

is not a problem.
Clogging or burn-out of injector

Missing or burn-out of bushing
Incorrect gear train backlash
Dust clogging of injector

Machine
operation state Machines operated for a long period E
Question
It is emitted gradually. Q
Unusual noise
It is emitted suddenly. Q Q Q
Unspecified fuel is used. Q
Oil supply rate has increased. w
Metal powder is output when oil is drained from oil filter. w w
Air leakage between turbocharger and cylinder head w
When engine is rotated, interference noise is generated around the turbocharger. w
When engine is rotated, abnormal noise is generated around the cylinder head. w w
When engine is rotated, chatter sound is heard around the muffler. w
Checkpoints
Some cylinder is found to be cool when exhaust manifolds are touched by hand
w Q
Exhaust gas
It is black Q w Q
Engine does not pick-up smoothly, and combustion is unstable. w
Abnormal noise is generated during acceleration. Q Q Q
Turbocharger is heavy to rotate when tried by hands. q

Unusual noise disappears when the muffler is removed. q
Diagnosis

Check the gear train. q q
When engine runs in cylinder cutout mode with some cylinder cut out, engine
q q
speed does not change.
Unusual noise is heard only when engine is started. q
Check it with the monitoring function of machine monitor. q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Remedy
40-582 GD535-5
(01)
40 Troubleshooting S-16 Vibration is excessive.
S-16 Vibration is excessive. 1
Generally, excessive vibration occurs if: Cause
q Parts are defective (abnormal wearing or damage).

q Alignment with the installed equipment is incorrect.
q Abnormal combustion occurs.
a If unusual noise is heard and vibration is excessive, perform troubleshooting for "S-15
Damage of valve operating system (valve and rocker arm)
Incorrect fuel injection timing (coolant temperature sensor

Unusual noise is heard" as well.
Displacement between engine and installed equipment

Loose engine mounting bolts or defective cushions
Damage of output shaft or inside of gear chamber

Wear of main metal and connecting rod metal
error or boost temperature sensor error)

Incorrect gear train backlash
Worn camshaft bushing
Machine
E E E
Question
Machines operated for a long period

operation state
It increased rapidly. Q Q
Vibration
It increased gradually. Q Q Q
Unspecified oil is used. Q Q
Metal powder is output when oil is drained from oil filter. w w
Metal powder is output when oil is drained from oil pan. w w
Oil pressure is low during low idle. Q Q
Checkpoints
Vibration is excessive during medium speed traveling. Q Q

Vibration increases according to the engine speed. Q Q Q Q
Exhaust smoke is black. w Q

Check the main metal and connecting rod metal. q
Check the gear train. q
Diagnosis
Check the camshaft bushing. q

Check it with the monitoring function of machine monitor. q
Check the engine mounting bolts and cushions. q
A runout or surface deflection was found by checking. q
Check the output shaft or inside of gear chamber. q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Remedy
GD535-5 40-583
(01)
S-16 Vibration is excessive. 40 Troubleshooting
40-584 GD535-5
(01)
50 Disassembly and assembly
GD535-5 50-1
(02)
Contents 50 Disassembly and assembly
Contents 1
Acronyms - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-4
Related information on disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-9
How to read this manual- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-9
Coating materials list - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-11
Special tool list - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-15
Sketches of special tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-23
Removal and installation of supply pump assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-51
Removal and installation of injector assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-55
Removal and installation of cylinder head assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-64
Removal and installation of air conditioner compressor belt - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-82
Removal and installation of alternator belt - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-83
Removal and installation of engine front oil seal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-85
Removal and installation of engine rear oil seal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-88
Removal and installation of cooling fan pump assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-91
Removal and installation of cooling fan and fan motor assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-93
Removal and installation of radiator assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-97
Removal and installation of aftercooler assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-101
Removal and installation of power train oil cooler assembly- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-105
Removal and installation of fuel tank assembly- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-108
Removal and installation of engine hood assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-112
Removal and installation of air conditioner compressor assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-114
Power train - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-116
Removal and installation of engine, transmission, and torque converter assembly - - - - - - - - - - - - - - - - 50-116
Disconnection and connection of engine, transmission, and torque converter assembly - - - - - - - - - - - - 50-124
Disassembly and assembly of torque converter assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-126
Disassembly and assembly of transmission assembly- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-137
Removal and installation of tandem drive and final drive assembly- - - - - - - - - - - - - - - - - - - - - - - - - - - 50-172
Disassembly and assembly of tandem drive assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-175
Disassembly and assembly of differential assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-181
Disassembly and assembly of final drive assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-194
Steering system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-203
Removal and installation of Orbitrol valve assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-203
Brake system- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-208
Disassembly and assembly of wheel brake assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-208
Removal and installation of center hinge pin - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-216
Removal and installation of hydraulic tank, battery, and frame assembly- - - - - - - - - - - - - - - - - - - - - - - 50-227
Removal and installation of hydraulic tank assembly- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-234
Removal and installation of control valve assembly- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-238
Disassembly and assembly of hydraulic cylinder assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-243
Work equipment- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-247
Removal and installation of blade assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-247
Removal and installation of circle drawbar assembly- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-248
Removal and installation of circle rotation gear assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-250
Disassembly and assembly of circle rotation gear assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-252
Cab and its attachments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-257
Removal and installation of operator's cab assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-257
Removal and installation of operator cab glass (adhered glass) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-266
Removal and installation of floor frame assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-276
Removal and installation of operator's cab and floor frame assembly - - - - - - - - - - - - - - - - - - - - - - - - - 50-280
Removal and installation of air conditioner unit assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-287
50-2 GD535-5
(02)
50 Disassembly and assembly Contents
Removal and installation operator's seat - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-293

Removal and installation seat belt - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-294
Removal and installation of engine controller assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-296
Removal and installation of machine monitor assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-298
Removal and installation of transmission controller assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-299
Removal and installation of rearview camera - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-301
Removal and installation of KOMTRAX terminal assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-303
GD535-5 50-3
(02)
Acronyms 50 Disassembly and assembly
Acronyms 1
System
Advanced Joystick
ARAC
braking force.
Automatic Retarder
Automatic Spin
Brake Cooling oil
Regulator
used independently.
Closed-center Load
Sensing System
injection timing.
ECU)
50-4 GD535-5
(02)
50 Disassembly and assembly Acronyms
Electronic Control
Modulation Valve

ECM)
Exhaust Gas
Recirculation
Equipment
Monitoring System
Electromagnetic
Forward-Neutral-
Reverse
Global Positioning
System
Plus) earth

Global Navigation
Satellite System

HSS
Hydro Static
control
Unit
motions.
GD535-5 50-5
(02)
KOMATSU Closed
KCSF Engine
KOMATSU Diesel
Oxidation Catalyst
muffler.
Particulate Filter
KOMATSU Traction
LIN
load.
LVDS
sensor.
Service
NC Normally Closed
NO Normally Open
PC Hydraulic system
50-6 GD535-5
(02)
50 Disassembly and assembly Acronyms
PCCS
Pre-stroke Control
Valve
Control
hydraulic pressure.
Hydraulic system
PTP

Structure
Selective Catalytic
Reduction
VGT Engine

D: Bulldozer
HD: Dump truck
WA: Wheel loader
GD535-5 50-7
(02)

A/C Air Conditioner
A/M Air Mix damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
ENG Engine
F.G. Frame Ground
GND Ground
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/M Transmission
50-8 GD535-5
(02)
50 Disassembly and assembly How to read this manual
Related information on disassembly and assembly 1
How to read this manual 1
(Rev.2013.05)
Removal and installation of assembly
Special tools k: This mark indicates safety-related precau-
q The special tools required for removal and instal- tions which must be followed when preforming
lation work are described in the list as symbols the work.
such as A1, ..., X1. Part number, part name, a : This mark gives knowledge or precautions when
necessity, and quantity are described. performing the work.
4
q Mark used in the column of necessity are : This mark shows the weight of the part or
explained below. equipment.
■: Tools are not substituted, must always be
equipped (used). 2 : This mark shows a specific coating agent to
q: Tools extremely useful if available or tools that be used.
can be substituted with commercially available 3 : This mark shows the specified tightening
tool. torque.
q For details and the sketches of the special tools, 5 : This mark shows the amount of oil or coolant
see "Special tool list" and "Sketches of special to be added.
tools." q For details of oil or coolant to be added
after installation, see Specification "Table of
Removal fuel, coolant and lubricants".
q In "removal" section, the work procedures, pre-
cautions and know-how to do the work, and the Disassembly and assembly of assembly
amount of oil and coolant to be drained are Special tools
described. q The special tools required for disassembly and
q The general tools required for "Removal" are assembly work are described in the list as sym-
listed as [1], [2], ..., without description of part bols such as A1, ..., X1. Part number, part name,
number, part name, and quantity. quantity, and necessity are described.
q Marks used in "Removal" section are explained q Mark used in the column of necessity are
below. explained below.
k : This mark indicates safety-related precau- ■: Tools are not substituted, must always be
tions which must be followed when preforming equipped (used).
the work. q: Tools extremely useful if available or tools that
a :This mark gives knowledge or precautions when can be substituted with commercially available
performing the work. tool.
[*1]: This mark indicates that knowledge or precau- q For details and the sketches of the special tools, see
tions for the assembly installation work are given in the "Special tool list" and "Sketches of special tools."
installation section.
6
Disassembly
: This mark shows the amount of oil or coolant
q "Disassembly" describes the work procedure as
to be drained.
well as the precautions, knowledge, and drain
4 : This mark shows the weight of the part or amounts of oil and coolant required for the work.
equipment. q The general tools required for "Disassembly" are
listed as [1], [2], ..., without description of part
number, part name, and quantity.
Installation q Marks used in the section of "Disassembly" are
q The work procedure of "Installation" is in the
explained below.
k : This mark indicates safety-related precau-
reversed order to removal unless otherwise speci-
fied.
tions which must be followed when preforming
q For knowledge and precautions required for
the work.
"Installation", a [*1] mark is assigned to the
a : This mark gives knowledge or precautions when
"Removal" work procedure to indicate the work
performing the work.
item of the installation knowledge or precaution.
q The general tools required for "Installation" are 6 : This mark shows the amount of oil or coolant
listed as [1], [2], ..., without description of part to be drained.
4
: This mark shows the weight of the part or
q Marks used in "Installation" section are explained
equipment.
below.
GD535-5 50-9
(02)
How to read this manual 50 Disassembly and assembly
Assembly
q The section of "Assembly" provides precautions
and knowledge related to the work to be per-
formed, and amount of oil or coolant to be refilled.
q The general tools required for "Assembly" are
listed as [1], [2], ..., without description of part
q Marks used in the section of "Assembly" are
explained below.
k : This mark indicates safety-related precau-
tions which must be followed when preforming
the work.
a : This mark gives knowledge or precautions when
performing the work.
4 : This mark shows the weight of the part or
equipment.
2 : This mark shows a specific coating agent to
be used.
3 : This mark shows the specified tightening
torque.
5 : This mark shows the amount of oil or coolant
to be added.
q For details of oil or coolant to be added
after installation, see Specification "Table of
fuel, coolant and lubricants".
50-10 GD535-5
(02)
50 Disassembly and assembly Coating materials list
Coating materials list 1
a The coating materials such as adhesives, liquid gasket, and grease used for disassembly and assembly are
listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
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GD535-5 50-11
(02)
Coating materials list 50 Disassembly and assembly
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50-12 GD535-5
(02)
50 Disassembly and assembly Coating materials list
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GD535-5 50-13
(02)
Coating materials list 50 Disassembly and assembly

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50-14 GD535-5
(02)
50 Disassembly and assembly Special tool list
Special tool list 1
How to read the special tool list.

q Part No.:
Tools with part number 79*T-***-**** are not supplied (they are to be manufactured locally).
q Necessity
■: Tools that are not able to substituted and must always be prepared (used)
●: Tools that are extremely useful if available or tools that can be substituted using commercially available
tools
q New/Redesign
N: Tools with new part numbers that have been, newly developed for this model.
R: Tools with advanced part numbers, developed by improving existing tools used with other models.
Blank: Tools already available for other models, that can be used without any modification.
q Sketch:
○: Indicates that a sketch of the special tool is provided.
All sketches of special tools with part number 79*T-***-**** are listed in "Sketches of special tools"
Tools for removal and installation of supply pump assembly
New/Redesign
Necessity
Sketch
Q'ty
Symbol Part No. Part name Remarks
6 795-799-6130 Support ■ 1
Commercially
7
available
Spinner handle ●
790-101-3201 Bearing puller ■ 1 Removal of supply pump

A
790-101-3211 q Block 1 assembly
8
790-101-3221 q Bolt 2
790-101-3230 q Nut 2
9 790-101-2501 Push puller ■ 1
Tools for removal and installation of injector assembly

New/Redesign
Necessity
Sketch
Q'ty
1 795-799-1131 Gear ■ 1 Adjusting valve clearance

A
2 795-799-6700 Puller ■ 1 Removal of injector assembly
Tools for removal and installation of cylinder head assembly

New/Redesign
Necessity
Sketch
Q'ty
1 795–799–1131 Gear ■ 1 Adjusting valve clearance

A
2 795–799–6700 Puller ■ 1 Removal of injector assembly
GD535-5 50-15
(02)
Special tool list 50 Disassembly and assembly
Tools for removal and installation of engine front oil seal
New/Redesign
Necessity
Sketch
Q'ty
3 795–931–1100 Seal puller assembly ■ 1 Removal of oil seal

A
4 795–799–6400 Seal driver ■ 1 Installation of oil seal
Tools for removal and installation of engine rear oil seal
New/Redesign
Necessity
Sketch
Q'ty
3 795–931–1100 Seal puller assembly ■ 1 Removal of oil seal

A
4 795–799–6500 Seal driver ■ 1 Installation of oil seal
Tools for disassembly and assembly of torque converter assembly
New/Redesign
Necessity
Sketch
Q'ty
790-501-5000 Unit repair stand (100 VAC) q 1

790-501-5200 Unit repair stand (110 VAC and 220 VAC) q 1 Disassembly and assembly of
1
790-901-2110 Bracket q 1 torque converter assembly
794T-613-1210 Plate q 1 ○
Removal and installation of ring nut
793-310-2141 Plate q 1
of stator shaft
2 793-647-1110 Wrench t 1
3 794-613-1110 Guide t 1 Assembly of damper assembly
4 794-613-1120 Guide t 1 Removal of housing and collar
5 790-201-3230 Bolt ● 2
C 790-101-2501 Push puller ■ 1

790-101-2510 q Block 1
790-101-2520 q Screw 1
791-112-1180 q Nut 1
Removal of torque converter
790-101-2540 q Washer 1
6 lockup housing
790-101-2630 q Leg 2
790-101-2570 q Washer 4
790-101-2560 q Nut 2
790-101-2660 q Adapter 2
790-201-2640 Plate ■ 1
7 790-101-5221 Grip ● 1 Removal of shaft
8 790-201-2750 Spacer ■ 1 Press fit of bearing
50-16 GD535-5
(02)
Tools for disassembly and assembly of transmission assembly
New/Redesign
Necessity
Sketch
Q'ty
794T-615-1500 Lifting tool t 1 Q

794T-615-1510 q Cap t 1 Q
794T-615-1520 q Pin t 1 Q
794T-615-1530 q Plate t 1 Q
Removal and installation of 2nd,
1 794T-615-1540 q Plate t 1 Q
3rd, and 4th clutches
794T-615-1550 q Hook t 1 Q
794T-615-1560 q Screw t 1 Q
794T-615-1570 q Collar t 1 Q
794T-615-1580 q Ball chain t 1 Q
2 794T-615-1610 Adjustment tool t 1 Q Removal and installation of 2nd,
3 794T-615-1710 Guide t 1 Q 3rd, and 4th clutches
794T-615-1300 Puller t 1 Q
4 794T-615-1310 q Plate t 1 Q Removal of 4th clutch gear
794T-615-1320 q Plate t 1 Q
793T-607-1220 Lifting tool t 2 Q Removal and installation of 1st
5
793-607-1230 Pin t 2 clutch and R and FH clutch
794T-615-1400 Puller t 1 Q
6 794T-615-1410 q Plate t 1 Q Removal of R clutch gear
794T-615-1420 q Plate t 1 Q
7 790-102-1871 Nut wrench t 1 Removal of nut
8 799-301-1600 Oil leak tester t 1 Operation check of clutches
D 9 790-101-3701 Gear puller q 1
10 790-201-1410 Plate q 1 Removal of bearing
11 790-101-3501 Gear puller q 1
12 791T-465-1130 Push tool t 1 Q
Removal of snap ring
13 790-201-2870 Spacer t 1
14 790-201-3230 Bolt t 2 Pullout of FH gear
790-101-2310 Block t 1
790-101-2320 Screw t 1
790-101-2330 Nut t 1
Removal of bearing and gear on
790-101-2340 Washer t 1
15 FL clutch side, and removal of
790-101-2390 Leg t 2 needle bearing
02215-11622 Nut t 2
790-101-2360 Plate t 4
790-101-2800 Bearing puller t 1
16 794T-615-1110 Push tool t 1 Q Press fit of bearing
Installation of torque converter
17 790-201-3130 Guide bolt t 1
assembly
18 793T-613-1370 Spacer t 1 Q
Press fit of bearing
19 794T-615-1210 Spacer t 1 Q
Installation of inner race and
20 796T-667-1120 Push tool t 1 Q
bearing
21 790-201-2740 Spacer t 1 Press fit of bearing
22 793T-613-1380 Spacer t 1 Q Installation of outer race
GD535-5 50-17
(02)
New/Redesign
Necessity
Sketch
Q'ty
Installation of bearing and

23 792T-423-1110 Push tool t 1 Q
spacer
24 - Forcing screw t 2
Transmission front case
25 - Eyebolt t 2
assembly
26 - Eyebolt t 2
27 - Bar handle t 2 Removal of snap ring
28 - Puller t 1 Removal of R clutch gear
29 - Block t 2 Installation of transmission case
30 790-101-5700 Puller t 1 Removal of clutch gear
D
31 - Plate t 1
Removal of 2nd clutch gear
32 - Plate t 1
33 - Plate t 1
Removal of FH clutch gear
34 - Plate t 1
35 790-201-2660 Plate t 1 Installation of bearing
794T-114-1220 Push tool t 1 N Q
36 790-101-5421 Grip t 1
Press fiting oil seal, dust seal
01010-51240 Bolt t 1
37 794T-114-1230 Spacer t 1 N Q
Tools for disassembly and assembly of tandem drive assembly

New/Redesign
Necessity
Sketch
Q'ty
1 794T-720-1200 Chain puller t 1 Q

1-1 794T-720-1210 Plate t 2 Q
1-2 794T-720-1220 Plate t 4 Q
1-3 794T-720-1230 T-shaped wrench t 1 Q
Attaching and removing chain
1-4 794T-720-1240 Pin t 1 Q
1-5 794T-720-1250 Plate t 1 Q
1-6 794T-720-1260 Plate t 2 Q
1-7 794T-720-1270 Plate t 2 Q
9 794T-720-1600 Press fit jig t 1 Q
9-1 794T-720-1740 Shaft t 2 Q
G
9-2 794T-720-1630 Block t 1 Q
9-3 794T-720-1620 Plate t 1 Q
9-4 794T-720-1610 Block t 1 Q
Assembly of chain
9-5 794T-720-1550 Bolt t 2 Q
9-6 794T-720-1680 Bolt t 2 Q
9-7 794T-720-1670 Bolt t 1 Q
9-8 794T-720-1660 Block t 1 Q
9-9 794T-720-1650 Plate t 1 Q
Removal and installation of
19 - Hand pump t 1
chain
50-18 GD535-5
(02)
Tools for disassembly and assembly of differential assembly
New/Redesign
Necessity
Sketch
Q'ty
G 790-201-2720 Spacer q 1 Pullout of bevel pinion bearing

Commercially Pullout of bevel pinion bearing
H Bearing puller t 1
available and MTG bearing
Seat for pullout of bevel pinion
J 790-201-2870 Spacer q 1
bearing and MTG bearing
Guide bolt for removal of
K 790-201-3130 Guide bolt t 2
differential side bearing cage
Forcing bolt for removal of
L 790-201-3250 Bolt q 2
differential side bearing cage
Driving of inner race of
M - A Push tool t 1
differential R.H. side bearing
Driving of inner race of
N - A Push tool t 1
differential L.H. side bearing
P 790-101-5541 A Push tool t 1 Press fit of bearing outer race
Driving of differential seal ring
Q 790-201-2410 A Plate q 1
retainer
R 790-101-5471 A Push tool t 1 Press fit of bearing outer race
S 790-201-2760 Spacer t 1 Press fit of bearing
T 793T-615-1730 Spacer t 1 Q Press fit of bearing
Driving of large bearing at input
U - Push tool t 1
part
V 793T-613-1370 Spacer t 1 Q Press fit of bearing
Driving of seal at differential
W - Push tool t 1 N
input part
X 793T-613-1340 Spacer t 1 Q Press fit of dust seal
Y - Push tool t 1 N Press fit of dust seal
AE - Dial wrench t 1 Measurement of starting torque
AF 790-101-5491U Push tool t 1 Driving of bearing outer race
AG - U Push tool t 1 Driving of bearing inner race
AH - U Push tool t 1 Driving of bearing inner race
AJ 791-503-1001 Alignment tool t 1 Measuring bevel gear backlash
A: Only for differential lock specification

U: Only for non-differential specification
GD535-5 50-19
(02)
Tools fr disassembly and assembly of final drive assembly
New/Redesign
Necessity
Sketch
Q'ty
Seat for pullout of rear axle

A - Spacer t 1
bearing
Seat for pullout of rear axle
B 790-201-2860 Spacer t 2
bearing
C 790-101-5700 Gear puller q 1 Pullout of ring gear
D - Push tool t 1 Pullout of ring gear
Pullout of lock pin for planetary
E 799-501-1120 Pin t 1
gear shaft
F 790-445-5980 Guide bar t 1 Pullout of planetary gear shaft
Z - Plate t 1 Driving of side flange oil seal
790-101-5221 Grip t 1
AA 790-101-5341 Plate t 1 Driving of rear axle oil seal
01010-51225 Bolt t 1
Driving of rear axle bearing
AB 790-201-2870 Push tool t 1
outer race
Driving of rear axle bearing
AC 794T-420-1140 Spacer t 1 Q
inner race
AD - Block t 2 Seat for side case assembly
50-20 GD535-5
(02)
Tools for disassembly and assembly of wheel brake assembly
New/Redesign
Necessity
Sketch
Q'ty
790-101-2510 Block t 1
790-501-2520 Screw t 1
791-112-1180 Nut t 1
790-101-2540 Washer t 1
A Pullout of wheel shaft bearing
790-101-2610 Leg t 2
790-101-2560 Nut t 2
790-101-2570 Plate t 4
B 790-201-1410 Plate t 1 Pullout of wheel shaft bearing
Driving of wheel shaft bearing
C - Push tool t 1
inner race
Press fit of wheel shaft oil seal
D 793T-615-1710 Spacer t 1 ○ and sleeve
Driving of wheel shaft bearing

E 790-201-2310 Plate t 1
outer race
790-101-5531 Plate t 1
F 790-101-5421 Grip t 1 Driving of hub seal
01010-81240 Bolt t 1
Driving of outer race of wheel
G 790-201-2280 Plate t 1
shaft bearing on sprocket side
Driving of inner race of wheel
H 790-201-2850 Spacer t 1
shaft bearing on sprocket side
Press fit of wheel shaft oil seal
J - Push tool t 1
and sleeve
K 799-401-3300 Adapter assembly t 1 Pickup of brake oil pressure
L 02789-00422 Nut t 1 Pickup of brake oil pressure
799-101-5220 Nipple t 1 Pickup of brake oil pressure
N
07002-11023 O-ring t 1 Pickup of brake oil pressure
M 790-190-1500 Pump assembly t 1 Pickup of brake oil pressure
P 799-401-2320 Gauge t 1 Pickup of brake oil pressure
Q - Push-pull gauge t 1 Pickup of brake oil pressure
R 790-201-3290 Bolt t 4 Removal of cage
Tools for removal and installation of center hinge pin

New/Redesign
Necessity
Sketch
Q'ty
1 794T-646-1010 Push tool ■ 1 ○

2 794T-646-1021 Push tool ● 1 N ○
K Press fit of bearing
3 790-101-2102 Puller (294 kN {30 ton}) ■ 1
4 790-101-1102 Pump ■ 1
GD535-5 50-21
(02)
Tools for disassembly and assembly of hydraulic cylinder assembly
New/Redesign
Necessity
Sketch
Q'ty
790–502–1003 Cylinder repair stand ■ 1 Disassembly of hydraulic

1
790–101–1102 Hydraulic pump ■ 1 cylinder
Attaching and removing
2 790–330–1100 Wrench assembly ■ 1 cylinder head
Commercially
available
Socket (Width across flats: 30 mm) ■ 1
Commercially
available
Commercially Attaching and removing piston

3 available
nut
Commercially
available
790–302–1270 Socket (Width across flats: 50 mm) ■ 1

790–302–1290 Socket (Width across flats: 60 mm) ■ 1
790–201–1702 Push tool kit ■ 1
790–101–5021 q Grip 1
01010–50810 q Bolt 1
790–201–1731 q Push tool 1 Press-fit bushing into cylinder
4
790–201–1741 q Push tool 1 head
790–201–1751 q Push tool 1
U
790–201–1761 q Push tool 1
790–201–1771 q Push tool 1
790–201–1500 Push tool kit ■ 1
790–101–5021 q Grip 1
01010–50816 q Bolt 1
790–101–1540 q Plate 1 Press fit of dust seal to cylinder
5
790–101–1550 q Plate 1 head
790–101–1560 q Plate 1
790–101–1570 q Plate 1
790–101–1580 q Plate 1
6 790–720–1000 Expander q 1
796–720–1620 Ring q 1
07281–00609 Clamp q 1
796–720–1640 Ring q 1
07281–00909 Clamp q 1 Installation of piston ring
7
796–720–1650 Ring q 1
07281–01029 Clamp q 1
796–720–1670 Ring q 1
07281–01279 Clamp q 1
50-22 GD535-5
(02)
50 Disassembly and assembly Sketches of special tools
Sketches of special tools 1
k Note: Komatsu does not take any responsibility for special tools manufactured according to these
sketches.
794T-613-1210: Plate
794T-615-1500: Lifting tool
GD535-5 50-23
(02)
Sketches of special tools 50 Disassembly and assembly
794T-615-1510: Cap
794T-615-1520: Pin
50-24 GD535-5
(02)
794T-615-1530: Plate
794T-615-1540: Plate
GD535-5 50-25
(02)
794T-615-1550: Hook
794T-615-1560: Screw
50-26 GD535-5
(02)
794T-615-1570: Collar
794T-615-1580: Ball chain
GD535-5 50-27
(02)
794T-615-1610: Adjusting tool
794T-615-1710: Guide
50-28 GD535-5
(02)
794T-615-1300: Puller
794T-615-1310: Plate
GD535-5 50-29
(02)
794T-615-1320: Plate
793T-607-1220: Lifting tool
50-30 GD535-5
(02)
794T-615-1400: Puller
794T-615-1410: Plate
GD535-5 50-31
(02)
794T-615-1420: Plate
791T-465-1130: Push tool
50-32 GD535-5
(02)
794T-615-1110: Push tool
793T-613-1370: Spacer
GD535-5 50-33
(02)
794T-615-1210: Spacer
796T-667-1120: Push tool
50-34 GD535-5
(02)
793T-613-1380: Spacer
792T-423-1110: Push tool
GD535-5 50-35
(02)
794T-114-1220: Push tool
794T-114-1230: Spacer
50-36 GD535-5
(02)
794T-720-1200: Chain puller
C4G14218
GD535-5 50-37
(02)
794T-720-1210: Plate
794T-720-1220: Plate
50-38 GD535-5
(02)
794T-720-1230: T-shaped wrench
794T-720-1240: Pin
GD535-5 50-39
(02)
794T-720-1250: Plate
794T-720-1260: Plate
50-40 GD535-5
(02)
794T-720-1270: Plate
GD535-5 50-41
(02)
794T-720-1600: Press fit jig
50-42 GD535-5
(02)
794T-720-1740: Shaft
794T-720-1630: Block
GD535-5 50-43
(02)
794T-720-1620: Plate
794T-720-1610: Block
50-44 GD535-5
(02)
794T-720-1550: Bolt
794T-720-1680: Bolt
GD535-5 50-45
(02)
794T-720-1670: Bolt
794T-720-1660: Block
50-46 GD535-5
(02)
794T-720-1650: Plate
793T-615-1730: Spacer
GD535-5 50-47
(02)
793T-613-1370: Spacer
794T-420-1140: Spacer
50-48 GD535-5
(02)
793T-613-1340: Spacer
793T-615-1710: Spacer
GD535-5 50-49
(02)
794T-646-1010: Push tool
794T-646-1021: Push tool
50-50 GD535-5
(02)
50 Disassembly and assembly Removal and installation of supply pump assembly
Removal and installation of supply

pump assembly 1
Special tools
New/Redesign
Necessity
Sketch
Sym-
Q'ty
Part No. Part name
bol
6 795-799-6130 Support ■ 1 3. Remove clamp (3a), and disconnect connector

Commercially WIF1 (3).
7
available
Spinner handle ● 4. Remove 2 clamps (4a).
5. Remove 4 bolts (4b), and remove fuel prefilter (4)
790-101-3201 Bearing puller ■ 1
A and bracket (4c) as a unit.
790-101-3211 q Block 1
8
790-101-3221 q Bolt 2
790-101-3230 q Nut 2
9 790-101-2501 Push puller ■ 1
Removal
k Park the machine on a flat ground, set the gear
shift lever to P position, and lower the work
equipment to the ground.
k Stop the engine and chock the wheels.
k Check that the system operating lamp is off,
and then turn the battery disconnect switch to
OFF position.
(When the battery disconnect switch is not 6. Remove nut (6a), and disconnect clamp (6b) from
installed, disconnect the cable from the bat- bracket (6c). [*1]
tery negative (-) terminal.)
k When removing or installing fuel piping, be
careful to prevent foreign matter from enter-
ing. If any dirt or dust sticks to a part of the
fuel system, clean it off thoroughly with clean
fuel.
1. Set lock pin (1) to the frame.
2. Open cover (2) on the right side of the machine.

a Check that the lock lever is firmly locked in the
LOCK position.
GD535-5 50-51
(02)
Removal and installation of supply pump assembly 50 Disassembly and assembly
7. Remove hoses (6) and (7) between the fuel filter 10. Remove fuel spray prevention cap (9a), and
and supply pump. remove clamp (9b). [*2]
8. Disconnect fuel return hose (5) from the supply 11. Loosen sleeve nut (9c), and disconnect high-pres-
pump. sure pipe (9) from the supply pump. [*3]
a Remove any mud on connections of hoses (5),
(6), and (7). (Mud sometimes stiffens the lock
part (a).)
a Pull out hoses (5), (6), and (7) while pressing
locks (a) at respective hose connections from
both sides.
a When disconnecting the hoses (5), (6), and
(7), fuel will flow out. Insert a plug to the fitting
to prevent this from occurring.
a When doing this, do not use a wooden plug
since wood chips may enter the fuel line.
9. Disconnect connector (8).
12. Remove 3 nuts (10a), and remove supply pump

assembly (10) and gear (10b) as a unit. [*4]
a When removing nut (10a) in the back, you may
drop removed nut (10a) on the floor because of
tight space. To prevent loss of the nut, it is rec-
ommended to lay a cloth on the floor.
13. When it is needed to remove gear (10b) from the
supply pump, remove it according to the following
procedure. [*5]
50-52 GD535-5
(02)
50 Disassembly and assembly Removal and installation of supply pump assembly
2) Install tool A8 between the flange and gear

(10b) of the supply pump.
3) Install tool A9 on tool A8 and shaft (10d), and

attach center bolt A9-1 of tool A9 to the end of
the shaft.
4) Tighten center bolt A9-1 until gear (10b) comes
free from shaft (10d).
5) Remove tools A8 and A9.
6) Remove nut (10c), lock washer (10e) and gear

(10b) from shaft (10d).
1) Use tool A6 and tool A7 (1/2 inch) to lock gear

(10b), and loosen nut (10c).
a Do not remove nut (10c) from the shaft.
GD535-5 50-53
(02)
Removal and installation of supply pump assembly 50 Disassembly and assembly
Installation
q Perform installation in the reverse order of
removal.
k As a general rule, do not reuse a hose that has

been removed since the internal parts of its
adapter may have been damaged while it was
being removed. Be sure to replace it with a
new one for reassembly.
[*1]
3 Nut (6a):
32±4 Nm{3.2±0.4 kgm}
[*2]
3 Clamp (9b):
24±4 Nm{2.4±0.4 kgm} q Bleeding air from fuel circuit
[*3] Bleed air from the fuel circuit. For details, see
3 Sleeve nut (9c): Testing and adjusting, "Bleeding air from fuel cir-
35±3.5 Nm{3.6±0.4 kgm} cuit".
[*4]
3 Nut (10a):
24±4 Nm{2.4±0.4 kgm}
[*5]
If it is needed to install gear (10b) to the supply pump,
install it according to the following procedure.
a Before installation, clean dusts and foreign sub-
stances on the mating surfaces of shaft (10d) and
gear (10b), and keep the mating surfaces dry.
1) Install gear (10b) to shaft (10d).
2) Install lock washer (10e) and nut (10c), and
finger-tighten nut (10c) lightly.
3) Use tool A6 and tool A7 (1/2 inch) to lock gear

(10b), and tighten nut (10c).
3 Nut (10c):
105±5 Nm{10.7±0.51 kgm}
50-54 GD535-5
(02)
50 Disassembly and assembly Removal and installation of injector assembly
Removal and installation of injector

assembly 1
Special tools
New/Redesign
Necessity
Sketch
Sym-
Q'ty
Part No. Part name
bol
1 795-799-1131 Gear ■ 1
A
2 795-799-6700 Puller ■ 1
Removal
OFF position.
(When the battery disconnect switch is not
installed, disconnect the cable from the bat-
ing. If any dirt or dust sticks to a part of the
fuel system, clean it off thoroughly with clean
fuel.
a Check the connector numbers and installed posi-
tions before disconnecting wiring and hoses, and
write them down.
2. Remove the engine hood assembly. For details,
see "Removal and installation of engine hood
assembly".
4. Remove bolts (5), and remove bracket (6).
3. Remove 8 bolts (2), and raise muffler assembly (4)

and bracket (3) as a unit to remove it
5. Remove 2 clamps (7), and disconnect 3 connec-

tors (8) from cylinder head (13a).
6. Disconnect connector (9) from common rail (15),
and move wiring harness (10) out of the way. [*1]
GD535-5 50-55
(02)
Removal and installation of injector assembly 50 Disassembly and assembly
a While pressing the lock of the connector using

a flat-head screwdriver, insert another screw-
driver into the gap in the connector, and pry the
connector little by little to disconnect it.
9. Remove 12 fuel spray prevention caps (15a) for

fuel injection pipes (15c), (15d), (15e), (15f), (15g),
and (15h). [*4]
10. Loosen 12 sleeve nuts (15b), and remove fuel
7. Use a hexagonal wrench (3 mm) to remove 2 injection pipes (15c), (15d), (15e), (15f), (15g), and
hexagonal socket head bolts (11), and remove (15h). [*5]
blowby duct (12) from head cover (13). [*2] a For 12 sleeve nuts (15b), be sure to loosen
sleeve nuts both on cylinder head side and
common rail side.
a Do not remove fuel pressure sensor (15i) and
relief valve (15j) on common rail (15) for the
purpose of other than replacement.
[*6]
8. Remove 6 nuts (14), and remove head cover (13).

[*3]
a Clean the surrounding area of head cover (13)
in advance to prevent intrusion of mud and dirt.
50-56 GD535-5
(02)
14. Remove crossheads (22).

a Record the installed positions and directions of
the crossheads (22) (shapes of holes at por-
tions (a) and (b)). (For reassembly, install them
in the same direction as they were.)
11. Use tool A1 to rotate the crankshaft forward so that

the wide slit (b) of pulley (17) that has speed detec-
tion slits located at the rear of damper (16) over-
laps the top face (a) of the protrusion (crankshaft
position sensor mounting part) of the front cover.
a This operation is accepted if wide slit (b) over-
laps top face (a) of the protrusion.
a Note that this positioning does not set the cyl-
inder at its top dead center. (The No. 1 or No. 6
cylinder is positioned 76 to 88 degrees before
its top dead center.)
15. Remove retaining nut (23), and remove inlet

connector (24).
a Clean the surrounding area of the inlet connec-
tor in advance to prevent mud and dirt from
entering into its hole.
a Do not remove injector harness connector (25)
from the rocker housing except when required.
12. Loosen lock nut (18), and loosen adjustment screw [*7]
(19) 2 to 3 turns.
a This operation is needed to prevent the push
rod from being subjected to an excessive force
when installing rocker arms.
13. Remove bolts (20) and remove rocker arms (21).
16. Remove 2 harness nuts (27) from injector

assembly (26).
GD535-5 50-57
(02)
17. Remove 2 bolt (28), and remove holder (29). Installation

1. Install injector assembly (26) according to the
a Check that the sleeve of injector assembly (26)
is free of scratches and dirt.
1) Install O-ring (30) and gasket (31) to injector
assembly (26).
2 O-ring (30) and injector mounting bore:
Engine oil (EO15W-40)
2) Install holder (29) while aligning concave
portion (b) of holder (29) with convex portion (a)
of injector assembly (26).
3) Install injector assembly (26) to the cylinder
head with its fuel inlet hole facing the air intake
manifold.
18. Using tool A2, remove injector assembly (26).
4) Finger-tighten 2 bolts (28) 3 to 4 threads.
a Be careful to prevent dirt and foreign matter
from entering the mounting part of the injector
assembly (26).
5) Install a harness to injector assembly (26), and

tighten 2 nuts (27).
3 Nut (27):
1.5±0.25 Nm{0.15±0.03 kgm}
Wiring harness mounting position
Color of wiring harness Cylinder No.
White 1, 3, 5
Black 2, 4, 6
50-58 GD535-5
(02)
a Visually check the inlet connector (24). If any

of the following problems exists, replace both
fuel injector assembly (26) and inlet connector
(24) with new ones as a unit.
a There is wear or uneven seat contact on seal-
ing surface (e) at the front end of inlet connec-
tor (24).
a If there is leakage of high-pressure fuel in inlet
connector (24), thin lines or cracks erode the
sealing surface.
2. Install inlet connector (24) according to the

a When replacing injector assembly (26) with a
new one, be sure to replace inlet connector
(24) with a new one as well.
1) Install O-ring (32) to inlet connector (24).

2 O-ring (30) and mounting bore for inlet
connector (24) :
2) Insert inlet connector (24) into the cylinder head
completely while aligning its convex part (f) with
the side grooves in the cylinder head, and
loosely install inlet connector (24) by using
retaining nut (23).
3 Retaining nut (23):
a Visually check inlet connector (24). If following
defects are observed, replace it with a new 14.7±5.0 Nm {1.5±0.5 kgm}
one.
a Burrs or wear is found in top-end (a) or rear-
end (b) of inlet connector (24).
a Foreign matters are captured in the edge filter
at rear-end (c) of inlet connector (24).
a There are cracks or deterioration on the O-ring
at upper part (d) of inlet connector (24).
3) Tighten bolts (28) alternately.

3 Bolt (28):
8±0.8 Nm {0.8±0.08 kgm}
4) Secure inlet connector (24) by tightening
retaining nut (23) to the specified torque.
50±5 Nm{5.1±0.5 kgm}
GD535-5 50-59
(02)
a Check that the cap on the crosshead side

of rocker arm (21) contacts with the contact
surface of crosshead (22) on a level. (They
must not contact with each other at an
angle.)
a Check that the injector wiring harness does
not interfere with rocker arm (21).
2 Threaded part and seat surface of bolt
(20):
3) Tighten mounting bolts (20) of rocker arms (21)
to the specified torque.
3 Bolt (20):
36±5 Nm {3.6±0.5 kgm}
3. Install crossheads (22) and rocker arms (21) 4) Adjust the valve clearance. For details, see
according to the following procedure. Testing and adjusting, "Adjusting valve clear-
a Shapes of holes in (a) and (b) portions of ance".
crosshead (22) is not identical. So when reus- 3 Lock nut (18):
ing them, be sure to install them for the same 24±4 Nm {2.45±0.41 kgm}
intake or exhaust valve and in the same direc-
tion.
a When installing crosshead (22), check that
valves securely are seated in holes (a) and (b).
q Perform subsequent installation in the reverse

order to removal.
[*1]
k Install each fuel injection pipe and wiring har-
1) Install crossheads (22). ness at least 10 mm apart from each other.
[*2]
3 Blowby duct mounting bolt (11):
7±2 Nm {0.7±0.2 kgm}
[*3]
3 Head cover mounting nut (14):
24±4 Nm {2.4±0.4 kgm}
[*4] [*5]
q Install 12 fuel spray prevention caps (15a) and fuel
injection pipes (15c), (15d), (15e), (15f), (15g),
and (15h) according to the following procedure.
k Do not apply bending correction to fuel
injection pipes (15c), (15d), (15e), (15f),
(15g), and (15h) for the use of them.
k Be sure to use genuine clamps for fuel
2) Install rocker arms (21), finger-tighten bolts injection pipes (15c), (15d), (15e), (15f),
(20), and check the following. (15g), and (15h), and observe the specified
a Check that the ball of adjustment screw tightening torque.
(19) securely is set in the push rod socket.
50-60 GD535-5
(02)
k For fuel injection pipes (15c), (15d), (15e),

(15f), (15g), and (15h), check the followings
before installation.
If the fuel injection pipe has any defect, re-
place it with a new one since fuel may leak.
q Make sure with visual check that the taper seal
part of the connection (a) part: 2 mm area from
the tip-end is free from longitudinal slits (b) or
pits (c).
q Make sure that end (d) (2 mm from the tip end)
is free from steps you can feel by your finger-
nail. (free from fatigue.)
3) Install 12 fuel spray prevention caps (15a) to

respective fuel injection pipes.
a Install fuel spray prevention cap (15a) with
its slit outward (a) and down (b).
a Fuel spray prevention caps (15a) are
installed so that fuel will not spout over the
high temperature part of the engine and
catch fire when it leaks by any chance.
4
1) Loosely install 12 sleeve nuts (15b) on the

cylinder head side and common rail side (15)
for fuel injection pipes (15c), (15d), (15e), (15f),
(15g), and (15h).
3 Sleeve nut (15b):
0.2 to 0.8 Nm {0.02 to 0.08 kgm}
2) Tighten fuel injection pipes (15c), (15d), (15e),
(15f), (15g), and (15h) in the order shown
below.
1] Sleeve nuts on cylinder head side (13a) for
fuel injection pipes (15c) and (15h)
2] Sleeve nuts on common rail side (15) for
fuel injection pipes (15h) and (15c)
fuel injection pipes (15d), (15e), (15f), and
(15g)
4] Sleeve nuts on common rail side (15) for
fuel injection pipes (15d), (15e), (15f), and
(15g)
GD535-5 50-61
(02)
2. To replace relief valve (15j), follow the procedures

below.
1) Before removing relief valve (15j), remove mud
etc. from around it thoroughly and clean it.
2) Remove relief valve (15j).
3) If the leakage from relief valve (15j) exceeds
the specified value, do not reuse it.
4) Check the relief valve (15j) and high-pressure
sealing surface (A) on common rail (15) for
damages.
5) Install relief valve (15j).
3 Threaded part of relief valve (15j):
Gear oil (#90)
3 Relief valve (15j):
[*6]
1. To replace fuel pressure sensor (15i), follow the 100±4 Nm {10.2±0.4 kgm}
procedures below. a Excessive tightening may cause leakage.
a Removal of fuel sensor (15i) from common rail Take care not to tighten excessively.
(15) is allowed for the replacement purpose
alone.
a Be sure to replace fuel pressure sensor (15i)
removed from common rail (15) with a new
sensor.
1) Before removing fuel pressure sensor (15i),
remove mud etc. from around it thoroughly and
clean it.
2) Remove fuel pressure sensor (15i).
3) Check the fuel pressure sensor connector for
crack, breakage, damage of the seal, foreign
matter on the pin and corrosion, bend and
breakage of the pin.
4) Install new fuel pressure sensor (15i). 6) Start the engine and check for fuel leakage.
2 Threaded part of fuel pressure sensor a For the testing procedure, see Testing and
(15i): adjusting, "Testing fuel circuit for leakage".
Gear oil (#90) [*7]
3 Fuel pressure sensor (15i): q When injector harness connector (25) is removed,
70±5 Nm {7.1±0.5 kgm} install it according to the following procedure.
1) Apply liquid gasket to O-ring (25a) of injector
harness connector (25) and flange surface (n).
2 O-ring (25a) and flange surface (n):
Liquid gasket (LG-7)
a Apply liquid gasket (LG-7) to the O-ring
until its groove is filled up completely (a
bead approximately 3 mm in diameter).
a If O-ring (25a) is damaged, replace the
injector harness assembly as a unit.
5) Connect the engine wiring harness. At this

time, be careful not to reverse connection of
connector.
6) Start the engine and check for fuel leakage.
a For the testing procedure, see Testing and
adjusting, "Testing fuel circuit for leakage".
50-62 GD535-5
(02)
2) Install injector harness connector (25) to rocker

housing (33), and tighten bolt (25b) to secure it.
3 Injector harness connector mounting
bolt (25b):
10±2 Nm {1.0±0.2 kgm}
q Bleeding air from fuel circuit

Bleed air from the fuel circuit. For details, see
cuit".
GD535-5 50-63
(02)
Removal and installation of cylinder head assembly 50 Disassembly and assembly

cylinder head assembly 1
Special tools
New/Redesign
Necessity
Sketch
Sym-
Q'ty
Part No. Part name
bol
1 795–799–1131 Gear ■ 1
A
2 795–799–6700 Puller ■ 1
Removal 3. Remove the engine hood assembly. For details,

k Park the machine on a flat ground, set the gear see "Removal and installation of engine hood
shift lever to P position, and lower the work assembly".
k Stop the engine and chock the wheels. 4. Remove 8 bolts (3), and raise muffler assembly (5)
k Check that the system operating lamp is off, and bracket (4) as a unit to remove it
OFF position.
careful to prevent foreign matter from entering.
If any dirt or dust sticks to a part of the fuel sys-
tem, clean it off thoroughly with clean fuel.
2. Loosen drain valve (2) to drain the coolant.

6 Coolant:
21.1 ℓ
a After the drain is completed, close drain valve
(2).
50-64 GD535-5
(02)
50 Disassembly and assembly Removal and installation of cylinder head assembly
5. Remove bolts (6), and remove bracket (7). 9. Remove clamp (12), and remove 2 bolts (13).
6. Remove the air conditioner compressor assembly.

For details, see "Removal and installation of air
conditioner compressor assembly".
7. Loosen 2 clamps (8), and disconnect hose (9).
10. Remove 4 bolts (14), and remove muffler mounting

bracket (15).
8. Remove 2 bolts (10), and remove muffler drain

tube (11).
11. Remove 2 clamps (16), and disconnect 3 connec-

tors (17) from the cylinder head.
12. Disconnect connector (18) from the common rail,
and move wiring harness (19) out of the way. [*1]
a While pressing the lock of the connector by
using a flat-head screwdriver, insert another
screwdriver into the gap in the connector, and
pry the connector little by little to disconnect it.
GD535-5 50-65
(02)
14. Turn up rubber cover (21a), and disconnect intake

air heater terminal E07 (21) from intake air heater
(24).
15. Remove 4 bolts (22), and remove air intake
connector (23) and intake air heater (24). [*3]
13. Turn up rubber cover (20a), and remove ambient

pressure sensor connector (20). [*2]
a To disconnect ambient pressure sensor con-
nector (20), move lock (a) to the right and pull
out the connector while pressing part (b).
a Move wiring harness (20b) out of the way.
16. Remove 2 clamps (86), and disconnect connector

(87).
17. Remove 6 bolts (88a) and remove bracket (88).
[*4]
50-66 GD535-5
(02)
18. Remove nut (25a), and remove clamp (25). [*5] 20. Remove 2 clamps (30a), and disconnect connector
19. Remove hoses (26) and (27) between fuel filter (30).
(28) and supply pump (29). a Leave connector (30) removed from connector
a Remove any mud on connections of hoses mount (30b).
(26) and (27). (Mud sometimes stiffens the 21. Remove 6 clamps (31), and move wiring harness
lock part (a).) (32) out of the way.
a Pull out hoses (26) and (27) while pressing 22. Remove 2 joint bolt (33a), and then disconnect fuel
locks (a) at respective hose connections from return hose (33) from bracket (35). [*6]
both sides. 23. Remove joint bolt (34a), and then disconnect fuel
a When disconnecting the hoses (26) and (27), return hose (34) from bracket (35). [*7]
fuel will flow out. Insert a plug to the fitting to
prevent fuel from flowing out.
a Do not use a wooden plug because wood
chips may enter the fuel line.
GD535-5 50-67
(02)
26. Remove clamp (37a) for fuel injection pipe (37).

[*9]
27. Remove clamp (38), and remove fuel spray
prevention cap (39a). [*10]
24. Remove 2 bolts (28a) and 1 stud bolt (28b), and

remove fuel filter (28) and bracket (35) as a unit.
[*8]
25. Remove clamp (36a) for wiring harness (36).
28. Loosen sleeve nuts (39b), and remove fuel
injection pipe (39) from supply pump (29). [*11]
a Also remove the fuel spray prevention cap and
loosen the sleeve nut on the common rail side.
50-68 GD535-5
(02)
29. Remove 12 fuel spray prevention caps (40a) for 32. Disconnect radiator upper hose (42). [*16]
fuel injection pipes (40c), (40d), (40e), (40f), (40g), 33. Disconnect coolant temperature sensor connector
and (40h). [*12] (43).
30. Loosen 12 sleeve nuts (40b), and remove fuel
injection pipes (40c), (40d), (40e), (40f), (40g), and
(40h). [*13]
a For 12 sleeve nuts (40b), be sure to loosen
sleeve nuts both on cylinder head side and
common rail side.
34. Remove clamp (44a), and disconnect hose (44c)

from tube (44b). [*17]
35. Remove 2 clamps (45a), and disconnect hose
(45c) from tube (45b). [*18]
36. Remove 2 bolts (46a), and remove hose (44c),
tube (45b), and bracket (46) as a unit.
37. Remove clamp (47c).
38. Remove 2 bolts (47a) and 2 bolts (47b), and
remove cover (47).
31. Remove 4 bolts (41a) to remove common rail (41).

[*14]
a Do not remove fuel pressure sensor (41a) and
relief valve (41b) on common rail (41) for the
purpose of other than replacement. [*15]
GD535-5 50-69
(02)
41. Disconnect cables from terminals (50), (51), and

(52) of alternator (53).
39. Remove 2 nuts (48a) and 2 bolts (48b), and

remove cover (48).
42. Remove 2 bolts (54a), and remove cover (54).
44. Apply a wrench (approximately 450 mm) to part (a)
(width across flats: 12.7 mm) of tensioner
assembly (56), and turn the wrench in (b) direction
to decrease the tension of alternator belt (57).
k Check that the wrench is set on tensioner
assembly (56) at part (a) before turning it.
(The spring of the tensioner assembly is
strong. If the wrench is loosely set, it may
accidentally come off. This can be extreme-
ly dangerous.)
k After removing alternator belt (57), slowly
and carefully restore tensioner assembly
(56).
k Be careful not to get your fingers caught be-
tween the pulley and alternator belt (57) dur-
ing work.
50-70 GD535-5
(02)

[*21]
45. Remove alternator belt (57).

46. Loosen bolt (58), and remove bolt (59). [*19]
47. Tilt alternator (53) in (c) direction.
48. After tilting it, install removed bolt (59) to alternator
(53) again.
49. Wind the belt string around installed bolt (59) to
sling alternator (53). 52. Remove 3 bolts (61a), and remove tube (61). [*22]
a Before removing tube (61), clean the surround-
50. Remove bolt (58), and raise alternator (53) to ing area of it to prevent intrusion of mud and
remove it. [*20] dirt into the thermostat.
GD535-5 50-71
(02)
53. Loosen sleeve nut (62a), and disconnect turbo-

charger lubricating oil inlet tube (62). [*23]
54. Remove 2 bolts (63a), and disconnect turbo-
charger lubricating oil outlet tube (63).
55. Sing exhaust manifold and turbocharger assembly

(64).
56. Remove 12 bolts (64a) and 2 bolts (64b), and raise
exhaust manifold and turbocharger assembly (64)
to remove it. [*24]
59. Use tool A1 to rotate the crankshaft forward so that

the wide slit (b) of pulley (68) with speed detection
slits located at the rear of damper (67) overlaps top
face (a) of the protrusion (crankshaft position
sensor mounting part) of the front cover.
a This operation is accepted if wide slit (b) over-
laps top face (a) of the protrusion.
a Note that this positioning set no cylinder at its
top dead center. (The No. 1 or No. 6 cylinder is
positioned 76 to 88 degrees before its top dead
center.)
57. Use a hexagonal wrench (3 mm) to remove 2

hexagonal socket head bolts (65a), and remove
blowby duct (65) from head cover (66). [*25]
58. Remove 6 nuts (66a), and remove head cover (66).
[*26]
a Clean the surrounding area of head cover (66)
in advance to prevent intrusion of mud and dirt.
50-72 GD535-5
(02)
60. Loosen lock nut (69), and loosen adjustment screw a Do not remove injector harness connector (76)
(70) 2 to 3 turns. from the rocker housing except when required.
a This operation is needed to prevent the push [*27]
rod from being subjected to an excessive force
when installing rocker arms.
61. Remove bolts (71) and remove rocker arms (72).
64. Remove 2 harness nuts (78) from injector

assembly (77).
65. Remove 2 bolt (79), and remove holder (80).
62. Remove crosshead (73).
a Record the installed positions and directions of
crossheads (73) (shapes of holes at portions
(a) and (b)). (For reassembly, install them in
the same direction as they were.)
66. Using tool A2, remove injector assembly (77).

a Be careful to prevent dirt and foreign matter
from entering the mounting part of the injector
assembly (77).
63. Remove retaining nut (74) and remove inlet

connector (75).
a Clean the surrounding area of the inlet connec-
tor in advance to prevent mud and dirt from
entering into its hole.
GD535-5 50-73
(02)
67. Remove push rods (81). Installation

68. Remove rocker housing assembly (82). 1. Cylinder head assembly
Install cylinder head assembly (84) according to
1) Measure stem length (a) of every cylinder head
mounting bolt and check that it is within the
using limit.
a Allowable limit of bolt length (a): Less than
132.1 mm
a If a bolt is longer than the allowable limit, do
not reuse it. Replace it with a new one.
69. Remove mounting bolts (83) (26 pieces), sling

cylinder head assembly (84) and remove it.
70. Remove cylinder head gasket (85).
2) Set cylinder head gasket (85) to the cylinder

block.
a Check that cylinder head mounting surface
and inside of cylinders are free from dirt or
foreign matters.
a Check that the holes in the cylinder head
gasket are aligned with the holes in the cyl-
inder head.
3) Raise cylinder head assembly (84), install it
onto the cylinder block, and finger-tighten 26
mounting bolt (83) 2 to 3 turns.
4) Tighten 26 cylinder head mounting bolts (83)

according to the following procedure in the
sequence from bolt [1] to bolt [26] shown in the
figure.
2 Threaded portion and head seat surface
of mounting bolt (83):
50-74 GD535-5
(02)
1] 3 1) Install O-ring (89) and gasket (90) to injector

Tighten the bolts to 70 ± 6 Nm {7 ± 0.6 assembly (77).
kgm}. 2 O-ring (89) and injector mounting bore:
2] Using an angle tightening tool, tighten all Engine oil (EO15W-40)
bolts to 360 ± 5 degrees. 2) Install holder (91) while aligning concave
3] 3 portion (b) of holder (91) with convex portion (a)
Tighten the bolts to 105 ± 3 Nm {10.7 ± of injector assembly (77).
0.3 kgm}. 3) Install injector assembly (77) to the cylinder
4] Using an angle tightening tool, retighten all head with its fuel inlet hole facing the air intake
bolts to 90 ± 5 degrees. manifold.
a When not using an angle tightening tool, 4) Finger-tighten 2 bolts (79) 3 to 4 threads.
put a mark on the cylinder head and bolt
using a felt-tip pen and retighten bolt to 90
± 5 degrees.
2. Rocker housing
Two types of bolts different in length are used as
mounting bolts for rocker housing (82). Take care
not to use wrong bolts.
a Rocker housing mounting bolt (82a):
M8 × 1.25-50 (2 bolts)
a Rocker housing mounting bolt (82b):
8×1.25
3Rocker housing mounting bolt (82a) and
(82b):
24±4 Nm {2.4±0.4 kgm} 5) Install a harness to injector assembly (77), and
tighten 2 nuts (78).
3 Nut (78):
1.5±0.25 Nm {0.15±0.03 kgm}
Wiring harness mounting position
Color of wiring harness Cylinder No.
White 1, 3, 5
Black 2, 4, 6
3. Injector assembly
Install injector assembly (77) according to the fol-
lowing procedure.
a Check that the injector sleeve is free from
scratches and dirt.
GD535-5 50-75
(02)
a Visually check inlet connector (75). If any of

the following problems exists, replace both fuel
injector assembly (77) and inlet connector (75)
with new ones as a unit.
q There is wear or uneven seat contact on
sealing surface (e) at the front end of inlet
connector (75).
q If there is leakage of high-pressure fuel in
inlet connector (75), thin lines or cracks
erode the sealing surface.
4. Inlet connector
Install inlet connector (75) according to the follow-
ing procedure.
a When replacing injector assembly (77) with a
new one, be sure to replace inlet connector
(75) with a new one as well.
1) Install O-ring (92) to inlet connector (75).

2 O-ring (92) and mounting bore for inlet
connector (75):
2) Insert inlet connector (75) into the cylinder head
completely while aligning its convex part (f) with
the side grooves in the cylinder head, and
loosely install inlet connector (75) by using
retaining nut (74).
a Visually check inlet connector (75). If following

defects are observed, replace it with a new
one.
q Burrs or wear is found in top-end (a) or
rear-end (b) of inlet connector (75).
q Foreign matters are captured in the edge
filter at rear-end (c) of inlet connector (75).
q There are cracks or deterioration on the O-
ring at upper part (d) of inlet connector
(75).

14.7±5.0 Nm {1.5±0.5 kgm}
3) Tighten bolts (79) alternately.
3 Bolt (79):
8±0.8 Nm {0.8±0.08 kgm}
4) Secure inlet connector (75) by tightening
retaining nut (74) to the specified torque.
50±5 Nm {5.1±0.5 kgm}
50-76 GD535-5
(02)
2) Install rocker arms (72), finger-tighten bolts

(71), and check the following.
a Check that the ball of adjustment screw
(70) securely is set in the push rod socket.
a Check that the cap on the crosshead side
of rocker arm (72) contacts with the contact
surface of crosshead (73) on a level. (They
must not contact with each other at an
angle.)
a Check that the injector wiring harness does
not interfere with rocker arm (72).
2 Threaded part and seat surface of bolt
(71):
5. Crosshead and rocker arm 3) Tighten mounting bolts (71) of rocker arms (72)
Install crossheads (73) and rocker arms (72) to the specified torque.
3 Bolt (71):
a Shapes of holes in (a) and (b) portions of 36±5 Nm {3.6±0.5 kgm}
crosshead (73) is not identical. So when reus- 4) Adjust the valve clearance. For details, see
ing them, be sure to install them for the same Testing and adjusting, "Adjusting valve clear-
intake or exhaust valve and in the same direc- ance".
tion.
a When installing crosshead (73), check that
valves securely are seated in holes (a) and (b).
3 Lock nut (69):

24±4 Nm {2.45±0.41 kgm}
1) Install crossheads (73). q Perform subsequent installation in the reverse

order to removal.
[*1]
k Install each fuel injection pipe and wiring har-
ness at least 10 mm apart from each other.
[*2]
a After connecting ambient pressure sensor con-
nector (20), be sure to move lock (a) to the left.
[*3]
3 Mounting bolt (22) of air intake connector (23):
34±4 Nm {3.7±0.4 kgm}
2 Mounting bolt (22) of air intake connector (23):
Adhesive (LT-2)
a Apply the adhesive 10 mm or more in width except

1st and 2nd threads.
[*4]
3 Mounting bolt (88a) of bracket (88):
24±4 Nm {2.4±0.4 kgm}
GD535-5 50-77
(02)
[*5] 3) Tighten fuel injection pipes (40c), (40d), (40e),

3 Nut (25a) of fuel hose clamp: (40f), (40g), and (40h) in the order shown
32±4 Nm {3.2±0.4 kgm} below.
[*6][*7]
3 Joint bolt (33a) of fuel return hose (33):
fuel injection pipes (40c) and (40h)
24±4 Nm {2.4±0.4 kgm}
[*8] 2] Sleeve nuts on common rail side (15) for
3 Mounting bolt (28a) of fuel filter bracket (35):
fuel injection pipes (40h) and (40c)
32±4 Nm {3.2±0.4 kgm} 3] Sleeve nuts on cylinder head side (84) for
3 Mounting stud bolt (28b) of fuel filter bracket fuel injection pipes (40d), (40e), (40f), and
(35): (40g) in order
32±4 Nm {3.2±0.4 kgm} 4] Sleeve nuts on common rail side (41) for
[*9][*10][*11][*12][*13][*14] fuel injection pipes (40d), (40e), (40f), and
q Install 12 fuel spray prevention caps (15a) and fuel (40g) in order
injection pipes (40c), (40d), (40e), (40f), (40g),
and (40h) according to the following procedure.
k Do not apply bending correction to fuel
(40g), and (40h) for the use of them.
k Be sure to use genuine clamps for fuel
(40g), and (40h), and observe the specified
tightening torque.
k For fuel injection pipes (40c), (40d), (40e),
(40f), (40g), and (40h), check the followings
before installation. If the fuel injection pipe
has any defect, replace it with a new one
since fuel may leak.
q Make sure with visual check that the taper seal 4) Install fuel injection pipe (39) (between fuel
part of the connection (a) part: 2 mm area from supply pump and common rail (41) according to
the tip-end is free from longitudinal slits (b) or the following procedure.
pits (c). 1] Finger-tighten sleeve nuts on fuel supply
q Make sure that end (d) (2 mm from the tip end) pump side and common rail side for fuel
is free from steps you can feel by your finger- injection pipe (39).
nail. (free from fatigue.)
2] Tighten sleeve nut on fuel supply pump side
first and then that on common rail side for
fuel injection pipe (39) to the torque shown
below.
3 Sleeve nut for fuel fuel injection pipe (39):
35±3.5 Nm {3.6±0.4 kgm}
1) Use 4 bolts (41a) to install common rail (41)

loosely.
3 Bolt (41a) (for loose installation):
0.2 to 0.8 Nm {0.02 to 0.08 kgm}
2) Loosely install 12 sleeve nuts (40b) on cylinder
head side (84) and common rail side (41) for
fuel injection pipes (40c), (40d), (40e), (40f),
(40g), and (40h).
3 Sleeve nut (40b) (for loose installation):
0.2 to 0.8 Nm {0.02 to 0.08 kgm}
50-78 GD535-5
(02)
5) Install 12 fuel spray prevention caps (40a) to 1) Before removing fuel pressure sensor (41i),
respective fuel injection pipes. remove mud etc. from around it thoroughly and
a Install fuel spray prevention cap (40a) with clean it.
its slit outward (a) and down (b). 2) Remove fuel pressure sensor (41i).
a Fuel spray prevention caps (40a) are 3) Check the fuel pressure sensor connector for
installed so that fuel will not spout over the crack, breakage, damage of the seal, foreign
high temperature part of the engine and matter on the pin and corrosion, bend and
catch fire when it leaks by any chance. breakage of the pin.
4) Install new fuel pressure sensor (41i).
2 Threaded part of fuel pressure sensor
(41i):
Gear oil (#90)
3 Fuel pressure sensor (41i):
70±5 Nm {7.1±0.5 kgm}
5) Connect the engine wiring harness. At this
time, be careful not to reverse connection of
connector.
6) Start the engine and check for fuel leakage.
a For the testing procedure, see Testing and
adjusting, "Testing fuel circuit for leakage".
2. To replace relief valve (41j), follow the procedures

below.
1) Before removing relief valve (41j), remove mud
etc. from around it thoroughly and clean it.
2) Remove relief valve (41j).
3) If the leakage from relief valve (41j) exceeds
the specified value, do not reuse it.
4) Check the relief valve (41j) and high-pressure
sealing surface (A) on common rail (41) for
damages.
5) Install relief valve (41j).
2 Threaded part of relief valve (41j):
[*15] Gear oil (#90)
1. To replace fuel pressure sensor (41i), follow the 3 Relief valve (41j):
procedures below. 100±4 Nm {10.2±0.4 kgm}

a Removal of fuel sensor (41i) from common rail a Excessive tightening may cause leakage.
(41) is allowed for the replacement purpose Take care not to tighten excessively.
alone. 6) Start the engine and check for fuel leakage.
a Be sure to replace fuel pressure sensor (41i) a For the testing procedure, see Testing and
removed from common rail (41) with a new adjusting, "Testing fuel circuit for leakage".
sensor.
GD535-5 50-79
(02)
[*21]
3 Bracket mounting bolt (60a):
24±4 Nm {2.4±0.4 kgm}
[*22]
3 Tube mounting bolt (61a):
10±2 Nm {1.0±0.2 kgm}
[*23]
3 Turbocharger lubricating oil inlet tube (62):
35±5 Nm {3.5±0.5 kgm}
[*24]
a Tighten exhaust manifold mounting bolts (64a) in
the order shown in the figure.
3 1st tightening: In the order of [1] to [12]:
24±4 Nm {2.4±0.4 kgm}
[*16] 3 2nd tightening: In the order of [1] to [12]:
3 Radiator upper hose mounting clamp: 53±5 Nm {5.4±0.5 kgm}
8.8±0.5 Nm {0.9±0.05 kgm} 3 3rd tightening: Only bolts [1] to [4] in the order
[*17][*18] of [1] to [4]:
3 Tube mounting clamp: 53±5 Nm {5.4±0.5 kgm}
7±1 Nm {0.7±0.1 kgm} [*25]
[*19] 3 Blowby duct mounting bolt (65a):
a Alternator top mounting bolt (59) tightens the alter- 7±2 Nm {0.7±0.2 kgm}
nator together with cover mounting plate (59a). [*26]
3 Alternator top mounting bolts (59): 3 Head cover mounting nut (66a):
77±12 Nm {7.8±1.2 kgm} 24±4 Nm {2.4±0.4 kgm}

[*27]
[*20]
a Alternator bottom mounting bolt (58) tightens the q When injector harness connector (76) is removed,
alternator together with cover mounting plate install it according to the following procedure.
(58a). 1) Apply liquid gasket to O-ring (76a) of injector
3 Alternator bottom mounting bolts (58): harness connector (76) and flange surface (n).
77±12 Nm {7.8±1.2 kgm} 2 O-ring (76a) and flange surface (n):
a Apply liquid gasket (LG-7) to the O-ring
until its groove is filled up completely (a
bead approximately 3 mm in diameter).
a If O-ring (76a) is damaged, replace the
injector harness assembly as a unit.
50-80 GD535-5
(02)
2) Install injector harness connector (76) to rocker

housing (82), and tighten bolt (76b) to secure it.
3 Injector harness connector mounting
bolt (76b):
10±2 Nm {1.0±0.2 kgm}
q Refilling with coolant

Refill the radiator with coolant to the specified
level through the water filler port. Run the engine
to circulate the coolant. Then check the coolant
level again.
a After the recheck, add coolant if the coolant
level is low.
5 Coolant:
21.1 ℓ

cuit".
GD535-5 50-81
(02)
Removal and installation of air conditioner compressor belt 50 Disassembly and assembly
Removal and installation of air 4. Loosen nuts (8), (9) and bolt (10). [*1]
conditioner compressor belt 1
5. Loosen bolt (11) and push in air conditioner
compressor assembly (13) in order to loosen the
Removal tensition of air conditioner compressor belt (12).
k Park the machine on flat ground, set the gear 6. Remove air conditioner compressor belt (12).
shift lever to the P position, and lower the work
OFF position.
Installation
order to removal.
[*1]
3 Nut (8):
98 to 123 Nm {10.0 to 12.5 kgm}
3 Nut (9):
245 to 309 Nm {25.0 to 31.5 kgm]
2. Open side covers (2) and (3) on the right side of the
engine.
3. Remove 3 bolts (4), and remove cover (5).
50-82 GD535-5
(02)
50 Disassembly and assembly Removal and installation of alternator belt

alternator belt 1
Removal
k Park the machine on flat ground, set the gear
OFF position.

2. Remove the air conditioner compressor belt.

For details, see "Removal and installation of air
conditioner compressor belt".
3. Open cover (2).
7. Apply a wrench (approximately 450 mm) to part (a)

(width across flats: 12.7 mm) of tensioner
assembly (10). Turn it in (b) direction to reduce the
tension of alternator belt (11).
k Check that the wrench is set on tensioner
assembly (10) at part (a) before turning it.
a Check that lock lever (3) is firmly locked in the (The spring of the tensioner assembly is
LOCK position. strong. If the wrench is loosely set, the
wrench can accidentally come off and this
is extremely dangerous.)
k After removing alternator belt (11), slowly
and carefully restore tensioner assembly
(10).
tween the pulley and alternator belt (11) dur-
ing work.
GD535-5 50-83
(02)
Removal and installation of alternator belt 50 Disassembly and assembly
8. Remove alternator belt (11).
Installation
removal.
50-84 GD535-5
(02)
50 Disassembly and assembly Removal and installation of engine front oil seal
Removal and installation of engine

front oil seal 1
Special tools
New/Redesign
Necessity
Sketch
Sym-
Q'ty
Part No. Part name
bol
Seal puller
3 795–931–1100
assembly ■ 1
A
4. Loosen nuts (1c), (1d), and bolt (1e). [*1]
4 795–799–6400 Seal driver ■ 1 5. Loosen bolt (1f) and push in air conditioner
compressor assembly (1h) in order to loosen the
Removal tensiton of air conditioner belt (1g).
k Park the machine on a flat ground, set the gear 6. Remove air conditioner compressor belt (1g).
OFF position.
7. Apply wrench [1] (approximately 450 mm) to part

(a) (width across flats: 12.7 mm) of tensioner
assembly (2). Turn wrench [1] in (b) direction to
decrease the tension of alternator belt (3).
k Be sure that wrench [1] securely is set to
part (a) of tensioner assembly (2), and turn
it. (The spring of the tensioner assembly is
strong. If wrench [1] is loosely set, it may ac-
cidentally come off. This can be extremely
dangerous.)
k After removing alternator belt (3), slowly and
carefully restore tensioner assembly (2).
2. Remove the engine, transmission, and torque
converter assembly. For details, see "Removal and
installation of engine, transmission, and torque tween the pulley and alternator belt (3) dur-
converter assembly". ing work.
a Place the engine, transmission, and torque 8. Remove alternator belt (3).
converter assembly on solid blocks.
3. Remove 3 bolts (1a), and remove cover (1b).
GD535-5 50-85
(02)
Removal and installation of engine front oil seal 50 Disassembly and assembly
3) Use tool A3 to apply impactive force (a) to front

oil seal (10) to remove it. (Apply impact evenly
so that front oil seal (10) is not tilted.)
9. Remove 6 bolts (6), and remove flange (7) and

damper (8). [*2]
Installation
q Use tool A4 to install front oil seal (10) to cover
(11).
a Check that end surface corners and front oil
seal rip sliding surfaces of the crankshaft, and
the front cover are free from scratch, burrs,
sharp edge, rust, etc.
a Clean, degrease, and dry the lip surface of the
front oil seal.
a Before installation of the front oil seal, clean,
degrease, and dry the seal contact face of the
crankshaft.
10. Remove pulley (9) with speed detection slits.
a The deflection of front oil seal (10) from front

cover (11) must meet the following criteria.
11. Remove front oil seal (10) according to the q Protrusion dimension (x) from front cover:
following procedure. Max. 0.38 mm
a Before removing front oil seal (10), drive in it q Facial runout (TIR) (y) of front oil seal: Max.
lightly to eliminate the stick. 0.25 mm
a Take care not to damage oil seal contact faces
of front cover (11) and crankshaft (12).
1) Drill several holes of approximately 3 mm in
diameter in front oil seal (10).
a Be sure to remove chips thoroughly.
2) Replace the tip tool of tool A3 with a drill type
one, and insert it into the drilled hole made in
above step.
50-86 GD535-5
(02)
50 Disassembly and assembly Removal and installation of engine front oil seal

order to removal.
[*1]
3 Nut (8):
98 to 123 Nm {10.0 to 12.5 kgm}
3 Nut (9):
245 to 309 Nm {25.0 to 31.5 kgm]
[*2]
k Attach the pulley with speed detection slits,
damper, and flange to crankshaft (12) while
aligning them with dowel pin (13), and tighten
mounting bolts according to the following pro-
cedure.
1) Tighten them diagonally to a torque of 55 ± 5

Nm {5.6 ± 0.5 kgm}
2) Tighten them 180 degrees.
3) Tighten them diagonally to a torque of 55 ± 5
Nm {5.6 ± 0.5 kgm}
4) (By using an angle tightening tool) Tighten
them 90 ± 5 degrees.
GD535-5 50-87
(02)
Removal and installation of engine rear oil seal 50 Disassembly and assembly

rear oil seal 1
Special tools
New/Redesign
Necessity
Sketch
Sym-
Q'ty
Part No. Part name
bol
Seal puller
3 795–931–1100
assembly ■ 1
A
4 795–799–6500 Seal driver ■ 1
6. Remove rear oil seal (7) according to the following
procedure.
a Before removing rear oil seal (7), drive in it
Removal
lightly to eliminate the stick.
a Be careful not to damage the rear oil seal con-
tact surfaces on flywheel housing (8) and
crankshaft (9).
1) Drill several holes of approximately 3 mm in
and then turn the battery disconnect switch to diameter in rear oil seal (7).
OFF position. a Be sure to remove chips thoroughly.
(When the battery disconnect switch is not 2) Replace the tip tool of tool A3 with a drill type
installed, disconnect the cable from the bat- one, and insert it into the drilled hole made in
tery negative (-) terminal.) above step.
1. Set lock pin (1) to the frame. 3) Use tool A3 to apply impactive force (a) to rear
oil seal (7) to remove it. (Apply impact evenly so
that rear oil seal (7) is not tilted.)

installation of engine, transmission, and torque
converter assembly".
a Place the engine, transmission, and torque
converter assembly on solid blocks.
3. Separate the engine, transmission, and torque
converter assembly. For details, see "Separation
and connection of engine, transmission, and
torque converter assembly".
a Place engine assembly (4) on a solid block [1].
4. Sling flywheel assembly (5) by using bolts.
5. Remove 8 bolts (6), set guide bolts, and raise
flywheel assembly (5) to remove it. [*1]
4 Flywheel assembly (5):
55 kg
50-88 GD535-5
(02)
50 Disassembly and assembly Removal and installation of engine rear oil seal
Installation
1. Do not remove pilot [3] attached to engine rear oil
seal (7) until it is installed to the crankshaft (9).
a When installing the seal, check that the seal

carrier is not bent.
a Check that end surface corners and seal rip

sliding surfaces of the crankshaft, and the front
cover are free from scratch, burrs, sharp edge,
rust, etc. before installing the engine rear oil
seal.
a Degrease, clean and dry the seal contact sur-
face of the crankshaft and the seal lip surface
to prevent oil leakage before installing the
engine rear oil seal.
a When installing the engine rear oil seal, do not
apply oil or grease to the crankshaft and seal
lip.
2. Install rear oil seal (7) with pilot [3] to crankshaft
(9), and press the seal carrier of rear oil seal (7) q Protrusion dimension (x) of rear oil seal (7)
into flywheel housing (8). from flywheel housing (8): Max. 0.38 mm
3. Remove pilot [3] and press in engine rear oil seal q Facial runout (TIR) (y) of rear oil seal: Max.
(7) further. 0.25 mm

order to removal.
[*1]
k Use offset wrench [4] to secure flywheel
assembly (5) to flywheel housing (8), and
tighten mounting bolts (6).
4. Use tool A5 to install engine rear oil seal (7) so that

it is flush with the end face of flywheel housing (8).
GD535-5 50-89
(02)
Removal and installation of engine rear oil seal 50 Disassembly and assembly
a Tighten flywheel assembly mounting bolts in the

order shown in the figure.
3 Flywheel mounting bolt (6):
137±7 Nm {14.0±0.7 kgm}
a Measure the radial runout and facial runout of the

flywheel according to the following procedure.
a Measurement of radial runout
1) Install dial gauge [5] to flywheel (5).
2) Apply the probe of dial gauge [5] perpendicular
to the spigot joint part (a) of flywheel housing
(8).
3) Set the pointer of dial gauge [5] to zero, rotate
the crankshaft 1 turn, and measure the differ-
ence between the lowest and the highest
values the pointer of dial gauge points.
a When the flywheel rotated 1 turn, check that the
pointer of dial gauge indicates the same value as
it of the starting rotation.
q Radial runout: Max. 0.13 mm
q Measurement of facial runout
1) Install dial gauge [5] to flywheel (5).
2) Apply the probe of dial gauge [5] perpendicular
to end face (b) at a point close to the outer
circumference of flywheel housing (8).
3) Set the pointer of dial gauge [5] to zero, rotate
the crankshaft 1 turn, and measure the differ-
ence between the lowest and the highest
values the pointer of dial gauge points.
a When measuring, move the crankshaft to either
front or rear end to eliminate error caused by the
end play.
a When the flywheel rotated 1 turn, check that the
pointer of dial gauge indicates the same value as
it of the starting rotation.
a Facial runout: Max. 0.20 mm
50-90 GD535-5
(02)
50 Disassembly and assembly Removal and installation of cooling fan pump assembly
Removal and installation of cooling 3. Disconnect the following hoses in order to secure
fan pump assembly 1
the space necessary for removing the cooling fan
pump assembly.
Removal 1) Disconnect hoses (5) and (6) used between the
k Park the machine on a level ground, and lower brake accumulators from charge valve.(4).
the work equipment to the ground with the gear [*1]
shift lever at P position. q Tape color of hose (5): White
k Stop the engine and set chocks under the tires. q Tape color of hose (6): Red
k Loosen the hydraulic tank cap to release the
pressure inside the hydraulic tank.
a Prepare an oil container since oil flows out when
the hydraulic hose and tube are disconnected.
a Plug the disconnected hose and tube to prevent oil
from flowing out.
1. Set lock pin (1) on the frame.
2) Remove clamp (7) and disconnect hose (8)

from charge valve (4).
3) Disconnect hose (9).
2. Open side covers (2) and (3) on the right side of the
engine.
4. Remove bolt (10).

5. Disconnect tube (11) from cooling fan pump (12).
GD535-5 50-91
(02)
Removal and installation of cooling fan pump assembly 50 Disassembly and assembly
6. Disconnect hose (13) from cooling fan pump (12). Installation

q Carry out installation in the reverse order to remov-
al.
[*1]
a Start the engine to pressurize the oil in the brake
accumulator.
q Refilling (hydraulic tank)

Refill hydraulic oil through the oil filler port to the
specified level. Let the oil circulate in the hydraulic
system by starting the engine. Then check the oil
level again.
7. Remove two mounting bolts (14) for cooling fan

pump and remove cooling fan pump assembly
(12).
a The assembly must be removed to prevent a
spanner from interfering with bolt (15) when re-
moving the bottom side mounting bolts for cool-
ing fan pump.
50-92 GD535-5
(02)
50 Disassembly and assembly Removal and installation of cooling fan and fan motor assembly
Removal and installation of cooling

fan and fan motor assembly 1
Removal
k Park the machine on a level ground, and lower
the work equipment to the ground with the gear
shift lever at P position.
k Stop the engine and set chocks under the tires.
OFF position.
(When the battery disconnect switch is not in-
stalled, disconnect the cable from the battery
3) Disconnect connector FL6 (5) on the right side
k Loosen the hydraulic tank cap to release the
of the machine.
pressure inside the hydraulic tank.
a Prepare an oil container since oil flows out when
the hydraulic hose and tube are disconnected.
a Plug the disconnected hose and tube to prevent oil
from flowing out.
1. Set lock pin (1) on the frame.
4) Remove 3 clamps (6).

5) Disconnect connectors RL1 (7) and CAM1 (8).

assembly".
3. Remove the radiator guard assembly according to
the following procedures.
1) Install the lifting tool to position (a) and hold
radiator grille while slinging.
2) Remove 4 bolts (3), then sling to remove radi- 6) Remove 4 bolts (8a), and remove cover (8b).
ator grille (4).
4 Radiator grille (4):
23 kg
GD535-5 50-93
(02)
Removal and installation of cooling fan and fan motor assembly 50 Disassembly and assembly
7) Remove 2 clamps (8c). 10)Lift off radiator guard assembly (10).

4 Radiator guard and assembly:
80 kg
4. Remove 5 clamps (11) and remove cover (12).
8) Remove clip (8d), and disconnect hose (8e).
9) Remove 3 radiator guard mounting bolts (9)

being provided on each side.
5. Disconnect three hoses (13), (14) and (15).
50-94 GD535-5
(02)
50 Disassembly and assembly Removal and installation of cooling fan and fan motor assembly
6. Remove clamp (16). 11. Remove bolt (23) to remove lock plate (24).
7. Disconnect three connectors RT6 (17), RT7 (18) [*1]
and RT8 (19). 12. Remove nut (25).
[*2]
8. Remove seven mounting bolts of fan guard (20).

13. Using puller [1], pull out cooling fan (26).
[*3]
9. Sling cooling fan and fan motor assembly (21).

10. Remove four mounting bolts of mounting bracket
(22) and lift off cooling fan and fan motor pump 14. Remove fan guard (20) from mounting bracket
assembly (21). (22).
4 Cooling fan and fan motor assembly: (In- [*4]
cluding fan guard): a Put a mark on the fan guard installation posi-
35 kg tion.
GD535-5 50-95
(02)
Removal and installation of cooling fan and fan motor assembly 50 Disassembly and assembly
15. Remove the clamp and disconnect three connec- Installation

tors RT6 (27), RT7 (28) and RT8 (29). q Carry out installation in the reverse order to
a Above three connectors are the female side removal.
ones being disconnected in step 7.
[*1] [*2]
3 Nut (25):
132 to 157 Nm {13.5 to 16 kgm}
a Tighten nut (25) to 142 Nm, and at the nearest po-
sition in the nut retightening direction, align the pin
hole with the nut on both the front and back sides
of lock plate (24). Then retighten the nut, align the
lock plate bolt hole position and tighten bolt (23).
2 Bolt (23):
Adhesive (LT-2)
3 Bolt (23):
59 to 74 Nm {6 to 7.5 kgm}
16. Remove four mounting bolts (30) of cooling fan
motor from mounting bracket (22).
[*3]
a Make sure that key (33) is firmly set in the shaft key
17. Remove cooling fan motor assembly (32) from the groove of cooling fan motor (32).
mounting bracket. a Install the cooling fan aligning it to key (33).
4 Cooling fan motor assembly:
17 kg
[*4]
a When installing the fan guard, align it to the mark
being put when it was removed.
50-96 GD535-5
(02)
50 Disassembly and assembly Removal and installation of radiator assembly
Removal and installation of radiator 2) Remove 4 bolts (3), then sling to remove radi-
assembly ator grille (4).
1
k Park the machine on flat ground, set the gear 23 kg

OFF position.
k To prevent burn injuries when the coolant tem-
perature is high, wait until the coolant temper-
ature lowers to an appropriate level and then
drain the coolant.
k Loosen the radiator cap gradually to release
the pressure inside the radiator.
Removal
3) Disconnect connector FL6 (5) on the right side

of the machine.
2. Drain the coolant through coolant drain valve (2).

6 Coolant:
21.1 ℓ


assembly".
GD535-5 50-97
(02)
Removal and installation of radiator assembly 50 Disassembly and assembly
6) Remove 4 bolts (8a), and remove cover (8b). 9) Remove 3 radiator guard mounting bolts (9)
7) Remove 2 clamps (8c).

10)Lift off radiator guard assembly (10).
80 kg
5. Remove 5 clamps (11).
50-98 GD535-5
(02)
50 Disassembly and assembly Removal and installation of radiator assembly
6. Remove 4 bolts (12), and move air conditioner 10. Remove clamp (20), and disconnect upper hose
condenser assembly (13) so that it does not hinder (21). [*1]
the work activities. 11. Remove 2 bolts (22), and disconnect bracket (23).
12. Remove clip (24), and disconnect tube (25).
7. Remove 4 bolts (14), and remove bracket (15).

13. Remove clamp (26), and disconnect lower hose
(27). [*2]
14. Disconnect hose (28).
8. Remove 4 bolts (16), and move fuel cooler

assembly (17) so that it does not hinder the work
activities.
15. Remove 2 bolts (29).
16. Remove 2 mounting bolts (31) of plate (30).
GD535-5 50-99
(02)
Removal and installation of radiator assembly 50 Disassembly and assembly
17. Remove plate (30), and remove plate and cushion 21. Sling radiator assembly (36) by using a sling.
(32) from inside. 22. Raise radiator assembly (36) to remove it.
4 Radiator assembly (36):
22 kg
23. Remove bolts (37) (2 pieces) from radiator (36),

and remove plate (38).
Installation
removal.
[*1]
3 Clamp (20):
8.8±0.5 Nm{90±5 kgcm}
[*2]
3 Clamp (26):
10.5±0.5 Nm{107±5 kgcm}
20. Remove 2 bolts (35). q Refilling with coolant
level again.
a After completing the recheck, add engine cool-
ant if the coolant level is low.
5 Coolant:
21.1 ℓ
50-100 GD535-5
(02)
50 Disassembly and assembly Removal and installation of aftercooler assembly

aftercooler assembly 1

OFF position.
tery negative (-) terminal.) 3) Disconnect connector FL6 (5) on the right side
Removal of the machine.
assembly".


2) Remove 4 bolts (3), then sling to remove radi-
ator grille (4).
23 kg
6) Remove 4 bolts (8a), and remove cover (8b).
GD535-5 50-101
(02)
Removal and installation of aftercooler assembly 50 Disassembly and assembly
7) Remove 2 clamps (8c). 10)Lift off radiator guard assembly (10).

80 kg
9) Remove 3 radiator guard mounting bolts (9)

5. Remove 4 bolts (12), and move air conditioner
condenser assembly (13) so that it does not hinder
the work activities.
50-102 GD535-5
(02)
50 Disassembly and assembly Removal and installation of aftercooler assembly
6. Remove 4 bolts (14), and remove bracket (15). 10. Remove 2 clamps (22), and disconnect lower hose
(23). [*2]
7. Remove 4 bolts (16), and move fuel cooler

assembly (17) so that it does not hinder the work 11. Sling aftercooler assembly (24) by using a sling.
activities. 12. Remove 2 bolts (25), and raise aftercooler
assembly (24) to remove it. [*3]
4 Aftercooler assembly:
15 kg
9. Remove 2 clamps (20), and disconnect upper hose

(21). [*1]
GD535-5 50-103
(02)
Removal and installation of aftercooler assembly 50 Disassembly and assembly
Installation
removal.
[*1]
q Install the two clamps with their threaded parts
180 degrees apart from each other.
3 Upper hose mounting clamp:
10.5±0.5 Nm{1.1±0.05 kgm}
[*2]
q Install the two clamps with their threaded parts
180 degrees apart from each other.
3 Lower hose mounting clamp:
10.5±0.5 Nm{1.1±0.05 kgm}
[*3]
a Sling the aftercooler and check that convex parts
(a) on the mounting face of the aftercooler can fit
into concave parts (b) of the frame.
50-104 GD535-5
(02)
50 Disassembly and assembly Removal and installation of power train oil cooler assembly
Removal and installation of power

train oil cooler assembly 1

OFF position.
3) Disconnect FL6 (5) on the right side of chassis.
Removal
assembly".

5) Disconnect connectors RL1 (17) and CAM1
(18).

radiator grille (4) while slinging.
2) Remove 4 bolts (3), then sling to remove radi-
ator grille (4).
23 kg
6) Remove 4 bolts (8a), and remove cover (8b).
GD535-5 50-105
(02)
Removal and installation of power train oil cooler assembly 50 Disassembly and assembly
7) Remove 2 clamps (8c). 10)Sling radiator guard assembly (10).

4 Radiator guard assembly:
80 kg
4. Remove 2 bolts (11), and disconnect bracket (12).

6. Remove 2 bolts (15), and remove flange (16).
9) Remove radiator guard mounting bolts (9) (3

pieces on RH and LH).
7. Remove 2 bolts (17) , and diconnect bracket (18).
50-106 GD535-5
(02)
50 Disassembly and assembly Removal and installation of power train oil cooler assembly
8. Remove 2 bolts (19) and disconnect flange (20). Installation

removal.
[*1]
a Insert the power train oil cooler and screw in bolts
(22) in bolt holes (a).
q Refilling (transmission case)

Refill it with genuine Komatsu oil to the specified
level through the oil filler port. Run the engine to
circulate the oil through the piping. Then check the
oil level again.
a After completing the recheck, add genuine
Komatsu oil if the oil level is low.
45 ℓ
11. Raise power train oil cooler assembly (23) to
remove it. [*1]
GD535-5 50-107
(02)
Removal and installation of fuel tank assembly 50 Disassembly and assembly
Removal and installation of fuel

tank assembly 1

OFF position.
ing. If any dirt or dust has adhered to parts of
the fuel system, clean it off thoroughly using
clean fuel.
Removal
1. Support the rear of the machine by using stands [1]
(target: approximately 600 mm high) .
a The aim of this task is to provide enough space
to pull out the fuel tank being lowered under
the machine.
a Height dimension (a) of fuel tank: 460 mm
a Height dimension (b) of fuel tank: 700 mm
a Ground clearance dimension (c) of fuel tank
bottom: 380 mm 3. Open engine hood (2). (Each side of the machine)
a Check that lock lever (2a) is firmly locked in the
LOCK position.
50-108 GD535-5
(02)
50 Disassembly and assembly Removal and installation of fuel tank assembly
5. Open drain valve (4) at the rear left of the machine

to drain the fuel.
6 Fuel tank:
271 l (when the tank is full)
(4).
9. Remove 3 clamps (7a).
6. Install the lifting tool to position (a) and hold radi-

ator grille (5) while slinging.
7. Remove 4 bolts (5a), then sling to remove radiator
grille (5).
23 kg
GD535-5 50-109
(02)
Removal and installation of fuel tank assembly 50 Disassembly and assembly
10. Remove 2 bolts (7b) and move hose (7) aside so 14. Remove 2 clamps (11).
that it does not hinder work activities. 15. Remove clamp (12), and disconnect connector
ET39 (13).
11. Remove clip (8a), and disconnect breather hose

(8). 16. Remove 2 bolts (14), and remove cover (15) .
12. Remove clamp (9). 17. Remove 3 clamps (16).
13. Remove 4 clamps (10). 18. Remove clamps (17) (3 pieces).

20. Disconnect hoses (20) and (21),
a Fit plugs to 2 disconnected hoses (20) and (21)
and the mounting positions to prevent oil leak-
age and dust entry.
50-110 GD535-5
(02)
50 Disassembly and assembly Removal and installation of fuel tank assembly
Installation
removal.
[*1]
3 Bolt (23): 785 to 980 Nm {80 to 100 kgm}
3 Bolt (25): 785 to 980 Nm {80 to 100 kgm}
q Refilling (fuel tank)

Refill the fuel tank with fuel to the specified level
through the fuel filler port. Start the engine to cir-
culate the fuel through the piping, and check the
21. Pull hose (22) out of part (e). fuel level again.
a After completing the recheck, add fuel if the
fuel level is low.
5 Fuel tank : 271 l

cuit".
22. Use a jack to support fuel tank assembly (24).

23. Remove bolt (23) and bolt (25) (one each on either
side). [*1]
24. Operate the jack to lower fuel tank assembly (24),
and then pull out it toward you.
4 Fuel tank assembly (24): 160 kg
GD535-5 50-111
(02)
Removal and installation of engine hood assembly 50 Disassembly and assembly
Removal and installation of engine 3. Remove 3 bolts (4), and remove cover (5).
hood assembly 1

OFF position.
Removal
4. Sling cover (2) by using a sling.
5. Remove 4 bolts (6), and raise cover (2) to remove
it.
4 Cover (2): 22 kg
2. Open cover (2).

a Check that lock lever (3) is firmly locked in the 6. Remove clamp (7), and disconnect hose (8). [*1]
LOCK position.
7. Disconnect hose (8a).
50-112 GD535-5
(02)
50 Disassembly and assembly Removal and installation of engine hood assembly
8. Remove bolts (9) (2 pieces), and remove cover 12. Remove bolt (15). (Each side)
(10).
13. Raise engine hood assembly (16) to remove it. [*2]

9. Remove clamp (11), and disconnect hose (12). 4 Engine hood assembly (16):
85 kg
10. Remove bolt (13). (Each side)

Installation
removal.
[*1]
3 Clamp (7):
8.8±0.5 Nm{90±5 kgcm}
[*2]
a Install the engine hood assembly while aligning
the exhaust pipe with the muffler.
11. Remove cap (14). (Each side)
GD535-5 50-113
(02)
Removal and installation of air conditioner compressor assembly 50 Disassembly and assembly
Removal and installation of air

conditioner compressor assembly 1
Removal
k Place the machine on a level surface, and set
the lock bar to frames to lock front and rear
frames.
k Lower the work equipment to the ground
completely and stop the engine. Apply the
parking brake and put the blocks under the
wheels.
k Check that the system operating lamp is off, 4. Remove 3 mounting bolts (4), and remove cover
and then turn the battery disconnect switch to (5).
OFF position.
installed, disconnect the cable from the battery
k Before disconnecting air conditioner hoses,
collect the refrigerant (air conditioner gas:
R134a) from the air conditioner circuit.
a Never release the refrigerant (air conditioner gas:
R134a) to the atmosphere.
a Ask a qualified person for collecting, adding and
filling operations of the refrigerant (air conditioner
gas: R134a). (Only registered persons can work.)
k If refrigerant (air conditioner gas: R134a) gets
5. Loosen nuts (8), (9) and bolts (10). [*2]
in your eyes, you may lose your sight. And if it
6. Loosen bolts (11) and push in air conditioner
touches your skin, you may suffer from
compressor assembly (13) in order to loosen the
frostbite. Put on the protective eyeglasses,
tension of air conditioner compressor belt (12).
gloves and working suits with long sleeves
during collecting or filling operation. 7. Remove air conditioner compressor belt (12).
1. Collect the refrigerant (air conditioner gas: R134a)

from the air conditioner circuit. [*1]
q Collection amount: 1150 ± 50g
2. Set lock pin (1) to frame.
8. Remove 2 clamps (14), and disconnect air

conditioner hoses (15) and (16). [*3]
3. Open engine side covers (2) and (3) on the right

side of engine.
50-114 GD535-5
(02)
50 Disassembly and assembly Removal and installation of air conditioner compressor assembly
9. Remove nut (8), bolt (10), and remove air Installation

conditioner compressor assembly (13). q Perform installation in the reverse order to
removal.
[*1]
a Charging with refrigerant (air conditioner gas:
R134a)
Refill the air conditioner circuit with refrigerant (air
conditioner gas: R134a).
Refill amount: 1150 ± 50 g
a Refilling with air conditioner compressor oil

See Air conditioner, "Filling of compressor oil".
10. Remove bolts (17) (7 pieces), and remove air [*2]

conditioner compressor assembly (13) from 3 Nut (8):
brackets (18) and (19). 98 to 123 Nm {10.0 to 12.5 kgm}
3 Nut (9):
245 to 309 Nm {25.0 to 31.5 kgm]
[*3]
a When installing the hose for the air conditioner
circuit, be careful not to let dirt, dusts and water
going into the hose.
a Check that the O-rings are fitted to the joints when
connecting the air conditioner piping.
a Once an O-ring is used, it is deformed and
deteriorated. Accordingly, do not reuse it.
a Apply compressor oil (DENSO: ND-OIL8) for
refrigerant (R134a) to O-ring.
3 Air conditioner hoses (3) and (4):
20 to 25 Nm {2.0 to 3.0 kgm}
GD535-5 50-115
(02)
Removal and installation of engine, transmission, and torque converter assembly 50 Disassembly and assembly
Power train 1
Removal and installation of engine,

transmission, and torque converter
assembly 1
Removal
and then turn the battery disconnect switch to 3. Collect the refrigerant (air conditioner gas: R134a)
OFF position. from the air conditioner circuit. [*1]
(When the battery disconnect switch is not a Never release the refrigerant (air conditioner
installed, disconnect the cable from the bat- gas: R134a) to the atmosphere.
tery negative (-) terminal.) a Ask a qualified person for collecting, adding
k Loosen the cap of the hydraulic tank gradually
and filling operations of the refrigerant (air con-
to release the pressure remaining inside the ditioner gas: R134a). (Only registered persons
hydraulic tank.
k When coolant temperature is high, to prevent
can work.)
k If refrigerant (air conditioner gas: R134a)
burn injures, wait until the temperature lowers gets in your eyes, you may lose your sight.
sufficiently and then drain the coolant.
k Loosen the radiator cap gradually to release
And if it touches your skin, you may suffer
from frostbite. Put on the protective eye-
the pressure inside the radiator. glasses, gloves and working suits with long
a Check the connector numbers and installed posi- sleeves during collecting or filling opera-
tions before disconnecting wiring and hoses, and tion.
write them down. q Collection amount: 1150 ± 50g
a Prepare an oil container to receive oil flowing out 4. Remove the engine hood assembly. For details,
when hydraulic hoses and tubes are discon- see "Removal and installation of engine hood
nected. assembly".
a Plug the disconnected hoses and tubes to prevent 5. Remove 8 bolts (4), and raise muffler assembly (6)
oil from flowing out. and bracket (5) as a unit to remove it.
2. Drain the coolant through coolant drain valve (2).

6 Coolant: 21.1 ℓ
50-116 GD535-5
(02)
50 Disassembly and assembly Removal and installation of engine, transmission, and torque converter assembly
9. Remove clamps (12a) (2 pieces), and remove

tubes (12b) and (12c). [*2]
6. Remove bolt (7), and remove bracket (8).

11. Loosen drain valve (15) and drain the hydraulic oil.
7. Remove 4 bolts (9), and remove bracket (10). 6 Hydraulic oil: 51.5 ℓ
(15).
12. Remove the hydraulic tank, battery, and frame

assembly. For details, see "Removal and installa-
tion of hydraulic tank, battery, and frame
assembly".
13. Remove 2 clamps (16), and disconnect hose (17).
GD535-5 50-117
(02)

18. Disconnect connector R11 (23).
14. Disconnect hose (18) from the charge valve.
19. Remove 3 bolts (24), and move charge valve (25)

out of the way so that it does not hinder work activ-
ities.
15. Remove joint bolt (19), and disconnect fuel supply

hose (20) from the supply pump. [*3]

21. Remove 2 bolts (27), and move hose (28) out of
the way so that it does not hinder work activities.
16. Disconnect hose (21) from the steering pump.
22. Remove clamp (31), and disconnect hose (33)

from tube (32). [*4]
23. Remove 2 clamps (34), and disconnect hose (36)
from tube (35). [*5]
24. Remove 2 bolts (37a), and remove hose (33), tube
(35), and bracket (37) as a unit.
50-118 GD535-5
(02)
26. Remove clamp (40), and disconnect radiator lower

hose (41). [*7]
27. Remove bolts, and disconnect connectors T20

(42), T21 (43), and T22 (44).

29. Remove clamp (44b).
30. Disconnect connector R23 (44c).
25. Remove clamp (38), and disconnect radiator upper

hose (39). [*6]
31. Remove bolts (45), and disconnect ground cable

(46).
GD535-5 50-119
(02)
32. Remove 2 bolts (46a), and remove cover (46b). 37. Remove clamp (54a).
38. Remove hoses (54b) and (54c).
33. Remove clamp (47).

34. Remove bolt (47a), and disconnect ground cable 39. Disconnect hoses (55a), (55b), and (55c) from the
(47b). priority valve.
q Hose (55a): Port LS
q Hose (55b): Port EF
q Hose (55c): Port CF
35. Remove 2 bolts (50), and remove connector cover

(51).
40. Remove clamps (56).

41. Remove 4 bolts (57), and disconnect hose (58).
36. Remove clamp, and disconnect connectors ER02

(52), ER3 (53), and ER1 (54).
50-120 GD535-5
(02)
42. Loosen sleeve nut (59), and disconnect hose (60). 48. Remove clamp (65d) (2 pieces).
43. Remove 4 bolts (61), and disconnect hose (62). 49. Remove clip (65e), and disconnect hose (65f).
44. Remove 2 bolts (63), and disconnect hose (63a). 50. Remove 4 bolts (66) and 4 bolts (67), and remove
45. Loosen sleeve nut (64), and disconnect power universal joint (68) between the transmission and
train oil cooler lower hose (65) from the bottom of final drive. [*8]
the transmission.
51. Remove mounting bolt (69) on the engine side. (1

46. Remove clamps (65a) (2 pieces). bolt each on right and left sides) [*9]
47. Remove clip (65b), and disonnect hose (65c). 52. Remove mounting bolts (70) on the transmission
side. (2 bolts each on right and left sides) [*10]
GD535-5 50-121
(02)
a Take care not to lose nut (71) under the bolt. Installation
removal.
[*1]
a Charging with refrigerant (air conditioner gas:
R134a)
Refill the air conditioner circuit with refrigerant (air
Refill amount: 1150 ± 50 g
a Refilling with air conditioner compressor oil

See Air conditioner, "Filling of compressor oil".
53. Attach slings to lifting points (a), and raise the [*2]
engine, transmission, and torque converter a When installing the hose for the air conditioner
assembly (72) to remove it. circuit, be careful not to let dirt, dusts and water
a Check that there are no pipes and wiring har- going into the hose.
nesses left being connected when disconnect- a Check that the O-rings are fitted to the joints when
ing them. connecting the air conditioner piping.
4 Engine, transmission, and torque converter deteriorated. Accordingly, do not reuse it.
assembly (72): 1660 kg a Apply compressor oil (DENSO: ND-OIL8) for
3 Air conditioner hoses (12b) and (12c):
20 to 25 Nm {2.0 to 3.0 kgm}
[*3]
3 Joint bolt (22) of fuel supply hose :
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
[*4], [*5]
3 Tube mounting clamp:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*6]
3 Radiator upper hose mounting clamp (38):
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*7]
3 Radiator lower hose mounting clamp (40):
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*8]
2 Mounting bolts (66) and (67) of universal joint:
Adhesive (LT-2)
3 Mounting bolts (66) and (67) of universal joint:
98 to 123 Nm {10 to 12.5 kgm}
[*9]
2 Mounting bolt (69) on engine side: Adhesive
(LT-2)
3 Mounting bolt (69) on engine side:
610 to 765 Nm {62.5 to 78.0 kgm}
[*10]
2 Mounting bolt (70) on transmission side:
Adhesive (LT-2)
3 Mounting bolt (70) on transmission side:
610 to 765 Nm {62.5 to 78.0 kgm}
50-122 GD535-5
(02)
q Refilling with coolant

level again.
5 Coolant:
21.1 ℓ
a After the recheck, add engine coolant if the
coolant level is low.
q Refilling with oil (hydraulic tank)

Refill the hydraulic tank with Komatsu genuine oil
to the specified level through the oil filler port. Start
the engine to circulate the oil through the piping,
and check the oil level again.
5 Hydraulic oil:
51.5 ℓ
a After the recheck, add hydraulic oil if the oil
level is low.
GD535-5 50-123
(02)
Disconnection and connection of engine, transmission, and torque converter assembly 50 Disassembly and assembly
Disconnection and connection of 6. Sling engine assembly (5).

engine, transmission, and torque
converter assembly 1
Disconnection
installation of engine, transmission, and torque
4 Engine, transmission, and torque converter
assembly: 1660 kg
2. Place engine, transmission, and torque converter
assembly (1) on solid blocks [1].
7. Remove 12 mounting bolts (7) used to mount
engine assembly (5) to transmission and torque
converter assembly (6). [*2]
3. Disconnect power train oil cooler hose (2) from the

transmission.
8. By using forcing screws [2] on each side, separate

engine assembly (5) from transmission and torque
converter assembly (6). [*3]
4. Disconnect hose (3) from the flywheel housing,

and drain oil.
a Prepare an oil container.
5. Remove elbow (4). [*1]
a This step is necessary to place a block there
after separation.
50-124 GD535-5
(02)
50 Disassembly and assembly Disconnection and connection of engine, transmission, and torque converter assembly
9. Sling engine assembly (5) to remove it from trans- Connection

mission and torque converter assembly (6). q Perform connection in the reverse order of sepa-
4 Engine assembly (5): 585 kg ration.
4 Transmission, and torque converter
assembly (6): 1075 kg [*1]
2 Elbow (4): Adhesive (LT-2)
3 Elbow (4): 45±4 Nm {4.6±0.4 kgm}
[*2]
2 Mounting bolt (7): Adhesive (LT-2)
3 Mounting bolt (7): 54 to 74 Nm {6 to 7.5 kgm]
[*3]
a Before connecting engine assembly (5) to trans-
mission and torque converter assembly (6), check
that O-ring (8) is fitted to the mating face on the
transmission side.
a Take care not to twist O-ring (8) when connecting
the assemblies.
GD535-5 50-125
(02)
Disassembly and assembly of torque converter assembly 50 Disassembly and assembly
Disassembly and assembly of

torque converter assembly 1
Special tools
New/Redesign
Necessity
Sketch
Q'ty
Symbol Part No. Part name
Unit repair stand

790-501-5000 q 1
(AC100 V)
Unit repair stand
790-501-5200
(AC110 V, 220 V)
q 1
2. Torque converter lockup housing
1
790-901-2110 Bracket q 1 1) Remove bolt (4).
794T-613- 2) Sling housing and case assembly (5) by using eye
Plate q 1 ○ bolts [1], and remove it from pump assembly (6).
1210
4 Housing and case assembly (5):
793-310-2141 Plate q 1
70.5 kg
2 793-647-1110 Wrench t 1
3 794-613-1110 Guide t 1
4 794-613-1120 Guide t 1
5 790-201-3230 Bolt ● 2
C
790-101-2501 Push puller ■ 1
790-101-2510 q Block 1
790-101-2520 q Screw 1
791-112-1180 q Nut 1
790-101-2540 q Washer 1
6
790-101-2630 q Leg 2
790-101-2570 q Washer 4
790-101-2560 q Nut 2
790-101-2660 q Adapter 2 3) Remove snap ring (7), and remove spacer (8).
790-201-2640 Plate ■ 1
7 790-101-5221 Grip ● 1
8 790-201-2750 Spacer ■ 1
Disassembly
1. Pilot
1) Set torque converter assembly (1) on work
bench C1 with its pilot side up.
2) Remove mounting bolt (2), and remove pilot (3)
by using forcing screws.
50-126 GD535-5
(02)
50 Disassembly and assembly Disassembly and assembly of torque converter assembly
4) Support housing and case assembly (5) by 8) Remove bearing (15) from housing (14).
using blocks [2].
5) Using tool C6, remove turbine assembly (10).
9) Remove piston (16) from housing (14).
6) Remove spacer (11) and split collar (12).
10)Remove seal ring (18) from piston (16).

7) Remove bolts (13), and remove the torque
converter lockup housing (14) by using forcing
screws C5.
GD535-5 50-127
(02)
11)Remove seal ring (17) from housing (14).
5. Stator assembly
3. Drive case 1) Remove stator assembly (34).
a Pull it up while rotating it clockwise when
1) Remove disc (20) from the top of drive case
viewed from above.
(19).
4. Turbine assembly and damper assembly 2) Disassembly of stator assembly

1) Remove bolts (21), and remove damper (22). 1] Remove snap ring (35), and remove race
2) Remove bolts (23), and remove turbine (24). and free wheel assembly (36) from stator
(37).
3) Remove bolts (25), washers (26), and nuts

(27), and disassemble the damper assembly
into 2 plates (28), hub (29), drum (30), outer
springs (31), 6 inner springs (32), and 3 inner
springs (33).
50-128 GD535-5
(02)
2] Remove snap ring (38) from stator (37). 2) Remove spacer (44).
3] Remove bushings (39), and remove free
wheel (40) and balls (41) from race (42).
Be careful not to lose ball (41).
3) Use blocks [3] to support gear (46) of pump and

stator shaft assembly (45), and remove stator
6. Stator shaft shaft (47) by using tool C7.
1) Remove nut (43) by using tool C2.
4) Remove seal ring (48) from stator shaft (47).

5) Remove inner race (49) from stator shaft (47).
a Take care not to damage the shaft when
removing the inner race.
GD535-5 50-129
(02)
7. Pump assembly Assembly

1) Remove mounting bolts (50), and press a Clean all parts ,and check them for dirt or damage
bearing (51) from the opposite side to remove before installation.
pump (53) along with gear (46) and collar (52). a Check that a snap ring is securely fitted into
groove.
a Apply approximately 6 cc of power train oil TO10
or TO30 to an assembled bearing and turn it 10
times.
1. Pump assembly
1) Install collar (52) to gear (46).
a Be sure to match bolt holes with each other.
a Leave the forcing tap displaced.
2) Install bearing (51) to collar (52).
a Check that the stamping mark is
"QJ215EX1C3". Take care not to incor-
rectly install the turbine bearing with stamp-
ing mark "06340-06214".
2) Using forcing screws C5, remove gear (46)

from collar (52).
3) Set gear (46) and bearing (51) on pump (53),

and tighten mounting bolts (50).
2 Mounting bolt:
3) Remove bearing (51) from collar (52).
Adhesive (LT-2)
3 Mounting bolt:
66.15 ± 7.35 Nm {6.75 ± 0.75 kgm}
50-130 GD535-5
(02)
a When assembling it, check that the assembling 6) Install nut (43) by using tool C2.
accuracy shown in the figure is satisfied. 2 Threaded part of stator shaft:
Adhesive (LT-2)
a Be sure to apply the adhesive (LT-2) to the
male threaded part of the stator shaft.
3 Nut:
161.8 ± 14.7 Nm {16.5 ± 1.5 kgm}
2. Stator shaft
1) Install the inner race to stator shaft (47).
2) Install seal ring (48) to stator shaft (47).
2 Outer circumference of seal ring:
Grease (G0-LI or G2-LI)
3) Set stator shaft (47) on a work bench, and

install it to pump assembly (53).
4) Install inner race (54).
5) Install spacer (44).
GD535-5 50-131
(02)
3. Stator assembly 3] Install race and free wheel assembly (36) to

1) Assembly of stator assembly stator (37), and then install snap ring (35).
1] Install free wheel (40) to race (42), and a Be sure to install free wheel "711-61-
install bushings (39) and balls (41) via 12160" so that the cage end face with
expansion fit. the arrow indicated on it faces the input
a Check in advance which end face of the side, and check that the stator "23H-13-
cage of the free wheel has an arrow 15900" rotates correctly when viewed
marked on. from the input side.
2 Sliding surface:
q Clockwise: Slips.
q Counterclockwise: Locks.
power train oil (TO10 or TO30)
a Take care not to damage the sprag of
the free wheel.
2) Install stator assembly (34) while rotating it to

the right (clockwise).
a Check the behavior of the stator by rotation
direction when viewed from the turbine
2] Install snap rings (38) to stator (37).
(input) side.
q Clockwise: Slips.
q Counterclockwise: Locks.
a If the stator rotation direction differs from
that shown above, install the race and free
wheel assembly in the opposite direction
and check the behavior of the stator again.
a Be careful about the installed direction of

stator "23H-13-12110".
Referring to the figure, install it with larger
shell outside diameter side facing turbine
"711-50-51520".
A: Stator, B: Turbine side
50-132 GD535-5
(02)
a Inner spring (33): With identification paint

(white)
4. Turbine assembly and damper assembly

1) Set nut (27) (width across flats: 17 mm) and
washer (26) in order at 3 locations of tool C3. 5) Set spring assembly (53) and spring assembly
2) Set plate (28) and hub (29). (54).
a Set 3 spring assemblies (54) at intervals of
120 degrees, and set spring assemblies
(52) between them.
3) Set drum (30).
6) Set tool C4 with its level face up.

7) Set plate (28).
8) Loosely tighten 3 bolts M10 (25) with washer
(26).
4) Install inner spring (32) and inner spring (33) to

outer spring (31) to make spring assemblies
(54) and (55) respectively.
a Identify inner spring (32) and inner spring
(33) depending on whether the end coil has
identification paint.
a Inner spring (32): Without identification
paint
GD535-5 50-133
(02)
9) Remove tools C3 and C4 from the damper 12)Install turbine (24) to hub (56) by using bolts
assembly. (23).
10)Tighten all of 9 bolts M10 (25) with washer (26) 2 Mounting bolt: Adhesive (LT-2)
and nuts (27) to the specified torque. 3 Mounting bolt:
2 Bolt (25): Adhesive (LT-2) 58.8 to 73.5 Nm {6 to 7.5 kgm}
3 Bolt (25): 13)Install damper (22) to hub (56) by using bolt
58.8 to 73.5 Nm {6.0 to 7.5 kgm} (21).
2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
98 to 123 Nm {10 to 12.5 kgm}
11)Check that the clearance (a) between the

spring and plate is 0.6 mm or more above the
clearance confirmation range (b) on both inner
and outer circumference sides by sliding a 5. Turbine and case
feeler gauge from side to side at the 9 windows Place turbine assembly (10) on block [6], and set
(55) where respective damper springs are drive case (19) to turbine assembly (10).
supported.
6. Disc
Install disc (20).
2 Sliding surface:
Power train oil (TO10 or TO30)
50-134 GD535-5
(02)
2) Using eyebolts [2], sling housing assembly (14)

and set it to drive case (19).
4 Housing assembly (14): 30 kg
3) Tighten mounting bolts (13).
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
27 to 34 Nm {2.8 to 3.5 kgm}
4) Install split collar (12) and spacer (11).
7. Complete housing assembly

1) Assembly of complete housing
1] Install seal rings (17) to housing (14).
2] Install seal ring (18) to piston (16), and
insert the piston into housing (14).
a Seal rings (17) and (18) has a installation
direction. Install them as shown in the fig-
ure.
8. Bearing
Grease (G0-LI or G2-LI) 1) Press-fit bearing (15) until it touches turbine
assembly (10) by using push tool [8].
q A gap is provided at part (a).
a Take care not to incorrectly install the pump
bearing "711-47-51160".
a Press-fit the outer race and inner race at a
time.
GD535-5 50-135
(02)
2) Remove block [6], and press-fit bearing (15) 10. Housing and case assembly
until it touches complete housing assembly (14) 1) Sling housing and case assembly (5) by using
again. eyebolts [1], and install it to pump assembly (6).
4 Housing and case assembly (5):
70.5 kg
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
53.9 ± 4.9 Nm {5.5 ± 0.5 kgm}
a When assembling it, check that the assembling

accuracy shown in the figure is satisfied.
11. Pilot
Install pilot (3) to torque converter assembly (1),
and then tighten mounting bolts (2)
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
66.15 ± 7.35 Nm {6.75 ± 0.75 kgm}
9. Plate and snap ring

Install spacer (8), and install snap ring (7).
a Check that a snap ring is securely fitted into
groove.
50-136 GD535-5
(02)
50 Disassembly and assembly Disassembly and assembly of transmission assembly
New/Redesign
Necessity
transmission assembly
Sketch
1
Sym-
Q'ty
Part No. Part name
bol
Special tools
New/Redesign
16 794T-615-1110 Push tool t 1 Q
Necessity
Sketch
Sym- 17 790-201-3130 Guide bolt t 1
Q'ty
Part No. Part name
bol Q
18 793T-613-1370 Spacer t 1
19 794T-615-1210 Spacer t 1 Q
794T-615-1500 Lifting tool t 1 Q 20 796T-667-1120 Push tool t 1 Q
794T-615-1510 q Cap t 1 Q 21 790-201-2740 Spacer t 1
794T-615-1520 q Pin t 1 Q 22 793T-613-1380 Spacer t 1 Q
794T-615-1530 q Plate t 1 Q 23 792T-423-1110 Push tool t 1 Q
1 794T-615-1540 q Plate t 1 Q 24 - Forcing screw t 2
794T-615-1550 q Hook t 1 Q 25 - Eyebolt t 2
794T-615-1560 q Screw t 1 Q 26 - Eyebolt t 2
794T-615-1570 q Collar t 1 Q 27 - Bar handle t 2
D
794T-615-1580 q Ball chain t 1 Q 28 - Puller t 1
2 794T-615-1610 Adjustment tool t 1 Q 29 - Block t 2
3 794T-615-1710 Guide t 1 Q 30 790-101-5700 Puller t 1
794T-615-1300 Puller t 1 Q 31 - Plate t 1
4 794T-615-1310 q Plate t 1 Q 32 - Plate t 1
794T-615-1320 q Plate t 1 Q 33 - Plate t 1
793T-607-1220 Lifting tool t 2 Q 34 - Plate t 1
5
793-607-1230 Pin t 2 35 790-201-2660 Plate t 1
794T-615-1400 Puller t 1 Q 794T-114-1220 Push tool t 1 N Q
D 6 794T-615-1410 q Plate t 1 Q 36 790-101-5421 Grip t 1
794T-615-1420 q Plate t 1 Q 01010-51240 Bolt t 1
7 790-102-1871 Nut wrench t 1 Q 37 794T-114-1230 Spacer t 1 N Q
8 799-301-1600 Oil leak tester t 1 Q
9 790-101-3701 Gear puller q 1 Disassembly
10 790-201-1410 Plate q 1 a Write down installed positions of hoses and wires
so that they are not installed incorrectly.
11 790-101-3501 Gear puller q 1
12 791T-465-1130 Push tool t 1 Q
q Preparation
13 790-201-2870 Spacer t 1
1) Secure the torque converter and transmission
14 790-201-3230 Bolt t 2 assembly by using a block, etc.
790-101-2310 Block t 1 k Be sure to secure it firmly so that it does
790-101-2320 Screw t 1 not fall.
790-101-2330 Nut t 1 2) Drain transmission oil from the transmission case.
790-101-2340 Washer t 1
15 45 l
790-101-2390 Leg t 2
02215-11622 Nut t 2
790-101-2360 Plate t 4
GD535-5 50-137
(02)
Disassembly and assembly of transmission assembly 50 Disassembly and assembly
1. Work equipment pump and steering pump 5) Remove bolts (9), and remove power train
assembly pump assembly (10).
Remove bolts (1), and remove work equipment
pump and steering pump assembly (2).
3. Connectors and sensors

1) Remove clamps (11), and disconnect
2. Power train pump assembly connector TM20 (13).
1) Remove U-bolts (3). 2) Remove bolt (14), and remove clamp (15).
2) Remove bolt (4), and remove bracket (5). 3) Remove transmission input shaft speed sensor
(16).
3) Remove bolt (6).

4) Remove bolts (17), and remove bracket (18).
4) Remove bolts (7), and remove tube (8).

5) Disconnect connector TM21 (19).
6) Remove bolt (20), and remove clamp (21).
7) Remove transmission intermediate shaft speed
sensor (22).
50-138 GD535-5
(02)
8) Remove bolt (23), and remove clamp (24). 16)Remove bolt (35), and remove clamp (36).
9) Disconnect connector TM22 (25). 17)Remove bolts (37), and remove clamps (38).
10)Remove bolt (26), and remove clamp (27). 18)Remove bolt (39), and remove clamp (40).
11)Remove transmission output shaft speed 19)Remove bolts (41), and remove bracket (42).
sensor (28).
20)Disconnect connectors on the top face of the

transmission
12)Remove bolts (29), and remove bracket (30). q TM1 (43): FH clutch pressure
q TM2 (44): FH clutch solenoid
q TM3 (45): FL clutch pressure
q TM4 (46): FL clutch solenoid
q TM5 (47): 2nd clutch pressure
q TM6 (48): 2nd clutch solenoid
q TM7 (49): 3rd clutch pressure
q TM8 (50): 3rd clutch solenoid
q TM10 (51): 1st clutch pressure
q TM11 (52): 1st clutch solenoid
q TM12 (53): R clutch pressure
q TM13 (54): R clutch solenoid
q TM14 (55): 4th clutch pressure
q TM15 (56): 4th clutch solenoid
13)Disconnect connector TM19 (31).
q TM16 (57): L/U clutch solenoid
14)Remove bolt (32), and remove clamp (33). q TM17 (58): T/C oil temperature sensor
15)Remove transmission lubricating oil temperature q TM18 (59): T/C oil pressure sensor
sensor (34). q TG1 (60): Ground
21)Remove bolt (61), and remove clamp (62).

22)Remove wiring harness (63).
GD535-5 50-139
(02)
4. Tubes and hoses 5. Lubrication tube

1) Remove elbow (64). 1) Remove joint bolt (72), and remove lubrication
tubes (73) and (74).
2) Remove bolts (65) and (66), and remove oil

filler tube (67). 2) Remove joint bolts (75), and remove lubrication
tubes (76) and (77).
3) Remove damper hose (68).

6. Main relief valve assembly and control valve
assembly
1) Remove bolt (78), and remove clamp (79).
2) Remove bolts (80), and remove main relief
valve assembly (81).
4) Remove bolts (69), and remove strainer cover

(70) and strainer (71).
50-140 GD535-5
(02)
3) Remove bolts (82), and remove control valve

assembly (84).
q Service bolts (83) also need to be
removed.
q Bracket (85) is secured along with control
valve assembly (84).
2) Using tools D25 and D26, remove front case

assembly (91).
a Use a lever block to adjust the position of
the front case assembly so that the clear-
ance between it and the transmission rear
case (92) becomes even.
7. Coupling and retainer

1) Remove coupling assembly (86).
2) Remove mounting bolts (87), washers (87a),
and remove retainer (88) by using forcing
screws.
3) Remove dust seal (89a), oil seal (89b), and O-
ring (90) from retainer (88).
3) Remove inner race (94) and gear (93) of the

shaft on the 1st clutch side by using tools D10
and D11.
a The reason for removing this gear is that
the 2nd clutch gear touches gear (93) and
cannot be removed if this gear is not
removed in advance.
8. Transmission front case assembly

1) Remove mounting bolts of front case assembly
(91), and separate the assembly from transmis-
sion rear case (92) by using tool D24.
GD535-5 50-141
(02)
9. Idler gear (for reverse) 10. 4th clutch assembly

1) Remove bolt (95) and remove plate (96). 1) Remove mounting bolts (104), and remove oil
2) Using tools D9 and D10, remove bearing (97) guide (105).
and gear (98) as a unit.
2) Using tool D1, remove 4th clutch assembly

(106) and 2nd and 3rd clutch assembly (107).
3) Remove collar (100), spacer (99), and bearing
(97) from the shaft .
4) Remove bearing (97) from gear (98).
3) Disassembly of 4th clutch assembly

1] Remove seal rings (108).
2] Remove bearing (109) by using tools D10
and D11.
5) Remove bearings (101), (102) and (103) from

front case (91).
3] Using tools D4, D10, and D11, remove

bearing (110) on the clutch side, spacer
(111), thrust washer (112), and 4th clutch
gear (113) from shaft (115).
50-142 GD535-5
(02)
4] Remove needle bearings (114) from 4th 8] Remove thrust washer (121).
clutch gear (113). 9] Remove piston assembly (122).
a Ensure that the piston is level before re-
moval. If it is tilted, it will not come off.
a Be careful not to remove the piston forc-
ibly because doing so damages the in-
ner surface of the cylinder.
10] Remove seal rings (123) and (124) from
piston assembly (122).
5] Using tool D27 or the like, push in end plate

(116) to remove snap ring (117).
6] Remove end plate (116).
11. 2nd and 3rd clutch assembly

1) Disassembly of 2nd and 3rd clutch assembly
7] Remove 7 plates (118), 6 springs (119), and

6 discs (120) alternately.
a Store the discs and plates in a level
place so that they do not deform.
GD535-5 50-143
(02)
2] Using tools D10 and D11, remove bearing

(126) on the 3rd clutch side, spacer (127),
thrust washer (128), and 3rd clutch gear
(129).
7] Remove thrust washer (136).

8] Remove piston assembly (137).
3] Remove needle bearings (130) from 3rd a Be careful not to remove the piston forc-
clutch gear (129). ibly because doing so damages the in-
4] Using tool D12, push in end plate (131) to

remove snap ring (132).
10] Using tools D30, D31, and D32, remove
bearing (140) on the 2nd clutch side, spacer
(141), thrust washer (142), and 2nd clutch
gear (143).

50-144 GD535-5
(02)
11] Remove needle bearings (144) from 2nd 15] Remove seal rings (152) and (153) from
clutch gear (143). piston assembly (151).
12] Using tool D13, push in end plate (145), and 12. 1st and FH clutch assembly and R and FL
remove snap ring (146) and end plate (145). clutch assembly
1) Using tool D5 (2 pieces), remove 1st and FH
clutch assembly (154) and R and FL clutch
assembly (155) at a time.
4 1st and FH clutch assembly (154):
48 kg
4 R and FL clutch assembly (155):
55 kg
a Since these 2 clutch assemblies intersect
with each other, they cannot be removed
except when they are raised at a time.
a Be sure to raise both the clutch assemblies
vertically.
13] Remove 12 plates (147), 11 springs (148),

and 11 discs (149) separately.
2) Disassembly of 1st and FH clutch assembly

a Note that the inner race at the end of the
shaft on the 1st clutch side and the interme-
diate gear have been removed in "Step
8.3)".
3] Remove 1st clutch gear (158).
14] Remove thrust washer (150), and remove
GD535-5 50-145
(02)
10] Pull out FH gear (168) by using tools D30,

D33, and D34, and remove bearing (169)
together with spacer (170) and thrust
washer (171).
4] Using tool D12, push in end plate (159) to

remove snap ring (160).
6 discs (163) alternately. 11] Remove thrust washer (172) and collar
a Store the discs and plates in a level (173) by using jigs. Remove needle bearing
place so that they do not deform. (174) and seal ring (175) from FH clutch
gear (168).

50-146 GD535-5
(02)
12] Using tool D27, push in end plate (176),

remove snap ring (177) and the bar handle,
and then remove end plate (176).
3) Disassembly of R and FL clutch assembly

1] Remove seal rings (186), (187), and (188).

and 11 discs (180) separately.
2] Using tool D15, remove inner race (189) on

the FL clutch side and gear (190).

a It can be removed smoothly because it is
placed in the sleeve.

16] Remove snap ring (184), and remove
sleeve (185) from piston assembly (181).
GD535-5 50-147
(02)
7] Using tool D27, push in end plate (196),

remove snap ring (197) and the bar handle,
and then remove end plate (196).
4] Remove FL clutch gear (192).

5] Remove needle bearing (193) and seal ring

(194) from gear (192).

placed in the sleeve.
6] Remove thrust bearing (195).
50-148 GD535-5
(02)
10] Remove seal rings (202) and (203) from 15] Using tool D27, push in end plate (213),
piston assembly (201). remove snap ring (214) and the bar handle,
11] Remove snap ring (204), and remove and then remove end plate (213).
sleeve (205).

12] Using tool D28, remove R clutch gear(206), 8 discs (217) alternately.
inner race (207), spacer (208), and thrust a Store the discs and plates in a level
washer (209). place so that they do not deform.
13] Remove needle bearing (210) and seal ring
(211) from R clutch gear (206).

14] Remove thrust bearing (212). placed in the sleeve.
GD535-5 50-149
(02)
18] Remove seal rings (219) and (220) from 3) Using nut wrench D7, remove nut (229).
piston assembly (218). a Lock either of drive gears nut (227) and
19] Remove snap ring (221), and remove (228) so that they do not make a drag turn.
sleeve (222).
a At this time, perform removal of "14. Torque

13. PTO idler gear and drive gear converter assembly".
1) Reverse the transmission case and set it on a 4) Drive gear (225) to remove it.
block securely.
2) Remove cover (223) and O-ring (224).
a Because the removal procedure is common
to the idler gears and drive gears, it is
described in the section of idler gear (225).
q (225): Idler gear
q (226): Idler gear
q (227): Drive gear (power train pump)
q (228): Drive gear (work equipment
pump)
a For the combination of gear and bearing,
see the following figure.
5) Remove bearing spacer (230B) or (231B) and

bearing (230A) or (231A) from gear (225).
50-150 GD535-5
(02)
6) Remove bearing (230C) or (231C), 2 outer

races (230D) or (231D), and snap ring (230E)
or (231E) from the transmission case.
15. Bearing (for rear case)

Remove bearing (234) from the transmission
case.
14. Torque converter assembly

1) Set transmission case (92) to 400 mm or more
high tool D29 securely.
2) Remove 7 mounting bolts (232) of the torque

converter assembly from the bottom.
3) Remove torque converter assembly (197) from

the transmission case by using tool D26.
GD535-5 50-151
(02)
Assembly 2) Install snap ring (230E) or (231E) and 2 outer

a Clean all parts, and check them for dirt or damage races (230D) or (231D) to the transmission
before installation. case.
a Apply oil to the sliding surface of each part before
installation.
a Apply approximately 6 cc of power train oil TO10
or TO30 to an assembled bearing and turn it 10
times.
a When installing the bearing by expansion fit, apply
approximately 6 cc of oil TO30 or TO10 to the
bearing and rotate the bearing about 10 turns
before cooling it in dry ice, etc.
1. PTO idler gear and drive gear

a Because the installation procedure is common
to the i dle r gear s and dri ve gear s, it is
3) Install gear (225) to the outer race of the trans-
described in the section of idler gear (225). mission case.
q (225): Idler gear 4) Using tool D16, install bearing (230C) or (231C)
q (226): Idler gear to gear (225) from the opposite side.
q (227): Drive gear (power train pump)
q (228): Drive gear (work equipment pump)
a For the combination of gear and bearing, see
the following figure.
a At this time, perform installation of "3. Torque

a For a bearing, be sure to check that the inner 5) Tighten nut (229) by using nut wrench D7.
2 Male threaded part of gear:
and outer races, bearing spacer, and snap ring
have an identical serial number, and use them Adhesive (LT-2)
as selectively combined parts. a Be sure to apply adhesive (LT-2) to the
1) Using tool D16, press-fit bearing (230A) or male threaded part of the gear.
(231A) to gear (225), and install bearing spacer 3 Nut:
(230B) or(231B). 314 to 392 Nm {32 to 40 kgm}

a Lock either of drive gears (227) and (228)
so that they do not make a drag turn.
a After tightening the nut, apply 6 cc of trans-
mission oil (TO10) to it and rotate it about
10 turns.
50-152 GD535-5
(02)
5) Reverse transmission case (92), and set it on

6) Install O-ring (224), and install cover (223). tools D29.

2 Mounting bolt:
2. Torque converter assembly
Adhesive (LT-2)
3
1) Set transmission case (92) on tool D29 with its
Mounting bolt:
torque converter side up.
a Mounting bolts of the torque converter 58.8 to 73.5 Nm {6 to 7.5 kgm}
assembly need to be loosely tightened from
the bottom. So, be sure to use 400 mm or
more high blocks.
3. Bearing (for rear case)

Install bearing (234) from the transmission case.
2) Check the position of the oil hole, and install

guide bolt D17 to the stator shaft.
a Put a mark near the bolt hole where the guide
bolt is inserted.
3) Using tool D26, install torque converter
assembly (233).
a Engage the PTO gear of the torque con-
verter with the idler gear.
4) Loosely tighten 2 to 3 mounting bolts from the
bottom.
GD535-5 50-153
(02)
4. R and FL clutch assembly and 1st and FH 4] Install 9 plates (215), 8 springs (216), and 8
clutch assembly. discs (217) alternately.
1) Assembly of R and FL clutch assembly a Immerse discs in clean power train oil
1] Set sleeve (222) to piston (218), and install (TO10 or TO30) for 2 minutes minimum
snap ring (221). before installation.
a Check that a snap ring is securely fitted a Ensure that the springs and discs do not
into the groove. overlap each other.
2] Install seal rings (219) and (220) to piston
(218).
a Ensure that a seal ring is not installed
with its pressure receiving side facing
the wrong way.
a Be sure to use a new seal ring.
2 Seal ring inner and outer circumfer-
ences:
5] Install end plate (213), push in it by using

tool D27 or the like, and install snap ring
(214).
a Check that a snap ring is securely fitted
into groove.
3] Install piston assembly (218) to the cylinder

part.
6] Install thrust bearing (212).

a Be sure to install it with its thicker race
on the clutch side.
7] Install needle bearing (210) and seal ring
(211) to R clutch gear (206).
2 Seal ring outer circumference:
50-154 GD535-5
(02)
11] Set sleeve (205) to piston (201), and install

snap ring (204).
into groove.
(201).
the wrong way.
2 Inner and outer circumferences of
seal ring:
8] Align internal teeth of discs, and install R
clutch gear (206).
a Gently move the gear from side to side
and up and down little by little to engage
it with the internal teeth of the discs.
9] Install thrust washer (209) and spacer
(208).
10] Using tool D18, press-fit inner race (207) to
the shaft.

part.
a After press fit of the inner race, check

that no clearance is provided at part (P).
a After press fit of the inner race, measure
clearance (e) between the thrust washer
and spacer.
q Clearance (e): 0.21 to 1.09 mm
GD535-5 50-155
(02)
14] Install 9 plates (198), 8 springs (199), and 8 17] Install needle bearing (193) and seal ring
discs (200) alternately. (194) to FL clutch gear (192).
a Immerse discs in clean power train oil 2 Outer circumference of seal ring:
(TO10 or TO30) for 2 minutes minimum Grease (G0-LI or G2-LI)
a Ensure that the springs and discs do not
overlap each other.
18] Align internal teeth of discs, and install FL

clutch gear (192).
15] Install end plate (196), push in it by using and up and down little by little to engage
tool D27 or the like, and install snap ring it with the internal teeth of the discs.
(197).
into groove.
19] Install thrust washer (191).

20] Install gear (190), and install inner race
(189) by using tool D18.
16] Install thrust bearing (195).
a Be sure to install it with its thicker race
on the clutch side.
50-156 GD535-5
(02)
a After the press fit of the inner race, check 2) Assembly of 1st and FH clutch assembly
that no clearance is provided at part (Q). 1] Set sleeve (185) to piston (181), and install
a After press fit of the inner race, measure snap ring (184).
clearance (e) between the thrust washer a Check that a snap ring is securely fitted
and gear. into groove.
assembly (146).
the wrong way.
seal ring:
21] Install seal rings (186), (187), and (188) to

the shaft.

part.
22] Using tool D8, pump air through the oil hole
in the shaft to check operation of the clutch.
a If the gear on the air pumping side is
locked, operation of the clutch is normal.
q Air pressure:
0.5 to 0.6 MPa {5.0 to 6.0 kg/cm2}
and 11 discs (180) alternately.
a Immerse discs in clean power train oil
(TO10 or TO30) for 2 minutes minimum
overlap each other.
GD535-5 50-157
(02)
5] Install end plate (176), push in it by using 8] Align internal teeth of discs, and install FH
tool D27 or the like, and install snap ring clutch gear (168).
(177). a Gently move the gear from side to side
a Check that a snap ring is securely fitted and up and down little by little to engage
into groove. it with the internal teeth of the discs.
6] Install collar (173) and thrust washer (172). 9] Install thrust washer (171) and spacer
a Be sure to install it with its thicker race (170).
on the clutch side. 10] Using tool D35, install bearing (169).
7] Install needle bearing (174) and seal ring a After press fit of the bearing, check that
(175) to FH clutch gear (168). no clearance is provided at part (P).
2 Outer circumference of seal ring: a After press fit of the bearing, measure
Grease (G0-LI or G2-LI) clearance (e) between the thrust washer
and spacer.
50-158 GD535-5
(02)

overlap each other.
15] Install end plate (159).
16] Using tool D12, push in end plate to install
snap ring (160).
into groove.

assembly (165).
the wrong way.
seal ring:
17] Align internal teeth of the discs, and install

1st clutch gear (158).
a Take care not to damage the bushing
when passing 1st gear (158) through the
shaft.
19] Install seal ring (156) to the shaft.
part.
q Air pressure:
0.5 to 0.6 MPa {5.0 to 6.0 kg/cm2}
GD535-5 50-159
(02)

part.
3) Using tool D5 (2 pieces), install 1st and FH

clutch assembly (154) and R and FL clutch
assembly (155) at a time.
a Be sure to raise both the 2 clutch assem- 4] Remove 12 plates (147), 11 springs (148),
blies vertically. and 11 discs (149) alternately.
overlap each other.
5. 2nd and 3rd clutch assembly

1) Assembly of 2nd and 3rd clutch assembly
assembly ((151).
the wrong way.
5] Install end plate (145).
6] Using tool D13, install snap ring (146).
seal ring:
into groove.
50-160 GD535-5
(02)
7] Install needle bearings (144) to 2nd clutch

gear (143).

assembly (137).
8] Align internal teeth of the discs, and install a Ensure that a seal ring is not installed
2nd clutch gear (143). with its pressure receiving side facing
a Gently move the gear from side to side the wrong way.
and up and down little by little to engage a Be sure to use a new seal ring.
it with the internal teeth of the discs. 2 Inner and outer circumferences of
9] Install thrust washer (142). seal ring:

10] Using tool D20, install inner race (140) and

spacer (141). 12] Install piston assembly (137) to the cylinder
part.
a After the press fit of the inner race, check

that no clearance is provided at part (Q).
a After press fit of the inner race, measure 14] Remove 9 plates (133), 8 springs (134), and
clearance (e) between the gear and 8 discs (135) alternately.
thrust washer. a Immerse discs in clean power train oil
q Clearance (e): 0.07 to 0.93 mm (TO10 or TO30) for 2 minutes minimum
GD535-5 50-161
(02)
a Ensure that the springs and discs do not 20] Using a press, install bearing (126).
overlap each other.
a After the press fit of the bearing, check

15] Install end plate (131). that no clearance is provided at part (P).
16] Using tool D12, push in the end plate to a After press fit of the bearing, measure
install snap ring (132). clearance (e) between the thrust washer
a Check that a snap ring is securely fitted and spacer.
into groove. q Clearance (e): 0.07 to 0.93 mm
17] Install needle bearings (130) to 3rd clutch 21] Install seal ring (125) to the shaft.
gear (129). 2 Outer circumference of seal ring:
18] Align internal teeth of the discs, and install

3rd clutch gear (129).
(127).
50-162 GD535-5
(02)
q Air pressure:
0.5 to 0.6 MPa {5.0 to 6.0 kg/cm2}
3] Install needle bearings (114) to 4th clutch

gear (113).
6. 4th clutch assembly

1) Assembly of 4th clutch assembly
assembly (122).
the wrong way.
seal ring:
Power train oil (TO10 or TO30) 4] Install 7 plates (118), 6 springs (119), and 6
discs (120) alternately.
a Hold the unstable shaft by hand.
a Immerse discs in clean power train oil for
2 minutes minimum before installation.
overlap each other.
2] Install piston assembly (86) and thrust

washer (121) to the cylinder part.
5] Install end plate (116), push in it by using

tool D27, and install snap ring (117).
a Check that a snap ring is securely fitted into
groove.
GD535-5 50-163
(02)
6] Align internal teeth of the discs, and install 9] Using tool D21, press-fit bearing (109).
4th clutch gear (113).
(111).
10] Install seal ring (108).

a Apply grease to the outer circumference
of the seal ring, and install it without de-
viation.
2 Seal ring outer circumference:
8] Press-fit bearing (110) to shaft by using tool
D21.
a After press fit of the bearing, check that

no clearance is provided at part (P).
a After the press fit of the bearing, check
that no clearance is provided at part (P).
a After press fit of the bearing, measure
clearance (e) between the thrust washer
and spacer.
50-164 GD535-5
(02)
2] Use bolt (104) to install oil guide (105).

2 Mounting bolt: Adhesive (LT-2)
in the shaft to check operation of the clutch. 3] Install gear (43) to the 1st clutch shaft.
a If the gear on the air pumping side is a Check that thrust washer (157) does not
locked, operation of the clutch is normal. come off.
q Air pressure: 4] Install inner race (44) by using tool D18.
0.5 to 0.6 MPa {5.0 to 6.0 kg/cm2}
a After press fit of the inner race, measure

2) Installation of 2nd and 3rd clutch assembly clearance (e) between the thrust washer
(107) and 4th clutch assembly (106) and gear.
q Clearance (e): 0.07 to 0.93mm
1] Place oil guide (105) on 4th clutch assembly
(106), and then install 2nd and 3rd clutch
assembly (107) and 4th clutch assembly
(106).
GD535-5 50-165
(02)
7. Transmission front case assembly 4) Install gear (98) while aligning matchmarks,
1) Use the push tool to install bearings (101), and install bearing (97) by using tool D23.
(102), and (103) to front case (91). a Install it while aligning its matchmark with
that on the outer race installed to the gear.
8. Idler gear (for reverse)

1) Using tool D22, install outer race (97A) to gear 5) Install plate (96), and tighten bolt (95).
(67). 2 Mounting bolt:
a Check that inner and outer races of the Adhesive (LT-2)

bearing have an identical serial number or 3 Mounting bolt:
match sign, and put a "matchmark" on 110.5 ± 12.5 Nm {11.25 ± 1.25 kgm}
them.
9. Installation of transmission front case

2) Install spacer (100) to the shaft. 1) Referring to the figure shown below, apply
a Install it with the face having largely cutout liquid gasket to transmission rear case (92).
inner diameter down. 2 Case mounting face:
3) Install bearing (97) and spacer (99) to the shaft Adhesive (LG-8)
by using tool D23. a Install the O-ring on the rear case surface.
a Take care not to squeeze liquid gasket into
the case and not to apply it excessively.
a Check that the case mounting face is not
damaged.
a Symbol (A) indicates that the mating case
has a forcing tap.
50-166 GD535-5
(02)
3) Press fit dust seal (89a) by using tool D36 and

D37.
a Dimension (b) becomes 25 ± 0.2 mm.
a When installing the dust seal, direct its lip
out.
2) Using tools D25 and D26 and lever blocks as

well, raise transmission front case assembly
(91) while keeping it level.
3) Install front case assembly (91) by lowering it
gently while aligning bearings of front case
assembly (91) with respective clutch shafts. 4) Apply or fill grease as shown below.
4) Tighten mounting bolts of front case assembly Portion “a”: Apply grease (G2-S or G2-LI) to
(91). the lip ends (4 places).
3 Mounting bolt: Portion "b": Fill grease (G2-S or G2-LI) into the
spaces "between the main lip and dust lip of oil
110.5 ± 12.5 Nm {11.25 ± 1.25 kgm}
seal", “between the dust seal and oil seal", and
"between the double lips of dust seal" up to 40
to 60%.
a Excessively applied grease can be mis-
taken for oozing oil. Take care.
a Wipe off the grease forced out to the inside
and outside.
Portion c: Grease may be forced out into the
space between oil seal and dust seal.
10. Coupling and retainer

1) Thinly apply liquid gasket (LG-5) to the oil seal
mounting face of retainer (88).
2) Press fit oil seal (89b) to retainer (88) by using
tool D36.
a Dimension (a) becomes 33 ± 0.2 mm.
GD535-5 50-167
(02)
5) Install retainer (88) to the case.

6) Install the coupling assembly (86).
2 Coupling spline: LM-S
2) Install seal washer, and use joint bolt (72) to

install lubrication tubes (73) and (74).
3 Lubrication tube:
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
11. Main relief valve assembly and control valve

assembly
1) Use bolts (82) and service bolts (83) to install
control valve assembly (84).
a Install the O-ring on the front case surface.
q Note that bracket (85) is tightened along
with control valve assembly (84).
13. Tubes and hoses

1) Install strainer (71).
2) Install O-ring, and use bolts (69) to install
strainer cover (70).
2) Use bolts (80) to install main relief valve

assembly (81).
a Install the O-ring on the rear case surface.
3) Use bolt (78) to install clamp (79).
3) Install damper hose (68).
12. Lubrication tube

1) Install seal washer, and use joint bolts (75) to
install lubrication tubes (76) and (77).
3 Lubrication tube:
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
50-168 GD535-5
(02)
4) Use bolts (65) and (66) to install oil filler tube

(67).
3) Install transmission input shaft speed sensor

(16).
5) Install elbow (64). a To adjust the clearance of the speed sen-
sor, apply the tip of the sensor lightly to the
tip of a gear tooth, return the sensor 1/2 to
1 turn from that point, and tighten the lock
nut so that the lead wire of the sensor can
be extended from within angle range A
(180 degrees).
2 Threaded part of sensor:
3 Lock nut:
49.0 to 68.6 Nm {5 to 7 kgm}
5) Use clamps (11) to connect connector TM20
(13).
14. Connectors and sensors
1) Install wiring harness (63) to the top face of the
transmission, and connect connectors.
q TM1 (43): FH clutch pressure
q TM2 (44): FH clutch solenoid
q TM3 (45): FL clutch pressure
q TM4 (46): FL clutch solenoid
q TM5 (47): 2nd clutch pressure
q TM6 (48): 2nd clutch solenoid
q TM7 (49): 3rd clutch pressure
q TM8 (50): 3rd clutch solenoid
q TM10 (51): 1st clutch pressure
q TM11 (52): 1st clutch solenoid
q TM12 (53): R clutch pressure
q TM13 (54): R clutch solenoid
q TM14 (55): 4th clutch pressure
q TM15 (56): 4th clutch solenoid
q TM16 (57): L/U clutch solenoid
q TM17 (58): T/C oil temperature sensor
q TM18 (59): T/C oil pressure sensor
q TG1 (60): Ground
GD535-5 50-169
(02)
6) Install transmission intermediate shaft speed

sensor (22).
8) Connect connector TM21 (19).
a To adjust the clearance of the speed sen-
sor, apply the tip of the sensor lightly to the
tip of a gear tooth, return the sensor 1/2 to
1 turn from that point, and tighten the lock
nut so that the lead wire of the sensor can
be extend from within angle range A (180
degrees).
3 Lock nut:
11)Use bolt (26) to install clamp (27).
12)Connect connector TM22 (25).
49.0 to 68.6 Nm {5 to 7 kgm}
9) Use bolts (17) to install bracket (18).

10)Install transmission output shaft speed sensor 14)Install transmission lubricating oil temperature
sensor (34).
3 Transmission lubricating oil temperature
(28).
a To adjust the clearance of the speed sen-
sor, apply the tip of the sensor lightly to the sensor:
tip of a gear tooth, return the sensor 1/2 to 29.4 to 49.0 Nm {3 to 5 kgm}
1 turn from that point, and tighten the lock 15)Use bolt (32) to install clamp (33).
nut so that the lead wire of the sensor can 16)Connect connector TM19 (31).
be extend from within angle range A (180
degrees).
3 Lock nut:
49.0 to 68.6 Nm {5 to 7 kgm}
50-170 GD535-5
(02)
17)Use bolts (29) to install bracket (30).

3) Install bolts (6).
4) Use bolts (4) to install bracket (5).
18)Use bolts (41) to install bracket (42).

20)Use bolts (37) to install clamp (38). 5) Install U-bolt (3).
16. Work equipment pump and steering pump

15. Power train pump assembly assembly
1) Remove bolts (9) to install power train pump Tighten bolts (1) to install work equipment pump
assembly (10). and steering pump assembly (2).
2) Use bolt (7) to install tube (8). q Refilling (transmission case)

Refill it with oil to the specified level through the oil
filler port. After completing installation of the trans-
mission assembly, run the engine to circulate the
oil through the piping and check the oil level again.
45 ℓ
GD535-5 50-171
(02)
Removal and installation of tandem drive and final drive assembly 50 Disassembly and assembly
Removal and installation of tandem

drive and final drive assembly 1

OFF position.
k After stopping the engine, depress the brake
6. Lower blade (3) to the g4round.
pedal slowly 30 or more times to release the
pressure in the accumulator circuit.
Removal
1. Remove the fuel tank assembly. For details, see
"Removal and installation of fuel tank assembly".
2. Jack up the entire machine until the height of the
rear end bottom of the rear frame is approximately
1 m above the ground.
3. Support the bottom of the front axle by using robust
support stand [1].
7. Sling wheel assembly (4), and remove 10

mounting bolts to remove 4 rear wheels. [*1]
a Be sure to place a block under the tandem
case because the tandem case may tilt if it is
not supported when a wheel on either side is
removed.
a Be sure to securely apply a lifting belt to the
center of the tire and place the removed
wheels in a stable location to prevent danger-
ous situations.
4 Wheel assembly (4)
: 145 kg (13.00-24-12PR)
4. Support the front end of the rear frame by using : 144 kg (14.00-24-12PR)
robust support stand [2].
5. Support the rear end of the rear frame by using

robust support stand [3].
50-172 GD535-5
(02)
50 Disassembly and assembly Removal and installation of tandem drive and final drive assembly

assembly".
9. Loosen drain plug (5) to drain the oil in the final
drive case. [*2]
6 Final drive case
: 13 l (for machines without differential,
standard specification)
: 14 l (for machines with optional differen-
tial)
14. Disconnect parking brake hose (14). [*4]

15. Remove cover (15A), and remove universal joint
(15) between the transmission and final drive. [*5]
10. Disconnect 2 connectors of differential lock sole-

noid connector R9 (6) and 2 differential oil temper-
ature sensor connectors R8 (7).
16. Remove both covers (16) on the top face of the

tandem case.
11. Remove clamp (8A), and disconnect hose (8) .

12. Remove 2 clamps (10), and disconnect hose (11)
from differential lock solenoid valve (12).
13. Remove oil filler tube (13). [*3]
17. Disconnect 2 front and rear wheel brake hoses (17)
on each side.
a Plug the disconnected hoses.
GD535-5 50-173
(02)
Removal and installation of tandem drive and final drive assembly 50 Disassembly and assembly
18. Remove the tandem drive and final drive assembly Installation
according to the following procedure. q Perform installation in the reverse order of
6
removal.
Tandem drive and final drive assembly:
2370 l (for machines without differential, [*1]
standard specification) 3 Wheel mounting bolt:
2425 l (for machines with optional differen- 610 to 765 Nm {62.5 to 78.0 kgm}
tial)
a While following 2 methods are commonly used [*2]
to dismount the assembly; one is 4-point lifting 3 Drain plug (3):
method using a crane and the other is a 58.8 to 78.4 Nm {6.0 to 8.0 kgm}
method using a folk lift, this section describes a
method using jacks. [*3]
1) Set robust blocks under the tandem case on 2 Threaded portion of oil filler tube (13):
each side. Adhesive (LT-2)
2) While slinging one tandem case by using a 3 Oil filler tube (13):
crane, use jacks to support the other. 49 to 98 Nm {5 to 10 kgm}
3) Remove 4 final drive case mounting bolts (18)
on each side. [*6] [*4]
a Install the parking brake hose without twisting it.
[*5]
3 Universal joint mounting bolt:
98 to 123 Nm {10 to 12.5 kgm}
[*6]
3 Final drive case mounting bolt (18):
1,150 to 1,440 Nm {118 to 147 kgm}
q Bleeding air (brake circuit)

Bleed air from the wheel brake circuit. For details,
see Testing and adjusting "Bleeding air from brake
4) While operating the crane to lower the circuit".
assembly slowly, lower the jacks in time with
the crane movement. q Refilling (final drive case)
While carrying out the work, take extra care to
Refill it with oil to the specified level through the oil
balance the assembly and be sure not to allow
filler port. Run the engine to circulate the oil
anyone to enter under the tandem drive and
through the piping. Then check the oil level again.
5 Final drive case: 14l (TO30)
final drive assembly.
a Replace blocks set in step 1) with those of
shorter height.
5) Instead of using the jacks and crane, use the
floor jacks [4] to pull the tandem drive and final
drive assembly (19) out of the machine.
50-174 GD535-5
(02)
50 Disassembly and assembly Disassembly and assembly of tandem drive assembly
Disassembly and assembly of 3. Disconnect brake tubes (2) and (3) from each
tandem drive assembly 1
tandem drive case.
Special tools
New/Redesign
Necessity
Sketch
Q'ty
1 794T-720-1200 Chain puller t 1 Q

1-1 794T-720-1210 Plate t 2 Q
1-2 794T-720-1220 Plate t 4 Q
T-shaped
1-3 794T-720-1230 t 1 Q
wrench
4. Remove 8 bolts (4a), and remove 2 top face covers
1-4 794T-720-1240 Pin t 1 Q (4) and 8 spacers (4b) from each tandem drive
1-5 794T-720-1250 Plate t 1 Q case.
1-6 794T-720-1260 Plate t 2 Q 5. Remove 8 bolts (5a), and remove 4 side face
covers (5) (2 covers each on the inside and
1-7 794T-720-1270 Plate t 2 Q
outside) from each tandem drive case.
9 794T-720-1600 Press fit jig t 1 Q
G
9-1 794T-720-1740 Shaft t 2 Q
9-2 794T-720-1630 Block t 1 Q
9-3 794T-720-1620 Plate t 1 Q
9-4 794T-720-1610 Block t 1 Q
9-5 794T-720-1550 Bolt t 2 Q
9-6 794T-720-1680 Bolt t 2 Q
9-7 794T-720-1670 Bolt t 1 Q
9-8 794T-720-1660 Block t 1 Q
9-9 794T-720-1650 Plate t 1 Q
19 - Hand pump t 1
Disassembly
1. Remove the tandem drive and final drive
assembly. For details, see "Removal and installa-
tion of tandem drive and final drive assembly".
2. Remove drain plug (1), and drain the oil in both
final drive cases.
6 Tandem drive case:
51 l (each side)
6. Chain
1) Use tool G19 to release parking brake (6).
2) Rotate disc (7) to set master pin part (8) of the
chain to the attaching/removing hole.
GD535-5 50-175
(02)
Disassembly and assembly of tandem drive assembly 50 Disassembly and assembly
3) Use tool G1 to retract chain (9), and pull out

cotter pin (10) to remove plate (11) and master 2) Sling tandem drive assembly (14), and remove
pin (12) from chain (9). 19 mounting bolts to remove the assembly from
4) Pull out chain (9) to remove it from the sprocket. final drive assembly (15).
5) Remove the chain on the opposite side simi- 4 Tandem drive case (each side):
larly. 330 kg
4 Final drive assembly (15):
910 kg
7. Tandem drive
1) Sling wheel brake assembly (13), and remove
the mounting bolts that secure the assembly to
tandem drive case (14) to remove each of 4
wheel brake assemblies (13) installed on the
front and rear of tandem drive on each side.
4 Wheel brake assembly (each):
180 kg
50-176 GD535-5
(02)
Assembly
1. Sling tandem drive case assembly (14), and install
it to final drive assembly (15).
4 Tandem drive case (14) (each side):
330 kg
2 Threaded part of mounting bolt:
Precoat adhesive (LT-2C)
3 Mounting bolt:
245 to 309 Nm {25 to 31.5 kgm}
3. Installation and adjustment of chain

1) Use tool G19 to release parking brake (6).
a For the adjusting method of the parking
brake, see Testing and adjusting, "Testing
and adjusting parking brake pad clear-
ance".
2. Sling wheel brake assembly (13), and install it to

tandem drive cases (14) at each of 4 locations, the
front and rear of tandem drive on each side.
a Align the 2 places marked with A as shown in
the figure, and then install it.
a Mounting bolt to be used at places marked with
A (12 bolts)
2 Threaded part of mounting bolt:
3 Mounting bolt (except bolts to be used at
places marked with A):
245 to 309 Nm {25 to 31.5 kgm} 2) Put chain (9) in tandem drive case (14), and
engage one end of the chain with the sprocket.
a Install the chain so that the sprocket on the
inside of the machine is placed on the front
side of the machine, and the sprocket on
the outside of the machine is placed on the
rear side of the machine.
3) Rotate the parking brake disc to wind up the
chain so that the master pin part of the chain is
set to attaching/removing hole (A).
GD535-5 50-177
(02)
4) Use tool G1 to gather chain (9), and install

master pin (12).
1] Insert tool G1 into the hole in the top face of
tandem drive case (20), and place the tip of
tool G1 on rollers (21) of chain (9).
1] Insert tool G9-1 under chain (9) through the

hole in the side face of tandem drive case
(20), then turn bolts (22) of tool G9-1 to
secure it to case (20).
2] Turn the handle at the top of tool G1 to

adjust the chain pitch, and then install
master pin (12) through the hole in the side
face of tandem drive case (20).
a If it is difficult to insert the master pin, do
not drive it in forcibly. Instead adjust the
chain pitch.
5) Use tool G9 to press-fit plate (11).
2] Adjust position of the chain so that the

projection at the end of the master pin can
fit into hole (b) of tool G9-1, then apply plate
(23) to tool G9-1.
50-178 GD535-5
(02)
3] Set plate (11) to tool G9-2, and attach it to

master pins (12).
a Do not reuse plates that were previously
press-fitted to master pins.
a Check that chamfered part (12a) of the
master pin is fitted into hole (11a) of the
plate.
6] Remove tool G9 and install cotter pins (10).

7] Install the chain on the opposite side in a
similar fashion.
4] Insert tool G9-3 into the hole in the side face

on the opposite side of tandem drive case
(20), and turn bolts (24) to secure it to case
(20).
4. Use 8 bolts (4a) to install 2 top face covers (4) with

gasket and 8 spacers (4b) to each tandem drive
case.
5] Turn the screw of tool G9-3 to press-fit plate

(11) until tool G9-2 stops.
a Check that clearance (a) is provided be-
tween the inside ring and plate.
a The plate stops at position (c) where the
end faces of tools G9-1 and G9-2 are
flush with each other.
GD535-5 50-179
(02)
5. Use 8 bolts (5a) to install 4 side face covers (5) with

gasket (2 covers each on the inside and outside) to
each tandem drive case.
2 Gasket (both face on case and cover):
2 Cover mounting bolt:
3 Mounting bolt
4a: 111 to 123 Nm {11.3 to 12.5 kgm}
5a: 98 to 123 Nm {10 to 12.5 kgm}
q Air bleeding
Bleed air from the brake circuit. For details, see
Testing and adjusting "Bleeding air from brake cir-
cuit".
6. Install brake tubes (2) and (3) to each tandem drive

case.
7. Tighten each drain plug.

3 Drain plug (1):
59 to 78 Nm {6.0 to 8.0 kgm}
8. Remove each oil filler plug (16), and refill with oil.
5 Tandem drive case (each side):
51 l (TO30)
3 Oil filler plug:
59 to 78 Nm {6.0 to 8.0 kgm}
50-180 GD535-5
(02)
50 Disassembly and assembly Disassembly and assembly of differential assembly

differential assembly 1
Tools for disassembly and assembly of differen-

tial assembly
New/Redesign
Necessity
Sketch
Sym-
Q'ty
Part No. Part name
bol
G 790-201-2720 Spacer q 1
Commercially
H Bearing puller t 1
available
J 790-201-2870 Spacer q 1 3. Remove mounting bolt (36), and remove holder
K 790-201-3130 Guide bolt t 2 (37) and coupling (39).
a Check and note down thickness and the num-
L 790-201-3250 Bolt q 2
ber of shims of shim pack (38).
M - A Push tool t 1
N - A Push tool t 1
P 790-101-5541A Push tool t 1
Q 790-201-2410A Plate q 1
R 790-101-5471A Push tool t 1
S 790-201-2760 Spacer t 1
T 793T-615-1730 Spacer t 1 Q
U - Push tool t 1
V 793T-613-1370 Spacer t 1 Q
W - Push tool t 1 N
X 793T-613-1340 Spacer t 1 Q
Y - Push tool t 1 N 4. Set cage assembly (35) on a press stand.
AE - Dial wrench t 1 5. Use tool G to press down bevel pinion (40), and
AF 790-101-5491U Push tool t 1 remove it from cage assembly (35).
a Take care not to drop the bevel pinion on the
AG - U Push tool t 1
floor when it comes off.
AH - U Push tool t 1
AJ 791-503-1001 Alignment tool t 1
A: Only for differential lock specification

U: Only for non-differential specification
k Thoroughly clean the parts completely and
inspect them for any foreign substances or
damage. Apply power train oil (TO30 or equiv-
alent) to the sliding surface before assem-
bling.
Disassembly
1. Remove mounting bolts of parking brake (34), and
remove the disc.
2. Remove the mounting bolts and raise cage
assembly (35) to remove it.
4 Cage assembly (35): 40 kg
a Note down thickness and the number of
installed shims.
GD535-5 50-181
(02)
Disassembly and assembly of differential assembly 50 Disassembly and assembly
6. Use tools H and J to remove bearing (41) from

bevel pinion (40).
a Do not pull out the bearing by applying heat or
remove by fusing.
13. Raise differential carrier assembly (47) to remove

it.
4 Differential carrier assembly: 90 kg
14. Remove each bearing cage (48) and shim pack
7. Remove dust seal (43a) and oil seal (43) from cage (50).
(42). a Write down thickness and the number of shims
8. Remove bearing (44) and bearing outer race (44a). used.
9. Remove bearing outer race (41a).
Disassembly of differential carrier assembly (dif- 15. Use tool L to remove bearing (51) from bearing
ferential lock specification) cages (48) and (49).
10. Remove tube (45), nipple (46), and adapter (46a). a The figure shows the bearing cage on the right
side.
a (a) indicates a screw hole for removal of bear-
ing.
remove by fusing.
11. Sling differential carrier assembly (47).

12. Remove mounting bolts of each bearing cage (48),
and use tool K and tool L to pull out bearing cage
(48).
50-182 GD535-5
(02)
16. Remove sleeve (48a) from bearing cage (48).
22. Reverse differential carrier assembly (47), and

17. Set differential carrier assembly (47) on a block, remove mounting bolts to remove case (58).
and remove mounting bolts to remove cage (52). a Put a matchmark on the mating part of case
(58) and case (62).
23. Remove washer (59), and remove gear (60).
24. Remove 2 seal rings (70).
18. Remove bearing outer race (51a) from cage (52).
25. Remove bearing outer race (51b) from case (58).
19. Remove washer (53), 8 plates (54), and 7 discs

(55).
20. Remove gear (56) and piston (57).
21. Remove seal rings (71) and (72) from piston (57).
GD535-5 50-183
(02)
26. Remove spider assembly (61).
32. Sling bevel gear assembly (84) to remove it.

27. Remove washers (69), pinions (68) and bushings 4 Bevel gear assembly (84): 50 kg
(67) from spider assembly (61). 33. Remove bearing cages (85) and (86) and shim
pack (87).
a Write down thickness and the number of shims
used.
28. Remove 12 mounting bolts (64), and remove bevel

gear (65) from case (62).
29. Pull out 4 dowel pins (63) from bevel gear (65).
34. Remove both bearing inner races (88a) and (89a)

from bevel gear assembly (84).
remove by fusing.
Disassembly of bevel gear assembly (non-differ-

ential specification)
30. Sling bevel gear assembly (84).
31. Remove mounting bolts of each bearing cage (85)
and (86), use tool K and tool L to pull out both
bearing cages (85) and (86).
35. Remove bearing outer races (88b) and (89b) from
both bearing cages (85) and (86).
a The figure shows the bearing cage on the right
side.
50-184 GD535-5
(02)
36. Remove 12 mounting bolts (90), and remove bevel 3. Use tool Q to press-fit sleeve (48a) to bearing cage
gear (91) from bevel gear assembly (84). (48).
37. Pull out 4 dowel pins (92) from bevel gear (91).
Assembly 4. Use tool R to press-fit bearing outer race (51b) to

a Clean all parts ,and check them for dirt or damage case (58).
a Apply power train oil to the sliding surface.
Assembly of differential carrier assembly (differ-
ential lock specification)
1. Use tools M and N to press-fit bearing (51) to
bearing cages (48) and (49).
2 Roller of bearing:
Power train oil (TO30)
a The figure shows the bearing cage on the right
side.
5. Loosely tighten 12 mounting bolts (64) to install

bevel gear (65) to case (62) loosely.
6. Drive in 4 dowel pins (63), and tighten mounting
bolts (64) to the specified torque.
a After driving in dowel pin (63), be sure to peen
it at 2 places.
2 Mounting bolt (64):
Adhesive (LT-2)
157 to 196 Nm {16 to 20 kgm}
2. Use tool P to press-fit bearing outer race (51a) to
cage (52).
GD535-5 50-185
(02)
Assembly of spider
7. Install bushings (67), pinions (68), and washers 12. Reverse case (62).
(69) to spider (61). 13. Install seal rings (71) and (72) to piston (57), and
insert the piston into case (62).
a Care about installed direction of the seal ring.
Spider assembly
8. Reverse the case, and install spider assembly
(61).
14. Install gear (56) to case (62), and insert 8 plates

9. Install gear (60) to spider assembly (61), and install
(54) and 7 discs (55) alternately.
2 Disc (55) (both sides):
washer (59).
10. Install 2 seal rings (70) to case (58).
2 Seal ring (70) (external surface and side
face):
Lithium grease (G2-LI)
11. Install case (58) to case (62).
a Align matchmarks on case (58) and case (62).
3 Mounting bolt:
98 to 123 Nm {10 to 12.5 kgm}
50-186 GD535-5
(02)
15. Install washer (53) to cage (52), and install the 20. Also install tool K to the opposite side, and insert
cage to case (62). shim pack (50) to tool K.
21. Install both bearing cages (48) and (49) to center
case (73).
16. Set cage (52) to case (62), and tighten mounting

bolts to the specified torque.
3 Cage mounting bolt: 22. Tighten mounting bolts of bearing cages (48) and
98 to 123 Nm {10 to 12.5 kgm} (49) to the specified torque.
3 Mounting bolt:
98 to 123 Nm {10 to 12.5 kgm}
17. Set center case (73) on a block.

18. Raise differential carrier assembly (47), put it in
center case (73), and keep on slinging it.
4 Differential carrier assembly (47): 90 kg
19. Attach tool K, and install shim pack (50).
a Insert the same number and thickness of
shims as those that were removed.
GD535-5 50-187
(02)
Assembly of bevel gear assembly (non-differen- 28. Raise bevel gear assembly (84), put it in center
tial specification) case (73), and keep on slinging it.
23. Use tool AF to press-fit bearing outer races (88b) 4 Bevel gear assembly (84): 50 kg
and (89b) to both bearing cages (85) and 29. Attach tool K, and install shim pack (87).
(86)respectively. a Insert the same number and thickness of
a The figure shows the bearing cage on the right shims as those that were removed.
side.
24. Install bevel gear (91) to cage (84a) by tightening 30. Also install tool K to the opposite side, and insert
12 bolts (90) loosely. shim pack (87) to tool K.
25. Drive in 4 dowel pins (92), and tighten mounting a Insert the same number and thickness of
bolts (90) to the specified torque. shims as those that were removed.
a After driving in the dowel pin, be sure to 31. Install both bearing cages (85) and (86) to center
peen it at 2 places, case (73).
Adhesive (LT-2)
157 to 196 Nm {16 to 20 kgm}
32. Tighten mounting bolts of both bearing cages (85)

and (86) to the specified torque.
26. Use tools AG and AH to press-fit both bearing 3 Mounting bolt:
inner races (88a) and (89a) to bevel gear assembly 98 to 123 Nm {10 to 12.5 kgm}
(84).
27. Set center case (73) on a block.
50-188 GD535-5
(02)
Cage assembly 37. Install coupling (39), shim pack (38), and holder
33. Use tools S and T to press-fit bearing outer races (37) to bevel pinion (40), and tighten mounting bolt
(41a) and (44a) to cage (42). (36).
245 to 309 Nm {25 to 31.5 kgm}
38. Measure the starting torque of the bevel pinion.
34. Use tool U to press-fit bearing (41) to bevel pinion

(40).
Power train oil (TO30) 1) Use tool AE to measure the starting torque of
the bevel pinion at coupling mounting bolt (36).
q Starting torque:
0.8 to 5.8 Nm {0.08 to 0.59 kgm}
a If the starting torque is outside the standard
value, adjust preload of the bearing by
increasing or decreasing shims of shim
pack (38) and re-measure the starting
torque.
Available shims: 0.1-mm, 0.2-mm, 0.5-mm,
and 0.15-mm shims
35. Set bevel pinion (40) on a press stand, install cage

(42) to it.
36. Use tool V to press-fit bearing (44) to bevel pinion
(40).
39. Remove bolt (36), holder (37), shim pack (38), and
coupling (39).
GD535-5 50-189
(02)
42. Install coupling (39), O-ring (74), shim pack (38),

and holder (37) to bevel pinion (40) again, and
tighten mounting bolt (36).
2 Contact surface of coupling and bearing:
Molybdenum disulfide lubricant (LM-P or
LM-CT)
Adhesive (LT-2)
245 to 309 Nm {25 to 31.5 kgm}
40. Use tools W and X to press-fit oil seal (43) to cage

(42).
41. Use tools Y and X to press-fit dust seal (43a) to
cage (42).
2 Part (a):
2 Part (b):
Liquid gasket (LG-I)
43. Raise cage assembly (35), install shim pack (75),

and install it to center case assembly (9).
shims as those of removed ones.
4 Cage assembly (35): 40 kg
3 Mounting bolt:
98 to 123 Nm {10 to 12.5 kgm}
50-190 GD535-5
(02)
Adjusting preload, and testing and adjusting Testing backlash

backlash and tooth contact 47. Use tool AJ to measure backlash of the bevel gear.
44. Perform preload adjustment of taper roller bear- a Standard backlash value: 0.2 to 0.28 mm
ings and backlash and tooth contact adjustments a Measure backlash at 3 places on the circum-
between the bevel gear and bevel pinion ference of the bevel gear.
45. Perform these adjustments so that the starting
torque of the bare bevel pinion is 0.8 to 5.8 Nm
{0.08 to 0.59 kgm}. (It has been already adjusted in
step 38. of "Assembling method of cage
assembly".)
a Perform preload adjustment and backlash and
tooth contact adjustments at a time.
a Measure the torque with bevel gear and bevel
pinion being engaged with each other.
Adjusting preload
46. Use tool AE to measure the starting torque of the
bevel pinion.
a Adjust shims on bearing cage on both sides so
that the starting torque exceeds the starting Adjusting backlash
torque of bare bevel pinion (0.8 to 5.8 Nm 48. If the backlash is out of the standard value, adjust
{0.08 to 0.59 kgm}) as follows. it by moving some shims of either shim pack (50a)
q For differential lock specification: 0.7 to 5.2 or (50b) to that on the opposite side.
Nm {0.07 to 0.53 kgm} a To keep preload of bearings (51a) and (51b)
q For non-differential specification: 1.7 to unchanged, be sure to perform this adjustment
11.1 Nm {0.17 to 1.13 kgm} by only moving shims between shim packs
Available shims: 0.05-mm, 0.1-mm, 0.2-mm, (50a) and (50b) so that the total thickness of
and 0.5-mm shims both shim packs remains unchanged.
a If the backlash is too large, reduce shims of
shim pack (50a) and add shims of same thick-
ness to shim pack (50b).
a If the backlash is too small, reduce shims of
shim pack (50b) and add shims of same thick-
ness to shim pack (50a).
GD535-5 50-191
(02)
Testing tooth contact When bevel pinion is apart from bevel gear
49. Apply a thin film of red lead to the tooth surface of excessively
7 to 8 teeth of the bevel gear. a The tooth contact pattern in this case is shown
50. Rotate the bevel gear in both forward and reverse in the figure.
travel directions, and check the tooth contact 1) Decrease shims of shim pack (75) to move the
patterns left on the bevel gear. bevel pinion in (C) direction.
A: Concave surface 2) Adjust shims between shim packs (50a) and
B: Convex surface (50b) to move the bevel gear in (D) direction.
C: Large end
D: Small end
E: Tooth root
F: Tooth top
g: 22±4 mm
h: 34±4 mm
j: 34±4 mm
k: 22±4 mm
n: 65 mm
When bevel pinion is close to bevel gear exces-

sively
a The tooth contact pattern in this case is shown
in the figure.
1) Increase shims of shim pack (75) to move the
bevel pinion in (E) direction.
2) Adjust shims between shim packs (50a) and
(50b) to move the bevel gear in (F) direction.
Adjusting tooth contact
51. If the tooth contact test shows an incorrect contact
pattern, adjust it according to the following proce-
dure.
a Perform this adjustment by increasing or
decreasing shims of shim packs (50a) and
(50b) (to move the bevel gear) and increasing
or decreasing shims of shim pack (75) (to
move the bevel pinion).
a To keep preload of bearings (51a) and (51b)
unchanged, keep the total thickness of shim
packs (50a) and (50b) unchanged.
a After the tooth contact is completed, test back-
lash again.
50-192 GD535-5
(02)
When bevel gear is close to bevel pinion exces- Tube (for differential lock specification)
sively 52. Install adapter (46a) and nipple (46) to tube (45),
a The tooth contact pattern in this case is shown and install the tube.
in the figure.
1) Decrease shims of shim pack (75) to move the
bevel pinion in (C) direction.
(50b) to move the bevel gear in (D) direction.
Parking brake
53. Install parking brake disc (34).
3 Parking brake disc mounting bolt:
98 to 123 Nm {10 to 12.5 kgm}
2 Mounting bolt:
When bevel gear is apart from bevel pinion Adhesive (LT-2)

excessively
a The tooth contact pattern in this case is shown
in the figure.
1) Increase shims of shim pack (75) to move the
bevel pinion in (E) direction.
(50b) to move the bevel gear in (F) direction.
GD535-5 50-193
(02)
Disassembly and assembly of final drive assembly 50 Disassembly and assembly
Disassembly and assembly of final Cover assembly (for machines without differential
drive assembly 1
lock)
5. Remove cover assembly (85).
Tools fr disassembly and assembly of final drive
assembly
New/Redesign
Necessity
Sketch
Sym-
Q'ty
Part No. Part name
bol
A - Spacer t 1
B 790-201-2860 Spacer t 2
C 790-101-5700 Gear puller q 1
D - Push tool t 1
E 799-501-1120 Pin t 1 Side case assembly
F 790-445-5980 Guide bar t 1 6. Remove bolts (5) and (6), and remove side case
assemblies (7) and (8) from center case assembly
Z - Plate t 1
(9).
790-101-5221 Grip t 1 a When removing side case assembly (7), be
AA 790-101-5341 Plate t 1 sure do so laterally so that it does not damage
01010-51225 Bolt t 1 the tooth surfaces of sun gear shaft (84), etc.
AB 790-201-2870 Push tool t 1
AC 794T-420-1140 Spacer t 1
AD - Block t 2
k Thoroughly clean the parts completely and

inspect them for any foreign substances or
damage. Apply power train oil (TO30 or equiv-
alent) to the sliding surface before assem-
bling.
Disassembly
Cover assembly (differential lock specification) 7. Raise side case assembly (7), and set it on tool AD
1. Remove filter assembly (82) and filter assembly with its sprocket side down.
mounting bracket (82a). 4 Side case assembly (7): 290 kg
2. Disconnect hose (1), and remove differential lock
solenoid valve assembly (2).
3. Disconnect strainer assembly (3) and hose (3a).
4. Remove cover assembly (4).
8. Remove mounting bolt (10).

a Leave holder (11) in carrier assembly (12).
50-194 GD535-5
(02)
50 Disassembly and assembly Disassembly and assembly of final drive assembly
9. Raise planetary carrier assembly (12) at parts (a)

to remove it. 14. Remove bolts (20), and remove plate (21) and
shim pack (22).
used.
15. Remove washer (23).
16. Remove plug (27a).
10. Reverse side case assembly (7) so that it lies with

the sprocket side up.
11. Remove mounting bolt (15), and remove holder
(16) and shim pack (17).
used.
12. Remove sprockets (18) and (19).
17. Use tools A and B to remove bearing (28) from
shaft (24).
remove by fusing.
13. Remove shaft (24) by using a press.

a Take care not to drop the shaft on the floor
when it comes off.
18. Remove bearing (25).

19. Lift flange (27) to remove it from side case (26).
4 Flange (27): 60 kg
GD535-5 50-195
(02)
20. Remove oil seal (29). 24. Remove seal (30) from flange (27).
21. Remove bearing outer races (25a) and (28a) from 25. Disassemble the side case assembly on the oppo-
side case (26). site side similarly.
22. Remove bushings (31) and (32) as well as washer
(33) from side case (26).
Planetary carrier assembly

26. Use tool E to drive in spring pin (79) of planetary
23. Using tools C and D, pull up ring gear (14) evenly carrier assembly (12) so that it does not break
to remove it from side case assembly (7). through shaft (80).
a Attach tool D to top end of tool C to adjust a Take care not to drive in the spring pin exces-
height. sively.
a Take care not to allow the claws of tool C to
detach from the ring gear.
50-196 GD535-5
(02)
27. Use tool F to pull out shaft (80). Assembly

a When pulling out shaft (80), be sure to place a Clean all parts, and check them for dirt or damage
planetary carrier assembly (12) on a flat floor before installation.
with its spline side up. a Apply power train oil (TO30) to the sliding surface.
Side case assembly

1. Press-fit ring gear (14) to side case (26), and drive
in pin (13).
a Be sure to align pin holes in side case (26) and
ring gear (14).
a Press-fit ring gear (14) horizontally so that it
does not tilt.
28. Remove gear (81) from planetary carrier assembly

(12).
a Be sure to remove holder (11) left in planetary
carrier assembly (12).
29. Remove bearing (81a) from gear (81).
2. Install washer (33) and bushings (32) and (31) to

side case (26).
2 Both faces of bushing and washer:
Molybdenum disulfide lubricant (LM-P)
a Install bushings (31) and (32) with their slits (E)

and (F) facing directions shown in the figure.
q Slit (E) of bushing (31): Install the bushing
so that the slit faces the upper side of the
machine.
q Slit (F) of bushing (32): Install the bushing
so that the slit faces the under side of the
machine.
GD535-5 50-197
(02)
4. Use tool AA to press-fit oil seal (29) to side case

(26).
a Align the surface of side case (26) with part (d)
of oil seal (29).
2 Part (c):
Liquid gasket (SEALEND 242)
2 80% of oil seal lip space:
Grease (G2-LI)
5. Use tool AB to press-fit bearing outer races (25a)
and (28a) to side case (26).
a Install washer (33) with its larger chamfered

inner diameter face down.
3. Use tool Z to press-fit seal (30) to flange (27).

2 Press-fitted part of oil seal:
Adhesive (Loctite No. 648)
2 50 % of oil seal lip space:
Grease (G2-LI)
6. Raise flange (27) to install it to side case (26).
50-198 GD535-5
(02)
Planetary carrier assembly 10. While aligning holes for spring pin (79) in shaft
7. Press-fit bearing (28) to shaft (24). (80), use tool E to drive in spring pin (79) so that it
a Place the shaft with its planetary carrier side is flush (j) with carrier (78).
(shorter spline length side) up, and press-fit
the bearing to dimension (L).
Dimension (L): 60 ± 2 mm
11. Tap the end face of shaft (80) and the differential
side of gear (81) to push back bearing (83), and
check that gear (81) can rotate lightly.
8. After temporarily placing holder (11) in planetary
carrier (12), install bearing (83) to gear (81), and
install the gear to planetary carrier (12).
12. Install planetary carrier assembly (12) to shaft (24),

press-fit bearing (28) while tightening mounting
bolt (10).
9. Press-fit shafts (80) to planetary carrier (78) while 2 Mounting bolt:
aligning their spring pin holes (79a) in shaft (80). Adhesive (LT-2)
2 Shaft: 3 Mounting bolt:
Power train oil (TO30) 245 to 309 Nm {25 to 315 kgm}
GD535-5 50-199
(02)
13. Install shaft assembly (24) with the planetary 16. Install shim pack (22) and plate (21), and tighten
carrier to side case assembly (7), and press-fit bolts (20).
bearing (25) to the shaft. a Measure the step dimension (b) between
2 Rollers of bearings (25) and (28): washer (23) on the flange (27) and side case
Power train oil (TO30) (26), determine thickness of shim pack (22)
14. Install plug (27a). depending on the dimension, and install shims
2 Plug (27a): as follows.
Liquid gasket (LG-5) q Thickness of shim pack: (b + 0.1) mm
3 Plug (27a): q Available shims: 0.1-mm, 0.2-mm, and
9.8 to 12.7 Nm {1.0 to 1.3 kgm} 0.5-mm shims
q Be sure to measure dimension (b) after install-
ing plate (21) temporarily.
15. Install washer (23) to side case assembly (7).

2 Both faces of washer:
a Install the washer with its chamfered part set

as shown in the figure.
50-200 GD535-5
(02)
17. Install sprockets (19) and (18). 24. After adjusting bearing preload, tighten mounting
18. Install shim pack (17) and holder (16), and then bolt (15) again.
tighten mounting bolt (15). 2 Mounting bolt (15):
a Insert the same number and thickness of Adhesive (LT-2)
shims as those of removed ones. 3 Mounting bolt (15):
2 Mounting bolt (15): 245 to 309 Nm {24 to 31.5 kgm}
Adhesive (LT-2)
3 Mounting bolt (15): 25. Put shaft (84) in center case assembly (9).
245 to 309 Nm {25 to 31.5 kgm} a Insert the sun gear shaft into;
q The gear within the differential carrier
assembly for differential lock specification
q Cage in the bevel gear assembly for non-
differential specification
Adjusting preload
19. Tighten mounting bolt (15) so that the starting
torque is as follows with shim pack (17) for bearing
preload adjustment removed.
q Starting torque:
0.8 to 5.0 Nm {0.08 to 0.51 kgm}
20. Rotate bearings (25) and (28) 3 to 4 turns for run- 26. Raise side case assemblies (7) and (8) horizon-
in operation.
2 Rollers of bearings (25) and (28):
tally, install them gently to center case assembly
(9) while aligning them with tooth grooves of sun
Power train oil (TO30) gear shaft (84), and tighten mounting bolts (5) and
21. Repeat steps 18 and 19 until starting torque stabi-
(6).
4 Side case assemblies (7) and (8): 290 kg
lizes.
2 Contact faces of side case and center
22. Fit shim pack (17) of the same thickness as that of
removed one, and tighten mounting bolt (15).
case:
Adhesive (Loctite No. 515)
27. Tighten mounting bolts (5) and (6) of side case
assemblies (7) and (8) diagonally.
3 Mounting bolts (5) and (6):
490 to 608 Nm {50 to 62 kgm}
23. Measure starting torque and check that it is within

the following torque range.
q Starting torque:
0.8 to 5.0 Nm {0.08 to 0.51 kgm}
a If the starting torque is outside the standard
value, adjust preload of the bearing by increas-
ing or decreasing shims of shim pack (17) and
re-measure the starting torque.
Available shims: 0.05-mm, 0.2-mm, 0.3-mm,
and 0.8-mm shims
GD535-5 50-201
(02)
Cover assembly (for differential lock specifica-

tion)
28. Install cover assembly (4).
2 Contact faces of center case and cover
assembly:
Adhesive (LG-8)
29. Install strainer (3).
30. Install filter assembly (82) and filter assembly
mounting bracket (82a).
31. Install differential lock solenoid valve assembly (2),

and connect hoses (1) and (3a).
a Apply adhesive to contact faces of the side
case, center case, and cover assembly (4) as
shown in the figure.
Cover assembly (non-differential specification)

32. Install cover assembly (85).
a Apply adhesive to contact faces of the side

case, center case, and cover assembly (4) as
shown in the figure.
50-202 GD535-5
(02)
50 Disassembly and assembly Removal and installation of Orbitrol valve assembly
Steering system 1
Removal and installation of Orbitrol

valve assembly 1
Removal
6. Remove bolts (7) (3 pieces), and remove cover (8).
OFF position.
[*2]
7. Remove cable tie (9).

2. Remove floor mat (2).

3. Remove the machine monitor assembly. For
details, see "Removal and installation of machine
monitor assembly".
9. Disconnect connectors FP7 (12) and FP4 (13).

10. Disconnect ground cable (14).
11. Disconnect connectors FP8 (15) and FP9 (16).
12. Disconnect 2 cable ties (17).
4. Remove cover (3) and needle (4).

5. Remove nut (5), and remove steering wheel (6).
[*1]
GD535-5 50-203
(02)
Removal and installation of Orbitrol valve assembly 50 Disassembly and assembly
13. Loosen 2 bolts (18), and remove turn signal switch

(19).
14. Remove bolts (20) (2 pieces), and remove bracket

(21).
15. Depress tilt pedal (22) to tilt steering column (23)

fully in the direction of the arrow.

(28). [*4]
16. Remove right and left joint bolts (24) and (25). [*3]
a Subsequent tasks must be carried out as part
of group work by two technicians.
a When right and left joint bolts (26) and (27) are
removed, the mounting bracket for the steering
valve assembly and the steering post are
detached simultaneously. Thus, one of the two
technicians must support the steering valve
assembly.
a When removing right and left joint bolts (26)
and (27), take care not to lose washer (28).
50-204 GD535-5
(02)
18. Remove bolts (29) (2 pieces), and remove cover 22. Remove nut (36) and screw (37).
(30).
19. Remove bolts (31) (2 pieces), and remove cover
(32).
23. Remove the cotter pin and nut (38).

24. Remove pin (39).
20. Remove 2 clamps (33). 25. Remove knob (40), and remove bolt (41).
21. Remove gas damper (35) from steering post (34). 26. Raise case (42) to provide clearance between it
[*5] and steering post (34).
a Lock the gas damper by using a wire, etc. so
that it does not extend.
GD535-5 50-205
(02)
Removal and installation of Orbitrol valve assembly 50 Disassembly and assembly
27. Pull out steering post (34) in the direction of the

arrow.
33. Remove right joint bolt (25) that has been tempo-
rarily inserted, and remove Orbitrol valve and
28. Temporarily insert right joint bolt (25) to support the bracket assembly (48).
mounting bolt of the steering valve. a Be sure to support the Orbitrol valve and
bracket assembly (48) when removing joint
bolt (25).
29. Disconnect hoses (43) and (44).

q Tape color of hose (43): Brown
q Tape color of hose (44): Gray 34. Remove 2 bolts (49), and remove Orbitrol valve
30. Remove 2 adapters (45). [*6] assembly (51) from bracket (50). [*8]
31. Disconnect hoses (46), (47) and (48).

q Tape color of hose (46): White
q Tape color of hose (47): White
q Tape color of hose (48): Orange
32. Remove adapter (49) and 2 adapters (50). [*7]
50-206 GD535-5
(02)
Installation
removal.
[*1]
3 Nut (5):
29.4±2.9 Nm {3.0±0.3 kgm}
[*2]
3 Bolt (7):
13.7 to 25.5 Nm {1.4 to 2.6 kgm}
[*3]
2 Joint bolts (24) and (25):
Adhesive (LT-2)
3 Joint bolts (24) and (25):
235 to 285 Nm {23.5 to 29.5 kgm}
[*4]
3 Bolt (27):
59 to 74 Nm {6.0 to 7.5 kgm}
[*5]
2 Mounting pin for gas damper (35):
Grease (G2-LI)
[*6]
3 Adapter (45):
45.1 to 83.3 Nm {4.6 to 8.5 kgm}
[*7]
3 Adapter (50):
13.7 to 25.5 Nm {1.4 to 2.6 kgm}
3 Adapter (50):
45.1 to 83.3 Nm {4.6 to 8.5 kgm}
[*8]
3 Bolt (49):
59 to 74 Nm {6.0 to 7.5 kgm}
GD535-5 50-207
(02)
Disassembly and assembly of wheel brake assembly 50 Disassembly and assembly
Brake system 1
Disassembly
Sprocket and cage
Disassembly and assembly of 1. Remove bolts (34), and remove plate (19) from
wheel brake assembly 1
cage (13).
Special tools
New/Redesign
Necessity
Symbol
Sketch
Q'ty
Part No. Part name
790-101-2510 Block t 1
790-501-2520 Screw t 1
791-112-1180 Nut t 1
790-101-2540 Washer t 1
A 2. Remove mounting bolt (1).
790-101-2610 Leg t 2
3. Remove holder (2), shim pack (3), and sprocket
790-101-2560 Nut t 2 (4).
790-101-2570 Plate t 4 a Check and note down thickness and the num-
790-101-3101 Bearing puller t 1 ber of shims of shim pack (3).
4. Use tool R to remove cage (5).
B 790-201-1410 Plate t 1
C - Push tool t 1
D 793T-615-1710 Spacer t 1 ○
E 790-201-2310 Plate t 1
790-101-5531 Plate t 1
F 790-101-5421 Grip t 1
01010-81240 Bolt t 1
G 790-201-2280 Plate t 1
H 790-201-2850 Spacer t 1
J - Push tool t 1
K 799-401-3300 Adapter assembly t 1
L 02789-00422 Nut t 1
799-101-5220 Nipple t 1
N
07002-11023 O-ring t 1
M 790-190-1500 Pump assembly t 1
P 799-401-2320 Gauge t 1
Q - Push-pull gauge t 1
R 790-201-3290 Bolt t 4
50-208 GD535-5
(02)
50 Disassembly and assembly Disassembly and assembly of wheel brake assembly
5. Remove outer race (5b). 9. Remove collar (11).

10. Remove cage (13) from shaft (12).
Brake piston and brake disc

6. Remove 6 brake plates (6) and 5 brake discs (7). 11. Use tools A and B to remove bearing (14) from
shaft (12).
remove by fusing.
Gear and shaft

7. Remove snap ring (9).
8. Remove gear (10).
12. Remove cover (19) and sleeve (20) from shaft (12).
GD535-5 50-209
(02)
Guide and spring Sleeve

13. Remove 6 guides (17), 6 washers (38), and 6 16. Remove washer (37) from cage (13).
springs (18).
17. Remove oil seal (21) and outer race (22).

Piston
14. Remove piston (16) from cage (13).
Disc wear gauge

18. Remove disc wear gauge (23).
15. Remove D-ring (24) from piston (16).
50-210 GD535-5
(02)
Assembly Brake piston, guide, and brake spring

a Clean all parts, and check them for dirt or damage 6. Install D-rings (24) to brake piston (16).
before installation. 2 D-ring and groove in piston:
Shaft Grease (G2-LI)
1. Install cover (19) to shaft (12) in advance, and use
tools D and J to press-fit sleeve (20).
a Make end faces of sleeve (20) and shaft (12)
contact with each other.
2 Sleeve mounting surface:
Power train oil (TO30) or molybdenum disul-
fide lubricant
7. Set washer (37) on cage (13).

2 D-ring sliding surface:
Grease (G2-LI)
2. Use tools C and D to press-fit bearing (14).

2 Bearing:
Seal and cage assembly

3. Use tool E to install outer race (22) to cage (13).
4. Use tool F to press-fit oil seal (21).
5. Fill part (a) with grease.
2 Part (a):
Grease (G2-LI)
GD535-5 50-211
(02)
8. Install brake piston (16) to cage (13). Gear

2 Piston insertion part inside cage: 13. Install gear (10).
Grease (G2-LI) 14. Install snap ring (9).
9. Install washers (38) to guides (17), and install Brake plate and brake disc
brake springs (18). 15. Install 6 brake plates (6) and 5 brake discs (7) alter-
q Installed height of brake spring: 60.5 mm nately.
q Free height of brake spring: 76.5 mm a Apply oil to both faces of brake disc (7).
q Load at installed length of brake spring: 735 2 Brake disc (7):
Nm {75 kg} Power train oil (TO30)
10. Tighten guides (17).

2 Threaded part of guide (17):
Adhesive (LT-2)
3 Guide (17):
49±7.4 Nm {5±0.75 kgm}
16. Use tool G to press-fit outer race (5b) to cage (5).
Cage
11. Install cage (13) to shaft (12).
12. Install collar (11).
50-212 GD535-5
(02)
Cage Sprocket
17. Install O-ring (23) to cage (5), and install cage (5) 19. Install sprocket (4).
to cage (13) by using mounting bolts (5c). a Installed direction of sprocket (4) differs
3 Mounting bolt (5c): between front and rear sprockets. The figure
147 to 196 Nm {15 to 20 kgm} shown below is for the front one.
Adjusting preload
20. Use tool Q to measure drag turning starting torque
(A) of the shaft.
21. Install shim pack (3) and holder (2), and install
mounting bolt (1).
Min. 203 Nm {21.0 kgm}
shims as those of removed ones.
18. Use tool H to press-fit bearing (5a).

a Do not impose preload on the bearing.
2 Bearing:
22. Adjust preload of both bearings by adjusting shim

pack (3) so that the preload is "Drag turning
starting torque (A) measured in step 20 + 2.94 to
7.35 Nm {0.30 to 0.75 kgm}".
23. After adjusting bearing preload, tighten holder
mounting bolt (1) again.
Adhesive (LT-2)
490 to 608 Nm {50 to 62 kgm}
GD535-5 50-213
(02)
Plate 27. Connect the hose of tool M to tool N.

24. Install plate (19) to cage (13).
59 to 74 Nm {6 to 7.5 kgm}
Testing oil leakage under low pressure

28. Operate tool M to apply a pressure of 0.10 MPa {1
kg/cm2}.
Testing airtightness of brake a Replace only the gauge with tool P for the test-
25. Install tool K to elbow (a). ing.
a Perform this testing after bleeding air from the
cylinder.
Criteria: Start the measurement 2 minutes after
the hydraulic oil piping is blocked and check that
the pressure drop over 5 minutes is zero.
a Do not move testing hoses to prevent pressure
fluctuation.
a If a pressure drop is observed, disassemble
the assembly again and check for the cause.
Testing oil leakage under high pressure
29. Operate tool M to apply a pressure of 4.3 MPa {44
kg/cm2}.
26. Install tools L and N to tool K. a Perform this testing after bleeding air from the
cylinder.
Criteria: Start the measurement 1 minute after the
hydraulic oil piping is blocked and check that the
pressure drop over 5 minutes is 0.10 MPa {1 kg/
cm2} or below.
a Do not move testing hoses to prevent pressure
fluctuation.
a If the pressure drop exceeds the standard
value, disassemble the assembly again and
check for the cause.
50-214 GD535-5
(02)
Adjusting disc wear gauge

a When the brake disc is replaced with a new one,
adjust the disc wear gauge according to the fol-
lowing procedure.
a The disc wear gauge for the brake disc need to be
set for new parts as the basis for measurement.
30. Remove cap (30) of the disc wear gauge.
35. Loosen nut (31).

36. Apply pin (32) to piston (16) to adjust dimension (a)
between end faces of the pin and guide (33) so that
the dimension reaches the value shown below,
and then tighten nut (31).
Dimension (a): 1.5 (0/-0.2) mm
3 Nut (31):
31. Install tool K to elbow (a). 49 to 63.7 Nm {5 to 6.5 kgm}
32. Install tools L and N to tool K.

37. Tighten cap (30).
3 Cap (30):
29.4 to 39.2 Nm {3 to 4 kgm}
33. Connect the hose of tool M to tool L.

34. Operate tool M to actuate the wheel brake.
a Hold this condition until this adjustment is com-
pleted.
a Wheel brake operating pressure:
4.3±0.4 MPa {44±4 kg/cm2}
GD535-5 50-215
(02)
Removal and installation of center hinge pin 50 Disassembly and assembly
Undercarriage and frame 1 1) Disconnect head-side hose (3) and bottom-side

hose (4) from articulate cylinder (2).
Removal and installation of center
hinge pin 1
Special tools
New/Redesign
Necessity
Sketch
Sym-
Q'ty
Part No. Part name
bol
1 794T-646-1010 Push tool ■ 1 ○

2 794T-646-1021 Push tool ● 1 N ○
K Puller (294 kN
3 790-101-2102
{30 ton}) ■ 1
4 790-101-1102 Pump ■ 1

OFF position.
installed, disconnect the cable from the bat- 2) Pull out rod-side pin (5) of articulate cylinder
tery negative (-) terminal.) (2).
a Write down the installed positions of the hoses a Turn the rod side of the articulate cylinder
and wires so that they are not re-installed incor- to the front side and secure it.
rectly.
a Prepare an oil container in order to receive oil out-
flow when the hydraulic hoses and tubes are dis-
connected.
a Plug the disconnected hoses and tubes to prevent
oil from flowing out.
Removal
3) Remove clamp (6), and remove 10 hoses (7).

a Write down their installed positions by
using their hose tape colors.
a Move the hoses (5 brake hoses) that were
disconnected in previous steps to the side
of the rear frame.
2. Remove the operator’s cab and frame assembly.

For details, see "Removal and installation of
operator’s cab and floor frame assembly".
3. Perform removal of following parts from the right-
hand side of the machine.
50-216 GD535-5
(02)
50 Disassembly and assembly Removal and installation of center hinge pin
8) Disconnect drain hose (15) from block (13)

under the work equipment valve.
a Remove the disconnected hoses from the
front frame and move them to the side of
the rear frame.
4) Disconnect connector FL9 (8).

5) Remove bolt (9), and remove right front
working lamp (10).
9) Disconnect hoses (15a) and (15b).
6) Remove clamps (11) and (12), and disconnect

the hoses.
4. Perform removal of the following parts from the left
side of the machine.
1) Remove 2 clamps (16a).
7) Remove 4 clamps (12a).
GD535-5 50-217
(02)
2) Disconnect hose (17) under the work equip-

ment valve from block (16).
the rear frame.
5) Pull out rod-side pin (24) of articulate cylinder

(21).
a Turn the rod side of the articulate cylinder
to the front side and secure it.
3) Disconnect hoses (18) and (19) from bank pin

(20).
the rear frame.
6) Remove clamp (25), and remove 2 wiring

harnesses (26) and remove 7 hoses (27) and
(28).
a Move 2 hoses that were disconnected in
4) Disconnect bottom-side hose (22) and head- previous steps to the side of the rear frame.
side hose (23) from articulate cylinder (21).
50-218 GD535-5
(02)
7) Disconnect hoses (29) and (30).

the rear frame.
12)Remove 2 bolts (36), then remove articulate

sensor cover (37).
8) Disconnect connector FL10 (31) and remove it

from the connector mounting.
9) Remove bolt (32), and remove left front working
lamp (33).
13)Disconnect rod (38) of the articulate sensor.

[*1]
a Write down the pin-to-pin dimension of the
rod.
10)Remove 5 clamps (34).
11)Disconnect hoses (35) and (35a) from ports B9

and A9 of the control valve respectively.
the rear frame.
GD535-5 50-219
(02)
5. Remove the center hinge pin according to the 4) Set 2 jack [3] (294 kN {30 ton}) to the front of the
following procedure. rear frame.
1) Check that both front wheels are chocked using
chock [1].
5) Sling the rear of the front frame (39) by using

sling [4].
2) Remove frame lock pin (1).
6) Remove 6 bolts (60) and 4 bolts (61) from the

lower hinge bottom of the rear frame.
3) Set jack [2] (490 kN {50 ton}) to the rear of the
rear frame.
7) Remove cover (62) and shim pack (63).

a Write down the thickness and the number
of shims used.
50-220 GD535-5
(02)
9) Use jack [5] (98 kN {10 ton}) to remove lower

hinge pin (65).
a If the spacer cannot be removed because
of displacement of front and rear frames,
perform fine adjustment of their positions
by using jacks [2] and [3], or using sling [4].
8) Remove spacer (64).

a A spacer inserted into each hinge to join
the rear and front frames needs to be
removed for separation of front and rear
frames.
10)Remove lock bolt (67) for upper hinge pin (66).
11)Use jack [6] (98 kN {10 ton}) to remove the

upper hinge pin.
GD535-5 50-221
(02)
12)Remove chocks [1] set to both front wheels. 2) Remove 10 bolts (70), and remove retainer (71)
and shim pack (72).
a Write down the thickness and the number
of shims used.
3) Remove dust seal (73) from retainer (71).
4) Remove bearing (74) and dust seal (75).
13)While slinging the rear of front frame (39), pull

front frame (39) in the direction of the arrow
(forward) to separate it from rear frame (68).
7. Disassemble the front frame upper hinge

1) Remove dust seals (76) and (77).
2) Remove bushing (78).
6. Disassemble the front frame lower hinge according

1) Remove spacer (69) from the top.
50-222 GD535-5
(02)
8. Disassemble the rear frame upper hinge according Installation

to the following procedure. 1. Assemble the rear frame upper hinge according to
1) Remove 2 bushings (79) and (80). the following procedure.
1) Press-fit 2 bushings (80) and (79).
2 Inner surface of bushing (pin contact
surface): Grease (G2-T)
2. Assemble the front frame upper hinge according to

1) Press-fit bushing (78).
2 Inner surface of bushing (pin contact sur-
face): Grease (G2-T)
2) Install dust seals (77) and (76).
3. Assemble the front frame lower hinge according to

1) Press-fit bearing outer race (74A) in the front
frame lower hinge by using tool K2 and 2
retainer bolts (70).
a Since the clearance of the bearing and
spacer is adjusted, do not change the com-
bination.
GD535-5 50-223
(02)
2) Remove tool K2, install bearing inner race 7) Fit dust seal (75) to the top of the front frame
(74B), and press-fit bearing outer race (74C) by lower hinge, and insert spacer (69).
using tools K1 and K3. a Insert the spacer with its tapered part
2 Inner surface of bushing (pin contact downward.
surface): 2 Inner surface of bushing (pin contact sur-
Grease (G2-T) face): Grease (G2-T)
3) Loosely install retainer (71) with dust seal (73)

to the front frame lower hinge by using 3
mounting bolts (70).
a Arrange 3 mounting bolts at intervals of
"108, 108, and 144 degrees" and tighten
them evenly.
3 Mounting bolt: 20±2 Nm {2.0±0.2 kgm}
4) Measure clearance (a) between front frame
lower hinge (59A) and retainer (71).
5) Select shims (72) so that clearance (a) reaches
the standard value.
a Standard value of clearance (a): Max. 0.1
mm
4. Assemble the center hinge pin according to the
a Available shims: 0.1-mm and 0.5-mm
shims
1) Attach a lever block [7] to front frame (59) and
6) Loosen 3 bolts (70) used to loosely install
rear frame (68) on each side, and use them to
retainer (71), insert selected shims (72), and
pull front frame (59) toward rear frame (68) so
install retainer (71) by tightening 10 bolts (70) to
that the center locations of front and rear
the specified torque.
frames are aligned with each other.
a Standard thickness of shim pack: 2.5 mm
3 Mounting bolt:
98 to 123 Nm {10 to 12.5 kgm}
50-224 GD535-5
(02)
2) Insert spacer (64) into the rear frame lower

hinge from the bottom. 4) Loosely install cover (62) to rear frame hinge
a Insert the spacer with its tapered part (68A) from the bottom by using 4 bolts (61) with
upward. washer.
a A spacer is inserted into each hinge to join 3 Mounting bolt: 20±2 Nm {2.0±0.2 kgm}
rear and front frames. 5) Measure clearance (b) between rear frame
a If the spacer cannot be inserted because of lower hinge (68A) and cover (62).
displacement of front and rear frames, per- a Select 3 holes from among 6 mounting bolt
form fine adjustment of their positions by holes as a measuring location.
using jacks [2] and [3], or using sling [4].
6) Select shims (63) so that clearance (b) reaches
the standard value.
a Standard value of clearance (b): Max. 0.2
mm
a Available shims: 0.2-mm, 0.5-mm and 1.0-
mm shims
7) Loosen 4 bolts (61) used to loosely install cover
(62), insert selected shims (63), and tighten 6
bolts (60) to the specified torque.
a Standard thickness of shim pack: 2.5 mm
2 Bolt (60): Adhesive (LT-2)
3 Bolt (60):
98 to 123 Nm {10 to 12.5 kgm}
8) Tighten 4 bolts (61) to the specified torque.
2 Bolt (61): Adhesive (LT-2)
3) Use jack [5] (98 kN {10 ton}) to insert lower 3 Bolt (61): 206±20 Nm {21±2 kgm}
hinge pin (65) from the top.
a If the spacer cannot be inserted because of
displacement of front and rear frames, per-
form fine adjustment of their positions by
2 Outer surface of lower hinge pin:
Grease (G2-T)
9) Insert upper hinge pin (66) from the top.

a If the spacer cannot be inserted because of
displacement of front and rear frames, per-
form fine adjustment of their positions by
2 Outer surface of upper hinge pin:
Grease (G2-T)
GD535-5 50-225
(02)
10)Install lock bolt (67) for upper hinge pin (66).

order of removal.
[*1]
a Adjust it. For details, see Testing and adjusting,
"Adjustment (Zero Point Adjustment For Art
Angle".
a Pin-to-pin dimension (d) of rod (38): 241 mm
(standard value)
q Bleeding air (steering circuit)

Bleed air from the steering circuit. For details, see
Testing and adjusting, "Bleeding air from steering
circuit".
50-226 GD535-5
(02)
50 Disassembly and assembly Removal and installation of hydraulic tank, battery, and frame assembly
Hydraulic system 1
4. Loosen drain valve (3) and drain the hydraulic oil.
Removal and installation of hydraulic (3).
tank, battery, and frame assembly 1 6 Hydraulic oil: 51.5 l
Removal
OFF position.
so as to release the pressure remaining inside.
tions before disconnecting wiring and hoses, and 5. Remove 6 bolts (4a), and remove cover (4).
write them down.
connected.
6. Remove 6 bolts (5a), and remove cover (5) above

the battery.

assembly".
3. Remove 6 bolts (2a), and remove cover (2). (On
the right side of the machine)
GD535-5 50-227
(02)
Removal and installation of hydraulic tank, battery, and frame assembly 50 Disassembly and assembly
7. Remove 4 bolts (5b), and remove cover (5c). 11. Remove 6 bolts (9a), and remove cover (9).
13. Remove 2 bolts (11a) and move strainer (11) aside

so that it does not hinder work activities.
50-228 GD535-5
(02)
14. Remove clamps (15). 18. Remove 4 bolts (16a), and remove fuel prefilter
(16) and the bracket as a unit.
a Fix fuel prefilter (16) so that it does not hinder
work activities.
15. Remove 2 bolts (12a), and disconnect tube (12)

from the hydraulic tank.
19. Remove bolt (18b), and disconnect bracket (18c)

from frame (14).
20. Remove 4 bolts (18a), and disconnect suction tube
(18) from the hydraulic tank.
16. Remove clamps (17).
17. Remove 2 bolts (13a) and remove bracket (13)

from frame (14).
GD535-5 50-229
(02)
24. Strip off 2 rubber covers (20a).
21. Remove bolt (19a), and remove 4 clamps (19b).

25. Disconnect cables from 2 terminals (20b).
22. Remove clamp (19c), and disconnect connectors

R15 (19d) and R16 (19e). 26. Remove bolt (20c), and remove slow-blow fuse
(20d).
27. Remove 2 bolts (21a), and move bracket (21) and

23. Disconnect connectors R18(19f) and R19(19g).
wiring harness as a unit aside so that it does not
hinder work activities.
50-230 GD535-5
(02)
28. Remove 3 clamps (22). 32. Move wiring harness (25) aside so that it does not

30. Move wiring harness (24) aside so that it does not 33. Remove 2 clamps (26).
34. Remove 2 bolts (27a) and move transmission filter

(28) and bracket (27) as a unit aside so that it does
not hinder work activities.
31. Remove 3 clamps (25a), and disconnect the cable

from terminal (25b).
GD535-5 50-231
(02)
35. Remove 2 bolts (29a), and disconnect bracket (29) 39. Attach sling [1] to lifting point (a), and sling accu-
from frame (14). mulator (34).
40. Remove 5 bolts (34a) and secure accumulator (34)
to the canopy side so that it does not hinder work
activities.
36. Remove clamp (30a), and disconnect hose (30)

37. Remove 2 bolts (31a), and disconnect hose (31)
38. Remove clamps (32) and (33).
41. Attach sling [2] to lifting points (b), and sling

hydraulic tank, battery, and frame assembly (35).
50-232 GD535-5
(02)
Installation
removal.
[*1]
3 Bolt (35a):
235 to 285 Nm {23.5 to 29.5 kgm}

Refill the hydraulic tank with genuine Komatsu oil
a After the recheck, add genuine Komatsu oil if
the oil level is low.
5 Hydraulic oil: 51.5 l

circuit".
42. Remove 8 bolts (35a), and raise hydraulic tank,

battery, and frame assembly (35) to remove it.
[*1]
4 Hydraulic tank, battery, and frame assem-
bly (35):
260 kg
GD535-5 50-233
(02)
Removal and installation of hydraulic tank assembly 50 Disassembly and assembly
Removal and installation of 4. Loosen drain valve (3), and drain the hydraulic oil.
hydraulic tank assembly 1
Removal (3).
OFF position.
tions before disconnecting wiring and hoses, and
write them down. 5. Remove 6 bolts (4a), and remove cover (4). (On
a Prepare an oil container in order to receive oil out- the left side of the machine)
connected.
6. Remove 6 bolts (5a), and remove cover (5) above

the battery.

assembly".
3. Remove 6 bolts (2a), and remove cover (2). (On
the right side of the machine)
50-234 GD535-5
(02)
50 Disassembly and assembly Removal and installation of hydraulic tank assembly
7. Remove 4 bolts (5b), and remove cover (5c). 11. Remove 6 bolts (9a), and remove cover (9).
13. Remove 2 bolts (11a) and move strainer (11) aside

so that it does not hinder work activities.
GD535-5 50-235
(02)
Removal and installation of hydraulic tank assembly 50 Disassembly and assembly
14. Remove 2 bolts (12a), and disconnect tube (12) 17. Remove clamp (14a), and disconnect hose (14)
from the hydraulic tank. from the hydraulic tank.
18. Remove 2 bolts (15a), and disconnect hose (15)
15. Remove bolt (13b), and disconnect bracket (13c)

from frame (13d).
16. Remove 4 bolts (13a), and disconnect suction tube 19. Attach sling to lifting point (a), and sling hydraulic
(13) from the hydraulic tank. tank assembly (16).
20. Remove 4 bolts (16a), and raise hydraulic tank

assembly (16) to remove it.
4 Hydraulic tank assembly (16): 90 kg
50-236 GD535-5
(02)
50 Disassembly and assembly Removal and installation of hydraulic tank assembly
Installation
removal.
q Refilling (hydraulic tank)


circuit".
GD535-5 50-237
(02)
Removal and installation of control valve assembly 50 Disassembly and assembly
Removal and installation of control

valve assembly 1

OFF position.
4. Remove 4 bolts (4), 6 bolts (5), and remove cover
(6).
a Write down installed positions of hoses so that
they are not re-installed incorrectly.
connected.
a Plug the disconnected hoses to prevent oil from
flowing out.
Removal

2. Open cover (2).
3. Loosen drain plug (3), and drain the hydraulic oil

through drain valve (3) on the hydraulic tank.
50-238 GD535-5
(02)
50 Disassembly and assembly Removal and installation of control valve assembly
6. Remove 3 bolts (9), and remove cover (10). q Hose (18): Port A1 (tape color: red)
q Hose (19): Port A2 (tape color: blue)
q Hose (20): Port A3 (tape color: green)
q Hose (21): Port A4 (tape color: white)
q Hose (22): Port A5 (tape color: white)
a Hose (22) is installed only to machines with
power tilt.
7. Remove 8 nuts (11) and disconnect 8 rods (12).

a For machines with power tilt, remove nut (11a)
and disconnect rod (12a). [*2]

q Hose (24): Port A7 (tape color: orange)
q Hose (25): Port A8 (tape color: green)
q Hose (27): Port T2
q Hose (28): Port B1 (tape color: white)

q Hose (29): Port B2 (tape color: yellow)
q Hose (30): Port B3 (tape color: brown)
8. Remove clamp (13). q Hose (31): Port B4 (tape color: red)
9. Remove 2 bolts (14), and disconnect bracket (15). q Hose (32): Port B5 (tape color: red)
10. Disconnect hoses and tubes shown below from the a Hose (32) is installed only to machines with
control valve. power tilt.
q Hose (16): Port P2
q Hose (17): Port T1
GD535-5 50-239
(02)
q Hose (33): Port B6 (tape color: yellow) 14. Remove cotter pin (45), and disconnect rod link
q Hose (34): Port B7 (tape color: gray) (46). (9 places)
q Hose (35): Port B8 (tape color: brown)
q Hose (36): Port B9 (tape color: red)
q Hose (37): Port P3
15. Remove 3 bolts (47), and remove control valve

(48).
11. Remove clamps (38), (39) and (40).
12. While attaching eyebolts to parts (a) and slinging

the assembly, remove 2 bolts (41) on each side.
[*1]
a Put mark (b) on plate (43) to indicate the
installed position of bracket (42).
13. Raise control valve assembly (44) and bracket (42)
as a unit to remove it.
4 Control valve assembly (44): 75 kg
50-240 GD535-5
(02)
50 Disassembly and assembly Removal and installation of control valve assembly
Installation
q Perform installation in the reverse order of removal.
a Take care not to connect the hoses to wrong installed positions.
Port Tape Port Tape

Actuator name Actuator name
name color name color
A1 R.H. blade lift (head side) Red B1 R.H. blade lift (bottom side) White
A2 Leaning (bottom side) Blue B2 Leaning (head side) Yellow
A3 Drawbar shift Green B3 Drawbar shift (head side) Brown
A4 Articulate White B4 Articulate Red
A5 Power tilt (head side) White B5 Power tilt (bottom side) Red
A6 Circle motor (port A) Blue B6 Circle motor (port B) Yellow
A7 Blade shift (head side) Orange B7 Blade shift (bottom side) Gray
A8 L.H. blade lift (head side) Green B8 L.H. blade lift, ripper (bottom side) Brown
A9 Scarifier lift, ripper (head side) Blue B9 Scarifier lift, ripper (bottom side) Red
P2 From work equipment pump P3 From work equipment pump
T2 Hydraulic tank drain T1 Hydraulic tank drain
GD535-5 50-241
(02)
[*1]
a Tighten bolts (41) while aligning bracket (42) with
installed position mark (a) put on plate (43).
[*2]
a Apply grease until it oozes from rod end (a).
2 Rod and ball (a): Grease (G2-LI)

q Air bleeding
Bleed air from the work equipment circuit. For
details, see Testing and adjusting, "Bleeding air
from work equipment circuit".
50-242 GD535-5
(02)
50 Disassembly and assembly Disassembly and assembly of hydraulic cylinder assembly
New/Redesign
Necessity
hydraulic cylinder assembly
Sketch
1
Sym-
Q'ty
Part No. Part name
Special tools bol
New/Redesign
Necessity
Sketch
Sym- 796–720–1650 Ring q 1
Q'ty
Part No. Part name
bol 07281–01029 Clamp q 1
U 7
796–720–1670 Ring q 1
Cylinder repair 07281–01279 Clamp q 1
790–502–1003
stand ■ 1
1
790–101–1102 Hydraulic pump ■ 1 a For target cylinders of tools, see "Special tool
List".
2 790–330–1100 Wrench assembly ■ 1
Socket Assembly
Commercially
available
(Width across flats: ■ 1 a Be careful not to damage the packings, dust seals,
30 mm)
O-rings, etc.
Commercially
Socket a Clean all parts, and plug piping ports and pin
available
(Width across flats: ■ 1 insertion holes after assembly so that dust does
36 mm) not enter into them.
Socket 1. Cylinder
Commercially
available
(Width across flats: ■ 1 Steering cylinder and power tilt cylinder
41 mm) Press-fit bushing (1), and install snap rings (2).
3
Socket a The figure shows a steering cylinder as an
Commercially
available
(Width across flats: ■ 1 example.
46 mm)
Socket
790–302–1270 (Width across flats: ■ 1
50 mm)
Socket
790–302–1290 (Width across flats: ■ 1
60 mm)
790–201–1702 Push tool kit ■ 1
U 790–101–5021 q Grip 1
01010–50810 q Bolt 1
790–201–1731 q Push tool 1
4
790–201–1741 q Push tool 1
790–201–1751 q Push tool 1 Leaning cylinder, articulate cylinder, scarifier
790–201–1761 q Push tool 1 cylinder and ripper cylinder
790–201–1771 q Push tool 1 Press-fit bushing (3) and dust seals (4).
a The figure shows a leaning cylinder as an
790–201–1500 Push tool kit ■ 1
example.
790–101–5021 q Grip 1
01010–50816 q Bolt 1
790–101–1540 q Plate 1
5
790–101–1550 q Plate 1
790–101–1560 q Plate 1
790–101–1570 q Plate 1
790–101–1580 q Plate 1
6 790–720–1000 Expander q 1
796–720–1620 Ring q 1
07281–00609 Clamp q 1
7
796–720–1640 Ring q 1
07281–00909 Clamp q 1
GD535-5 50-243
(02)
Disassembly and assembly of hydraulic cylinder assembly 50 Disassembly and assembly
2. Piston rod 3) Install snap rings (12) and (12a).

Power tilt cylinder 4) Install buffer ring (13). (steering cylinder only)
Press-fit bushing (6), and install snap rings (7). 5) Install rod packing (14).
6) Remove O-rings (15) and (16) as well as
backup ring (17).
a When installing the backup ring (17), do not
install it forcibly. Warm it in hot water at
approximately 50 to 60 °C, and install it.
q Steering cylinder
Leaning cylinder, articulate cylinder, scarifier

cylinder and ripper cylinder
Press-fit bushing (8) and dust seals (9).
a The figure shows a leaning cylinder as an
example.
q Cylinders other than steering cylinder
3. Cylinder head assembly

1) Press-fit bushing (10) by using tool U4.
2) Press-fit dust seal (11) by using tool U5. 7) Install cylinder head assembly (18) to piston
a The figure shows a leaning cylinder as an rod (19).
example.
50-244 GD535-5
(02)
50 Disassembly and assembly Disassembly and assembly of hydraulic cylinder assembly
4. Piston assembly 6) Set piston rod assembly (26) on tool U1.

1) Set piston ring (21) on tool U6, and rotate the 7) Using tool U3, tighten nut (25) with its machined
handle 8 to 10 turns to expand the piston ring. facing piston (22).
a Width across flats of piston nut
q Steering cylinder: 30 mm
q Blade lift cylinder (both): 41 mm
q Blade side shift cylinder: 41 mm
q Drawbar shift cylinder: 41 mm
q Leaning cylinder: 46 mm
q Power tilt cylinder: 41 mm (for machines
with power tilt)
q Scarifier cylinder: 50 mm (for machines
with scarifier)
q Articulate cylinder: 50 mm
q Ripper cylinder: 55 mm (for machine
with ripper)
2 Piston nut:
2) Remove piston ring (21) from tool U6, and Adhesive (Loctite No. 262 or equivalent)
install it to piston (22). 3 Piston nut:
3) Compress piston ring (21) by using tool U7. q Steering cylinder:
4) Install wear ring (23). 245±24.5 Nm{25±2.5 kgm}
q Blade lift cylinder (both):
618±62 Nm{63±6.3 kgm}
q Blade side shift cylinder:
618±62 Nm{63±6.3 kgm}
q Drawbar shift cylinder:
618±62 Nm{63±6.3 kgm}
q Leaning cylinder:
785±78.5 Nm{80±8 kgm}
q Power tilt cylinder:
647±64.5 Nm{66±6.6 kgm}
(For machines with power tilt)
q Scarifier cylinder:
1.08±0.11 kNm{110±11.0 kgm}
(For machines with scarifier)
q Articulate cylinder:
5) Install piston assembly (24) and nut (25) to 1080±108 Nm{110±11 kgm}
piston rod (19). q Ripper cylinder:
1.42±0.14 kNm{145±14.5 kgm}
(machine with ripper)
GD535-5 50-245
(02)
Disassembly and assembly of hydraulic cylinder assembly 50 Disassembly and assembly
5. Piston rod diameter

1) Remove piston rod assembly (26) from tool U1,
and install it to cylinder (27).
2) Set cylinder assembly (28) to tool U1.

3) Tighten the cylinder head using tool U2.
3 Cylinder head
q Steering cylinder:
392±39.0 Nm {40±4.0 kgm}
q Blade lift cylinder (both):
588±59.0 Nm {60±6.0 kgm}
q Blade side shift cylinder:
588±59.0 Nm {60±6.0 kgm}
q Drawbar shift cylinder:
588±59.0 Nm {60±6.0 kgm}
q Leaning cylinder:
569±57.0 Nm {58±5.8 kgm}
q Power tilt cylinder:
588±59.0 Nm {60±6.0 kgm}
(For machines with power tilt)
q Scarifier cylinder:
588±59 Nm {60±6 kgm}
(For machines with scarifier)
q Articulate cylinder:
569±57 Nm {58±5.8 kgm}
q Ripper cylinder:
735±73.5 Nm {75±7.5 kgm} (For ma-
chines with ripper)
50-246 GD535-5
(02)
50 Disassembly and assembly Removal and installation of blade assembly
Work equipment 1
Removal and installation of blade

assembly 1

OFF position.
a Be sure to move the lifting point step-by-step
toward the blade center while removing it.
4 Blade assembly (1): 610 kg
1. Operate the blade lift control lever to raise blade
Installation
assembly (1) approximately 100 mm, and place
q Perform installation in the reverse order to
block [1] under the circle to support the blade
removal.
firmly.
2. Operate the blade side shift control lever to shift
[*1]
3
the blade assembly (1) fully to the left, and stop the
Mounting bolt: (3):
engine.
235 to 285 Nm {23.5 to 29.5 kgm}
2
3. Temporarily sling rod (2) of the blade side shift
Hole for cylinder rod pin: Grease (G2-LI)
cylinder, and remove 4 mounting bolts (3) to
(If the cylinder rod pin is removed)
disconnect rod (2) and plate (4) as a unit from
[*2]
blade (1). [*1]
a Install blade assembly (1) according to the follow-
ing procedure.
1) Sling blade assembly (1) at its center location,
and install the right end of the blade to adjuster
(5).
2) Operate the blade side sift control lever to
extend rod (2) of the blade side shift cylinder
fully.
3) Push in blade assembly (1) to a position where
cylinder rod (2) and mounting plate (4) while
moving the lifting point step-by-step.
2 Blade guide rail (upper, lower):
Grease (G2-LI)
4) Install mounting plate (4) to blade assembly (1)
by using 4 mounting bolts (3).
235 to 285 Nm {23.5 to 29.5 kgm}
a After disconnecting the cylinder rod, support

the cylinder by using block [1].
4. Sling blade assembly (1), and remove the blade
while pushing it to the left. [*2]
GD535-5 50-247
(02)
Removal and installation of circle drawbar assembly 50 Disassembly and assembly
Removal and installation of circle

drawbar assembly 1

OFF position.
7. Disconnect hoses (9) and (10) on the right side of
the front frame.
q Tape color of hose (9): Green
q Tape color of hose (10): Brown
connected.
a Plug the disconnected hoses to prevent oil from
flowing out.
Removal
1. Remove the blade assembly. For details, see
"Removal and installation of blade assembly".
2. Operate the drawbar side shift control lever to set
the drawbar to the center.
3. Operate the blade lift control lever to make the
drawbar level, and support the adjuster and
bracket at the bottom of the circle by using blocks,
etc.
k Stop the engine, and operate the drawbar 8. Disconnect hoses (11) to (16) on the left side of the
side shift control lever and circle rotation front frame.
control lever to release remaining pressure q Tape color of hose (11): Red
in the piping. q Tape color of hose (12): White
4. Remove clamp (1), and disconnect hoses (2) and q Tape color of hose (13): Blue
(3) from drawbar side shift cylinder (4). q Tape color of hose (14): Yellow
5. Remove cap (5), and disconnect drawbar side shift q Tape color of hose (15): Orange
cylinder (4) from drawbar (6). [*1] q Tape color of hose (16): Gray
a Hoses (11) and (12) are installed only to
machines with power tilt.
a Secure the drawbar side shift cylinder to the

frame by using a lever block, etc.
6. Remove both caps (7), and disconnect rods (8) of
the blade lift cylinders from drawbar (6). [*2]
50-248 GD535-5
(02)
50 Disassembly and assembly Removal and installation of circle drawbar assembly
9. Sling circle drawbar assembly (17).

10. Remove 4 nuts (19), and remove holder (20) and
shims (21). [*3]
a Write down the number of shims used.
11. Disconnect ball joint (22) from the front frame, and
raise circle drawbar assembly (17) to remove it.
[*4]
4 Circle and drawbar assembly (17):
1219 kg

Refill it with genuine Komatsu oil to the specified
circulate the oil through the piping. Then check the
oil level again.
Installation
removal. q Bleeding air (work equipment circuit)
Bleed air from the work equipment circuit. For
[*1] details, see Testing and adjusting, "Bleeding air
2 Ball joint of drawbar side shift cylinder: from work equipment circuit".
[*2]
2 Ball joint of blade lift cylinder:
[*3][*4]
q Shim adjustment procedure of axial backlash of
ball joint
1) Loosely install ball joint (22) and holder (20) to
the frame without fitting shims by using 4 nuts
(19).
q Do not apply grease to the ball joint.
3 Nut (19):
58.8 to 73.6 Nm {6 to 7.5 kgm}
2) Measure clearance (a) between the front frame
and holder (20) at 4 locations close to their
joints, and calculate the mean value.
3) Select shims so that the thickness of the shim
pack equals the mean value of clearance (a) +
2 shims (0.29 × 2 = 0.58mm).
q Available shims: 0.29-mm shim
q Standard thickness of shim pack: 4 to 4.64
mm
4) Fit selected shims (21), and tighten nuts (19) to
the specified torque.
2 Joint bolt:
3 Nut (19):
785 to 980 Nm {80 to 100 kgm}
a Check that the ball joint moves smoothly
without unusual noise due to backlash.
GD535-5 50-249
(02)
Removal and installation of circle rotation gear assembly 50 Disassembly and assembly
Removal and installation of circle a Write down thickness and the number of
rotation gear assembly 1
shims used.

OFF position.
k After stopping the engine, operate the circle
rotation control lever to release remaining
pressure in the piping.
connected.
Removal
1. Disconnect 2 hoses (1) from circle motor (2).
5. Attach eyebolts to circle rotation gear assembly

(10), and raise the assembly to remove it.
4 Circle rotation gear assembly (10):
110 kg
2. Drive out 2 dowel pins (3) from the bottom.

3. Remove 4 mounting bolts (4) of the circle rotation
gear from the bottom. [*1]
4. Unbend lock plate (5), loosen 2 mounting bolts (6),

remove holder (7) and shims (8), and then remove
pinion (9). [*2]
k When removing mounting bolts (6), hold
pinion (9) by hand to prevent it from falling.
50-250 GD535-5
(02)
50 Disassembly and assembly Removal and installation of circle rotation gear assembly
Installation q Adjusting slip clutch

q Perform installation in the reverse order to Adjust the slip clutch. For details, see Testing and
removal. adjusting, "Testing and adjusting slip clutch type
circle drive".
[*1]
3 Mounting bolt (4): q Refilling with oil (hydraulic tank)
785 to 980 Nm {80 to 100 kgm}
[*2] Refill it with genuine Komatsu oil to the specified
q Perform shim adjustment according to the follow-
ing procedure. circulate the oil through the piping. Then check the
oil level again.
1) Install pinion (9), and loosely bolt on holder (7).
a Push pinion (9) upward so that it is pressed
against plate (12).
2) Measure clearance (b) between the end face of
shaft (11) and that of pinion (9), and then select q Bleeding air (work equipment circuit)
shims so that the thickness of the shim pack is
0.1 to 0.5 mm larger than clearance (b). Bleed air from the work equipment circuit. For
q Standard thickness of shim pack: 3 mm
details, see Testing and adjusting, "Bleeding air
q Available shims: 0.2-mm, 0.5-mm, and 1.0-
from work equipment circuit".
mm shims
a This is to provide the same amount of
clearance (a) between plate (12) and pinion
(9).
q Clearance (a): 0.1 to 0.5 mm
3) Install pinion (9), selected shims (8), and holder

(7) in order, tighten mounting bolts (6), and then
bend lock plate (5) firmly.
2 Contact surfaces (c) of plate (12) and
pinion (9):
2 Top (d) of pinion (9):
GD535-5 50-251
(02)
Disassembly and assembly of circle rotation gear assembly 50 Disassembly and assembly
Disassembly and assembly of circle 5. Remove 3 bolts from the worm wheel shaft, and
rotation gear assembly 1
remove plate (7), shims (8), and collar (9).
a Write down the type and number of shims
used.
Disassembly 6. Remove 4 mounting nuts, and remove cover (10)
1. Remove drain plug (25) to drain oil from circle rota- and shims (11).
tion gear case (1). a Write down the type and number of shims
6 Circle rotation gear case (1): 4.1 l used.
2. Remove 4 mounting bolts, and remove circle motor

assembly (2).
7. Using an eyebolt, raise the assembly of worm

wheel (12) and shaft (13) to remove it.
3. Remove 8 mounting bolts (4) from circle rotation

gear case (1), and remove cover (3).
a Before removing cover (3), check and write
down the installation direction of the oil filler
plug.
8. Remove belleville spring (14) and spacer (15).
4. Remove 8 mounting bolts (5), and remove cover

(6).
a Before removing cover (6), check and write
down the position of the oblong hole under the
oil filler plug.
9. Remove 6 discs (16) and 5 plates (17) from worm

wheel (12).
10. Remove shaft (13) from worm wheel (12).
50-252 GD535-5
(02)
50 Disassembly and assembly Disassembly and assembly of circle rotation gear assembly
Assembly
1. Press-fit bushing (22) to case (1).
2 Inner surface of bushing (22):
11. Remove spacer (18) from shaft (13).
2. Reverse case (1), and press-fit oil seal (21).

2 Shaft sliding surface of oil seal:
Grease (G2-LI)
12. Remove worm gear (19) from case (1).

13. Remove 2 bearings (20) from worm gear (19).
14. Reverse the case, and remove oil seal (21) and
bushing (22).
3. Install worm wheel (12), shaft (13), and spacer

(18).
4. Install a spacer to worm wheel (12), and then install

5 plates (17) and 6 discs (16) alternately.
a Apply oil to whole areas of disc (16) before
installation.
2 Disc (16) (front and back sides):
Gear oil (GO80W90)
GD535-5 50-253
(02)
8. Perform preload adjustment of the bearing.

a Perform this adjustment without worm wheel
(12).
1) Install nut (23) to the mounting bolt of cover
(10), fit shims (8), and tighten nut (23).
2) Measure the rotating torque of worm gear (19).
If this is not the standard value, adjust the
torque by increasing and decreasing shims (8).
q Standard value of rotating torque: 2.94 to
7.85 Nm {0.3 to 0.8 kgm}
q Available shims: 0.05-mm, 0.1-mm, 0.2-
mm, and 1.0-mm shims
q Standard thickness of shim pack: 0.7 mm
9. Install plate (17) and belleville spring (14) to worm
wheel (12).
10. Using an eyebolt, raise the assembly of worm
wheel (12) and shaft (13) to install it to case (1).
11. Install cover (6) to case (1) by using guide bolts,
and loosely tighten mounting bolts.
5. Press-fit 2 bearings (20) to worm gear (19).
a Install cover (6) so that its oblong hole (a) is

positioned under the oil filler plug. (See step 4.
of Disassembly.)
6. Install worm gear (19) to case (1).

7. Install cover (10) to case (1).
12. Install collar (9) and tighten mounting bolts of cover

(6).
2 Only 2 mounting bolt (5) of cover (6) (pass-
through part (b) of tapped hole in case):
Adhesive (LT-2)
50-254 GD535-5
(02)
50 Disassembly and assembly Disassembly and assembly of circle rotation gear assembly
13. Install shims (8). 15. Use 8 bolts to install cover (3).
a Select shims so that the thickness of the shim a Install cover (3) so that its oil filler plug (24) is
pack is 3.0 mm. positioned as indicated in the drawing.
q Available shims: 0.2-mm and 0.5-mm
shims
a After installing the circle rotation gear assem-
bly to the machine, adjust the slip clutch. For
details, see Testing and adjusting, "Testing and
adjusting slip clutch type circle drive".
a Check that the oblong hole of cover (6) is posi-

tioned at a location specified in step 11. If not,
rearrange cover (6).
16. Use 4 bolts to install circle motor assembly (2) to

the worm gear.
14. Use 3 bolts to install plate (7).
GD535-5 50-255
(02)
17. Tighten drain plug (25).

3 Drain plug (25):
14.7 to 19.6 Nm {1.5 to 2.0 kgm}
18. Remove oil filler plug (24), and refill with oil.
5 Circle rotation gear case (1):
4.1 l (Gear oil GO80W90)
19. Tighten oil filler plug (24).
3 Oil filler plug (24):
58.8 to 78.4 Nm {6.0 to 8.0 kgm}
20. After installing the circle rotation gear assembly to

the machine, adjust the slip clutch. For details, see
Testing and adjusting, "Testing and adjusting slip
clutch type circle drive".
50-256 GD535-5
(02)
50 Disassembly and assembly Removal and installation of operator's cab assembly
Cab and its attachments 1

operator's cab assembly 1
Removal
k Park the machine on a level ground, set the
gear gear shift lever to P position, and lower
the work equipment to the ground.
k Check that the system operating lamp is OFF,
turn the battery disconnect switch to OFF
position (If the machine is not equipped with
the battery disconnect switch, disconnect the
cable from the negative (-) terminal of battery.
4. Remove screws (5) (7 pieces) at the rear inside of

cab and bolt (6) (1 piece), and remove cover (7).
3. Remove bolts (3) (4 pieces), and remove oper-

ator's seat (4).
[*1]
4 Operator's seat (4):
55 kg
GD535-5 50-257
(02)
Removal and installation of operator's cab assembly 50 Disassembly and assembly
5. Remove screws (8) (6 pieces) at the rear inside of

cab, and remove cover (9).
9. Disconnect the following connectors. [*3]

q B25 (29)
6. Remove clamps (10) (6 places). q SP35 (30)
q SP14 (31)
q SP15 (32)
q SP12 (33)
q SP13 (34)
q SP40 (35)
q SP42 (36)
q SP11 (37)
q SP16 (38)
q C14 (39)
q TM43 (40)
q C12 (41)
q C31 (42)
q H15 (43)
7. Disconnect connectors TM41 (11), TM40 (12), and
q C22 (44)
TM39 (13). [*3]
q SP27 (45)
q C51 (46)
8. Disconnect the following connectors. [*3]

q SCT1 (14)
q SCT2 (15)
10. Remove band (47), and disconnect connector C16
q SP26 (16)
(48). [*3]
q SP46 (17)
q SP37 (18)
q SP38 (19)
q SP36 (20)
q SP30 (21)
q SP43 (22)
q SP18 (23)
q SP19 (24)
q SP31 (25)
q TM42 (26)
q SP32 (27)
q SP17 (28)
50-258 GD535-5
(02)
11. Remove screws (49) (6 pieces), and disconnect 15. Remove bolts (59) (6 pieces), and remove bracket
connectors FB1 (50), FB2 (51), and FB3 (52). [*3] (60).
12. Disconnect connector CAN (53) from connector 16. Disconnect washer hoses (61), (62), and (63).
block (54). [*3] a Write down the tape colors of washer hoses
(61), (62), and (63).
13. Disconnect connectors TEL (55) and CON (56).

[*3] 17. Disconnect connectors AC3 (64) and AC4 (65).
14. Remove bolts (57) (4 pieces), and remove cover 18. Disconnect connectors C2 (66), C1 (67), C46 (68),
(58). and C43 (69). [*3]
GD535-5 50-259
(02)
19. Remove bolts (69b) (4 pieces), and remove air 22. Remove hexagonal socket head bolts (69d) (4
conditioner duct (69c). pieces), and remove cover (69e).
20. Depress tilt pedal (70), and fully tilt steering column 23. Remove bolts (69f) (4 pieces), and remove
(71) in the arrow direction. brackets (69g) (2 pieces).
24. Remove air conditioner ducts (69j) and (69k).
21. Remove hexagonal socket head bolts (69u) (4

pieces), and remove cover (69v).
25. Remove bolts (69m) (2 pieces), and remove
bracket (69n).
50-260 GD535-5
(02)
26. Remove bolts (69p) (5 pieces), and remove hand-

rail (69q).
30. Remove bolts (74) (3 pieces), and move inching

pedal (75) inward so that it does not hinder the
27. Remove bolts (69r) (4 pieces), and remove hand- work.
rail (69s).
31. Remove bolts (76) (2 pieces).

28. Remove bolt (69t).
32. Remove bolts (77) (3 pieces), and move acceler-

29. Remove bolts (72) (10 pieces), and remove cover ator pedal (78) inward so that it does not hinder the
(73). work.
GD535-5 50-261
(02)
33. Remove bolts (79) (2 pieces). 36. Remove bolts (82) (4 pieces), and remove bracket
(83).
34. Install sling [1] to slinging positions (a), and sling

and hold operator's cab assembly (108). 37. Remove bolts (84) (3 pieces), and remove step
4 Operator's cab (108): (85).
825 kg
38. Loosen screws (86a) (2 pieces), and open cover

(86).

(81).
50-262 GD535-5
(02)
39. Remove clamps (88a) and (88b) (2 pieces each) 44. Remove clamp (96a).
on the back of cover (88).
(88).

(96) together with washer tank (95).
41. Remove clamps (89) (3 places).

(98).
42. Disconnect washer hoses (90) (3 pieces).
43. Disconnect connectors B15 (91), B16 (92), and
B17 (93).
GD535-5 50-263
(02)
47. Remove bolts (99) (4 pieces), and remove step 51. Sling and remove operator's cab assembly (108).
(100).
Installation
48. Remove bolts (101) (2 pieces), and remove q Perform installation in the reverse order of
bracket (102). removal.
[*1]
3 Bolt (3):
27 to 34 Nm {2.8 to 3.5 kgm}
[*2]
q Install bolt (103) according to the following proce-
dures.
1) Insert spacer (107) and cushion (106) in the
frame.
2) Insert cushion (105) in spacer (107), install
plate (104) and washer (103a), and tighten bolt
(103).
49. Remove bolts (103) (4 pieces) and washers (103a) a Check that cushion (105) is in contact uniformly.
(4 pieces), and remove plates (104) (2 pieces). 3 Bolt (103):
(R.H. and L.H.) [*2] 883 to 1001 Nm {90 to 102 kgm}
50. Remove cushions (105) and (106) and spacers
(107) (4 pieces each). (R.H. and L.H.) [*2]
50-264 GD535-5
(02)
[*3]
a Connect the connectors correctly.
GD535-5 50-265
(02)
Removal and installation of operator cab glass (adhered glass) 50 Disassembly and assembly
Removal and installation of operator cab glass (adhered glass) 1
a In this section, the procedures for replacing the ad- (a): Sticking surface of finisher
hered window glass are explained. (b): Apply GE Toshiba Silicon tosprum D to glass and
(1): Front window glass (adhered glass) plate surfaces and seal them with GE Toshiba Sili-
(2): Finisher con tosseal 381. (No extrusion shall not remain on
(3): Rear window glass (adhered glass) the glass front surface.) (on both right and left
(4): Finisher sides)
(5): Finisher
(6): Dam rubber
50-266 GD535-5
(02)
50 Disassembly and assembly Removal and installation of operator cab glass (adhered glass)
(6): Dam rubber

(7): Right upper side window glass (adhered glass)
(8): Right center side sash assembly (adhered)
(9): Right lower side window glass (adhered glass)
GD535-5 50-267
(02)
(1): Front window glass (adhered glass)

(6): Dam rubber
(10): Left door window glass (adhered glass)
(11): Left side window glass (adhered window glass)
(*1): Step dimension between door and cab body
(*2): Difference dimension between door body face
and cab body face
(A): Adjust the right door in the same manner.
50-268 GD535-5
(02)
Special tools (The figure shows the operator cab of a wheel

loader.)
New/Redesign
Necessity
Sketch
Q'ty
Lifter (Suction
1 793–498–1210 t 3
X cup)
2 20Y-54-13180 Stopper rubber t 3
Removal
a Remove the window glass to be replaced accord-
ing to the following procedure.
1. Use seal cutter [1] to cut the adhesive between
broken window glass (7) and operator cab (metal
sheet) (8).
a If the window glass is broken in small pieces, it
may be removed with knife [4] and a flat-head
screwdriver.
a Widening the cut with a flat-head screwdriver,
cut the adhesive and dam rubber with knife [4].
(The figure shows the operator cab of a wheel

loader.)
a If a seal cutter is not available, make holes on

the adhesive and dam rubber with a drill and
pass a fine wire (piano wire, etc.) [2] through
the holes. Grip the both ends of the wire with
pliers [3], etc. (or hold them by winding them
onto pliers) and move the wire to the right and
left to cut the adhesive and dam rubber. Since
the wire may be broken by the frictional heat,
2. Remove the window glass.
apply lubricant to it.
Since the wire may be broken by the frictional
heat, apply lubricant to it.
GD535-5 50-269
(02)
Installation 3. When the adhesive is removed with the scraper, if

1. Use scraper [5] to clean off adhesive remaining on any paint is flaked off, coat the bare part with paint.
the adhered surface. a If a glass, from which paint is partly peeled, is
a Dot not scratch the paint. installed as it is, rust will appear at the peeled
portions.
a Do not apply to a part which will be coated with
primer.
2. Remove oil, dust, dirt, etc. from the adhering

surfaces of cab (2) and window glass (3) with white
gasoline.
a If the adhering surfaces are not cleaned well,
the glass may not be adhered perfectly.
a Clean all the black part on the back of the win-
dow glass.
a After cleaning the adhering surfaces, leave
them for at lease five minutes to dry.
50-270 GD535-5
(02)
Applying primer 3) Evenly apply paint primer to the whole painting

4. Apply primer (10). area of operator cab (8).
a The primer is effective in performance for four (a): Whole range of 30 mm
months after the date of manufacture. Do not 2 Primer for paint for cab:
use the primer after the expiration date. Sun Star 435-98
a Use the primer within two hours after opening it. a Do not apply the primer more than two
a Even if the primer container is closed again just times.
after it is opened, use it within twenty-four hours (If it is applied more than two times, its
after it is opened for the first time. performance will be lowered.)
(Discard the primer in twenty-four hours after it a Never apply the wrong primer.
is opened.) If the glass primer, etc. is applied by
1) Mix the primers for painted surface and glass mistake, wipe it off with white gasoline.
sufficiently before using them. a After applying the primer, leave it for at least
a If the primer is stored in a refrigerator, leave 5 minutes in air to dry and stick the dam rub-
it at the room temperature for at least half a ber within 24 hours.
day before stirring it. (The figure shows the operator's cab of a
(If the primer container is opened just after hydraulic excavator.)
taken out of the refrigerator, water will be
condensed. Accordingly, leave the primer at
the room temperature for a sufficient time.)
2) When reusing primer brush (11), wash it in
white gasoline.
a After washing the brush, check it again for
dirt and contaminant.
a Prepare respective brushes for the paint
primer and glass primer.
a (8): Cab
GD535-5 50-271
(02)
4) Apply the primer for glass to the whole surface Adhering dam rubber
coated in black on window glass (9) 5. Adhere dam rubber (6) along the edge of cab (8).
(a): Whole range of 30 mm a Do not remove the release tape of dam rubber
2 Primer for glass: on the glass adhering side before adhering the
Sun Star 435-41 glass.
a Black coating on glass is for protection a When sticking the dam rubber, do not touch the
against optical degradation. cleaned surface to the utmost.
a Do not apply the primer more than two a Care should be taken not to float the dam rub-
times. ber in each adhering corner.
(Applying primer more than twice will
degrade the performance.)
a When adhering dam rubber (6) goes around,

mind not to overlap dam rubber at the both
a (9): Glass ends. Or, provide a clearance of approximately
5 mm at the mating portion (e).
1) Adhere dam rubber (6) for the right side window
glass to the position shown in the figure.
a (The figure shows the operator cab of a hy-
draulic excavator.)
a Never apply the wrong primer.

If you have applied the primer for painted
surface, etc. by mistake, wipe it off with
white gasoline.
50-272 GD535-5
(02)
Positioning window glass Applying adhesive

6. Position the new window glass. 7. Preparation for applying the adhesive.
1) Check the clearances between the window q Adhesive:
glass and the operator cab on the right, left, Sun Star Penguin Seal 560
upper, and lower sides, and then position the a The adhesive is effective in performance for
window glass with the clearance evenly. four months after the date of manufacture. Do
2) Stick tape [6] onto through window glass (9) not use the adhesive after the expiration date.
and operator cab (8), and draw positioning line a Keep the adhesive in a dark place where the
(n) on the tape. temperature is below 25 °C.
a Stick tapes [6] for positioning at three places a Never warm the adhesive higher than 30 °C.
of the right, left and lower sides of the glass, a When starting using the adhesive, remove the
and position them surely. all hardened part form the nozzle tip.
3) Cut the tape between window glass (9) and
operator cab (8) with a knife, etc. and then 1) Set adhesive cartridge (12) to caulking gun [7].
remove the window glass. a An electric caulking gun is more efficient.
a Do not remove the release tape of the dam
rubber on the glass adhering side before
adhering the glass.
(The figure shows the operator cab of a
hydraulic excavator.)
2) Cut the tip of the adhesive nozzle (14) so that

dimensions (q) and (r) are as follows.
q Dimension (q): 10 mm
q Dimension (r): 15 mm
3) Remove the release tape of the dam rubber on

the glass adhesive side.
GD535-5 50-273
(02)
8. Apply adhesive. Installation of window glass

a Apply adhesive (15) to dam rubber (6) of oper- 9. Install the window glass.
ator cab (8) in the (s) and (t) dimensions shown 1) Install window glass (9), with the lines on the
in the figure. positioning tapes drawn in step 6 above
q Dimension (s): 10 mm aligned.
q Dimension (t): 15 mm a Since the window glass cannot be removed
2 Adhesive: and adhered again, adhere it with utmost
Sun Star Penguin Seal 560 care.
a Apply adhesive (15) thicker than dam rubber 2) After adhering window glass (9), press the
(6). glass at the whole edges through until the glass
a Apply the adhesive evenly in height. adheres to the dam rubber.
a (a): Applying range of primer (mentioned a Press the corners of the window glass firm-
above) ly.
a Install window glass within 5 minutes after ap- (The figure shows the operator cab of a
plying the adhesive. hydraulic excavator.)
a After applying adhesive

a You can perform this work efficiently by pull-
ing window glass (9) from the inside of the
operator cab with suction cup X1.
a Wipe off the squeezed adhesive.
50-274 GD535-5
(02)
10. Fix window glass. 11. After installing the window glass, remove any
1) After installing right window glass (1) to the excess of the primer and adhesive on the operator
operator cab, insert stopper rubbers X2 in two cab and window glass.
places (v) on the lower side of the glass and fix a By using white gasoline, wipe off the adhesive
it. before it dries off.
(The figure shows the operator cab of a a When cleaning the glass, do not give an impact
hydraulic excavator.) on it.
a Only for the front glass and the front side glass
2) In order to adhere the window glass and the

dam rubber perfectly, use styrene foam [9] and
rubber bands [10] to fix and cure them for more
than 10 hours.
(The figure shows the operator cab of a
hydraulic excavator.)
GD535-5 50-275
(02)
Removal and installation of floor frame assembly 50 Disassembly and assembly
Removal and installation of floor

frame assembly 1
Removal
a Ask a qualified person for handling of the
refrigerant. (Only registered person can work.)
a Never release the refrigerant to the atmo-
sphere.
k If refrigerant gets in your eyes, you may lose
your sight. If it touches your skin, you may
get frostbite. Accordingly, put on the pro-
tective eyeglasses, gloves, and working
suits with long sleeves while you are col- 5. Remove clamp (7a).
lecting or adding the refrigerant. 6. Remove hexagonal socket head bolt (6), and
q Amount of refrigerant to collect: 1150 ± 50 g disconnect connector R1 (7).
7. Remove clamp (8), and disconnect connectors

BZ1 (9) and CAM2 (10).
3. Remove the operator’s cab assembly. For details,

see "Removal and installation of operator’s cab
assembly".
4. Remove nuts (2) and (4) (4 pieces each), and
disconnect rods (3) and (5) (4 pieces each).
a Fix rods (3) and (5) (4 pieces each) to the
operator's cab since they interfere when the
operator's cab and floor frame assembly is
slung.
a If the machine is equipped with the power tilt
specification, remove nut (2a) and disconnect
rod (3a).
50-276 GD535-5
(02)
50 Disassembly and assembly Removal and installation of floor frame assembly
8. Disconnect connectors R7 (11), R5 (12), R6 (13), 12. Disconnect hoses (25) and (26).
and R4 (14).
13. Remove clamps (27a) (2 places), and disconnect

9. Remove clamps (15), (16a), and (16b), and hoses (27) and (28).
disconnect ground cables (17a) and (17b).

10. Remove clips (18) and (19), and disconnect heater hoses (29) and (30).
hoses (20) and (21).
15. Remove clamp (31a), and disconnect hose (31).

B22 (24).
GD535-5 50-277
(02)
Removal and installation of floor frame assembly 50 Disassembly and assembly

air conditioner hoses (32) and (33). [*2]

and hold floor frame assembly (41).
17. Disconnect hoses (34), (35), and (36). 4 Floor frame assembly (41):
365 kg
18. Remove bolts (37) (2 pieces), and move bracket

(38) aside so that it does not hinder the work.
19. Disconnect connector FL17 (39).

a Disconnect remaining connector (39a) from
connector block (40).
50-278 GD535-5
(02)
50 Disassembly and assembly Removal and installation of floor frame assembly
21. Remove bolt (42). (R.H. and L.H.) [*3] Installation

removal.
[*1]
a Add refrigerant (air conditioner gas: R134a)
Add refrigerant (air conditioner gas: R134a) to the
air conditioner circuit.
Addition amount: 1150 ± 50 g
a Add air conditioner compressor oil
For details, see “Appendix”, "Add compressor oil".
[*2]
22. Sling and remove floor frame assembly (41). a When installing the air conditioner piping, take
care that no dust, dirt or water enters the hoses.
a When connecting the air conditioner piping, check
that O-rings are fitted to its joints.
a Do not reuse an O-ring since it is deformed and
deteriorated once it is used.
a Apply compressor oil (Denso: ND-OIL8) for refriger-
ant (R134a) to O-rings.
20 to 25 Nm {2.0 to 3.0 kgm}
[*3]
3 Bolt (42):
98 to 123 Nm {10 to 12.5kgm}
a Finger-tighten the bolt to a degree that it does not

fall off, then finger-tighten it 3 more turns, and then
tighten it with an impact wrench.
Bleed air (brake circuit)
q Bleed air from the brake circuit. For details, see
Testing and adjusting "Bleed air from brake cir-
cuit".
GD535-5 50-279
(02)
Removal and installation of operator's cab and floor frame assembly 50 Disassembly and assembly
Removal and installation of 4. Remove bolts (4) (4 pieces), and remove bracket
operator's cab and floor frame (5).
assembly 1
Removal
cable from the negative (-) terminal of battery. 5. Remove bolts (6) (3 pieces), and remove step (7).
a Ask a qualified person for handling of the
refrigerant. (Only registered person can work.)
a Never release the refrigerant to the atmo-
sphere.
k If refrigerant gets in your eyes, you may lose
your sight. If it touches your skin, you may
get frostbite. Accordingly, put on the pro-
tective eyeglasses, gloves, and working
suits with long sleeves while you are col-
lecting or adding the refrigerant.
q Amount of refrigerant to collect: 1150 ± 50 g
2. Set lock pin (1) to the frame. 6. Loosen screws (8) (2 pieces), and open cover (9).
50-280 GD535-5
(02)
50 Disassembly and assembly Removal and installation of operator's cab and floor frame assembly
7. Remove clamps (11) and (12) (2 pieces each) on 12. Remove clamp (22a).
the back of cover (14).
(14).

(22) together with washer tank (21).
9. Remove clamps (15) (3 places).

(24).
10. Disconnect washer hoses (16) (3 pieces).
B17 (19).
GD535-5 50-281
(02)
15. Remove bolts (25) (4 pieces), and remove step 18. Remove nuts (31) and (33) (4 pieces each), and
(26). disconnect rods (32) and (34) (4 pieces each).
a Fix rods (32) and (34) (4 pieces each) to the
operator's cab since they interfere when the
operator's cab and floor frame assembly is
slung.
a If the machine is equipped with the power tilt
specification, remove nut (31a) and disconnect
rod (32a).

(28).

(30).
19. Remove clamp (36a).

20. Remove hexagonal socket head bolt (35), and
disconnect connector R1 (36).
50-282 GD535-5
(02)
21. Remove clamp (37), and disconnect connectors 25. Disconnect connectors B20 (51), B21 (52), and
BZ1 (38) and CAM2 (39). B22 (53).
22. Disconnect connectors R7 (40), R5 (41), R6 (42), 26. Disconnect hoses (54) and (55).
and R4 (43).

23. Remove clamps (44), (45a), and (45b), and hose (56) and (57).
disconnect ground cables (46a) and (46b).

24. Remove clips (47) and (48), and disconnect heater hoses (58) and (59).
hoses (49) and (50).
GD535-5 50-283
(02)
29. Remove clamp (60a), and disconnect hose (60). 33. Disconnect connector FL17 (68).

air conditioner hoses (61) and (62). [*2]

31. Disconnect hoses (63), (64), and (65). and hold operator's cab and floor frame assembly
(70).
4 Operator's cab and floor frame assembly
(70):
1240 kg
32. Remove bolts (66) (2 pieces), and move bracket

(67) aside so that it does not hinder the work.
50-284 GD535-5
(02)
35. Remove bolt (71). (R.H. and L.H.) [*3] Installation

removal.
[*1]
a Add refrigerant (air conditioner gas: R134a)
Add refrigerant (air conditioner gas: R134a) to the
air conditioner circuit.
Addition amount: 1150 ± 50 g
a Add air conditioner compressor oil

For details, see “Appendix”, "Add compressor oil".
36. Remove bolts (74) (4 pieces) and washers (74a) (4 [*2]

pieces), and remove plates (75) (2 pieces). (R.H. a When installing the air conditioner piping, take
and L.H.) [*4] care that no dust, dirt or water enters the hoses.
37. Remove cushions (76) and (77) and spacers (78) a When connecting the air conditioner piping, check
(4 pieces each). (R.H. and L.H.) [*4] that O-rings are fitted to its joints.
a Do not reuse an O-ring since it is deformed and
deteriorated once it is used.
a Apply compressor oil (Denso: ND-OIL8) for refriger-
ant (R134a) to O-rings.
20 to 25 Nm {2.0 to 3.0 kgm}
[*3]
3 Bolt (71):
98 to 123 Nm {10 to 12.5 kgm}
a Finger-tighten the bolt to a degree that it does not
fall off, then finger-tighten it 3 more turns, and then
tighten it with an impact wrench.
[*4]
q Install bolt (74) according to the following proce-
dures.
1) Insert spacer (78) and cushion (77) in the
frame.
2) Insert cushion (76) in spacer (78), install plate
(75) and washer (74a), and tighten bolt (74).
a Check that cushion (76) is in contact uniformly.
3 Bolt (74):
883 to 1001 Nm {90 to 102 kgm}
38. Sling and remove operator's cab and floor frame
assembly (70).
GD535-5 50-285
(02)
Bleed air (brake circuit)

q Bleed air from the brake circuit. For details, see
Testing and adjusting "Bleed air from brake cir-
cuit".
50-286 GD535-5
(02)
50 Disassembly and assembly Removal and installation of air conditioner unit assembly
Removal and installation of air

conditioner unit assembly 1
k Place the machine on a level ground, set the

gear shift lever to P position, and lower the
work equipment to the ground.
k Stop the engine and chock the tires.
OFF position.
k If you disconnect the heater hose when the
coolant in radiator is still hot, you may be
scalded. Wait until the coolant temperature
drops before starting the work.
k If refrigerant (air conditioner gas: R134a) gets
in your eyes, you may lose your sight. Put on
protective eyeglasses during collecting or fill-
ing operation.
k Check the connector numbers and installed
positions before disconnecting wiring har-
nesses and hoses, and record them.
k Never release the refrigerant (air conditioner
gas: R134a) to the atmosphere.
k Ask a qualified person for collecting, adding 5. Remove knobs (4) (4 pieces) on the left side of the
and filling operations of the refrigerant (air operator's cab assembly, and remove cover (4a).
Removal
6. Remove hexagonal head bolts (5) (4 pieces), and

remove cover (5a).

from the air conditioner circuit.
Quantity of refrigerant to be collected: 1150±50 g
3. Loosen coolant drain valve (2), and drain the
coolant.
6 Radiator:
21.1 l
a After draining the coolant, close drain valve
(2).
GD535-5 50-287
(02)
Removal and installation of air conditioner unit assembly 50 Disassembly and assembly
7. Remove hexagonal head bolts (6) (4 pieces), and 11. Disconnect connectors OPT2 (9).
remove cover (6a).
12. Remove clamps (13) and (14) at the rear of the

8. Remove bolts (7) (6 pieces), and remove cover operator's cab assembly.
(7a). 13. Disconnect connectors (18), AC4 (15), AC3 (16),
and AC1 (17), and remove clamps (18a).
9. Remove the operator's seat. For details, see

“Removal and installation of operator's seat.” 14. Remove bolts (19) (8 pieces), and remove cover
10. Remove clamps (8) (3 places) on the left side of (20).
the operator's cab assembly.
50-288 GD535-5
(02)
15. Disconnect heater hoses (21) and (22).

k Be careful to prevent dust, dirt or water from
entering disconnected heater hoses (21)
and (22).
16. Remove bolts (24) and (25), and disconnect air

conditioner tubes (26).
k Be careful to prevent dust, dirt or water from
entering disconnected air conditioner tubes
(26).
19. Remove bolts (29) (4 pieces) and screws (30) (4

pieces), and remove air conditioner unit assembly
(31).

(27a).
20. Removal hot water cut valve as follows.

1) Disconnect hoses (32) and (33).
k Be careful to prevent dust, dirt or water
from entering disconnected hoses (32)
and (33).
2) Remove bolts (34) (2 pieces), and remove hot
water cut valve (35).
18. Remove air conditioner drain hose clamps (28) (4

places) from the bottom side of the floor frame.
GD535-5 50-289
(02)
Installation
1. Install hot water cut valve as follows.
1) Install hot water cut valve (35) with bolts (34) (2
pieces).
2) Connect hoses (32) and (33).
k Be careful to prevent dust, dirt or water
from entering hoses (32) and (33) when
connecting the hoses.
4. Install cover (27a) with bolts (27) (5 pieces).
2. Install air conditioner unit assembly (31) with bolts

(29) (4 pieces) and screws (30) (4 pieces).
3 Screw (30):
1.97 to 2.45 Nm {0.2 to 0.25 Nm}
5. Connect air conditioner tubes (26), and install bolts

(25) and (24).
a Be careful to prevent dust, dirt or water from
entering air conditioner tubes (26) when con-
necting the tubes.
a Check that the O-ring is fitted to the joint of air
conditioner tubes (26) when connecting the air
conditioner piping.
deteriorated. Accordingly, do not reuse it.
a When removing the O-rings, use a soft tool so
3. Install air conditioner drain hose clamps (28) (4 that the piping is not damaged.
places) at the bottom side of the floor frame. a Check that the new O-ring is not damaged or
deteriorated.
a Apply compressor oil (DENSO: ND-OIL8) for
3 Mounting bolt (25) for air conditioner
tube (26):
8 to 12 Nm {0.8 to 1.2 kgm}
50-290 GD535-5
(02)
6. Connect heater hoses (22) and (21). 10. Connect connector OPT2 (9) on the left side of the
k Be careful to prevent dust, dirt or water from operator's cab assembly.
entering heater hoses (22) and (21) when
connecting the hoses.
11. Install clamps (8) (3 places).
7. Install cover (20) with bolts (19) (8 pieces).
12. Install the operator's seat. For details, see

“Removal and installation operator's seat”.
8. Connect connectors (18), AC4 (15), AC3 (16), and 13. Install cover (7a) with bolts (7) (6 pieces) on the left
AC1 (17) at the rear of the operator's cab side of the operator's cab assembly.
assembly, and install clamp (18a).
9. Install clamps (14) and (13).
GD535-5 50-291
(02)
14. Install cover (6a) with hexagonal head bolts (6) (4 18. Remove lock pin (1) from frame.
pieces).
15. Install cover (5a) with hexagonal head bolts (5) (4 19. Refilling with coolant
pieces). Refill the radiator with coolant to the specified
level again.
5 Coolant:
21.1 ℓ
a After the recheck, add engine coolant if the
coolant level is low.
20. Refill the air conditioner circuit with refrigerant (air
Refrigerant quantity: 1150±50 g
21. Refill with air conditioner compressor oil. For
details, see Appendix, “HANDLE COMPRESSOR
16. Install cover (4a) with knobs (4) (4 pieces). OIL”.
22. Remove lock pin (1) from frame.
17. Install floor mat (3).
50-292 GD535-5
(02)
50 Disassembly and assembly Removal and installation operator's seat
Removal and installation operator's Installation

seat 1
1. Install operator's seat (5) with mounting bolts (4) (4
pieces on the right and left sides).
k Place the machine on a level ground, shift the 4 Operator's seat (5):
gear shift lever to P position, and lower the 55 kg
work equipment to the ground. 3 Bolt (4):
k Stop the engine, and chock the tires. 27 to 34 Nm {2.8 to 3.5 kgm}
k Check that the system operating lamp is off, a The crane cannot be used inside the operator's
and then turn the battery disconnect switch to cab. Install operator's seat (5) by 2 persons.
OFF position.
Removal
2. Remove bolts (4) (4 pieces on the right and left

sides), and remove operator's seat (5).
4 Operator's seat (5):
55 kg
a The crane cannot be used inside the operator's
2. Remove lock pin (1) from the frame.
cab. Remove operator's seat (5) by 2 persons.
GD535-5 50-293
(02)
Removal and installation seat belt 50 Disassembly and assembly
Removal and installation seat belt 1 3. Remove seat belt as follows. (For Turkey specifi-
k Place
cation)
the machine on a level ground, set the
1) Removal bolt (7), and remove seat belt (8) on
the reel side from left side of the operator’s
seat.
2) Remove bolt (9), and remove tether belt (10).
OFF position.
Removal
3) Remove belt (11), and remove seat belt (12) on

the catch side from right side of the operator’s
seat.
4) Remove bolt (13), and remove tether belt (14).
2. Removal seat belt as follows.

1) Remove bolt (2), and remove seat belt (3) on
the reel side from right side of the operator's
seat.
Installation
1. Install the seat belt as follows.
1) Install catch-side seat belt (6) on the right side
of the operator's seat with bolt (5).
3 Bolt (5):
37.2 to 41.2 Nm {3.8 to 4.2 kgm}
2) Remove bolt (5), and remove seat belt (6) on

the catch side from left side of the operator's
seat.
50-294 GD535-5
(02)
50 Disassembly and assembly Removal and installation seat belt
2) Install reel-side seat belt (3) on the right side of

the operator's seat with bolt (2).
3 Bolt (2):
37.2 to 41.2 Nm {3.8 to 4.2 kgm}
2. Install the seat belt as follows. (For Turkey specifi-

cation)
1) Install tether belt (14) with bolt (13).
3 Bolt (13):
83.4 to 108 Nm {8.5 to 11 kgm}
2) Install catch-side seat belt (12) on the right side
of the operator’s seat with bolt (11).
3 Bolt (11):
37.2 to 41.2 Nm {3.8 to 4.2 kgm}
3) Install tether belt (10) with bolt (9).

3 Bolt (9):
83.4 to 108 Nm {8.5 to 11 kgm}
4) Install reel-side seat belt (8) on the left side of
the operator’s seat with bolt (7).
3 Bolt (7):
37.2 to 41.2 Nm {3.8 to 4.2 kgm}
GD535-5 50-295
(02)
Removal and installation of engine controller assembly 50 Disassembly and assembly
Electrical system 1

controller assembly 1
Removal
OFF position.
tery negative (-) terminal.) 5. Disconnect connectors EC2 (4), ECM (5) and EC3
1. Set lock pin (1) to the frame. (6) from engine controller (3).
a Use a hexagonal wrench (4 mm) to remove
connectors EC2 (4) and ECM (5).
2. Remove air conditioner compressor assembly.

6. Remove 2 top nuts, and remove 2 clamps (7).
For detail, see "Removal and installation of air
conditioner compressor assembly".
3. Open cover (2) on the right side of the machine.
a Check that the lock lever is firmly locked in the
LOCK position.
50-296 GD535-5
(02)
50 Disassembly and assembly Removal and installation of engine controller assembly
7. Remove 2 stud bolts (8). 10. Remove bottom mounting bolts (11) and (11a). [*1]
a Bolt (11a) tightens the controller together with
ground terminal (11b).
8. Remove nut (9) on the right side, and remove the

clamp.
11. Remove engine controller assembly (3).
9. Remove stud bolt (10).

Installation
removal.
[*1]
a Use left side bolt (11a) to tighten the controller
together with ground terminal (11b).
GD535-5 50-297
(02)
Removal and installation of machine monitor assembly 50 Disassembly and assembly
Removal and installation of 4. Remove 4 bolts (5) of machine monitor assembly

machine monitor assembly 1
(6).
5. Lift machine monitor assembly (6) slightly, discon-
nect connectors FP3 (7) and FP1 (8) on its back
Removal side, and remove machine monitor assembly (6).
OFF position.
2. Remove 4 mounting bolts (2) of cover (3). [*1]

3. Lift cover (3) slightly, disconnect connector FP12
(4) on its back side, and remove cover (3).
Installation
removal.
[*1]
3 Bolt (2): 8.8 to 10.8 Nm {0.9 to 1.1 kgm}
50-298 GD535-5
(02)
50 Disassembly and assembly Removal and installation of transmission controller assembly

transmission controller assembly 1
k Place the machine on a level ground, set the

OFF position.
Installation
Removal
1. Install transmission controller assembly (9) with
bolts (8) (4 pieces).
2. Connect connectors TM39 (5), TM40 (6), and
TM41 (7) to transmission controller assembly (9).
a Connect connectors TM39 (5), TM40 (6), and
TM41 (7) by using hexagonal wrench (4 mm).
2. Remove bolt (2) (1 piece) and hexagonal head

bolts (3) (7 pieces) at the rear of the operator's cab,
and remove cover (4).
3. Install cover (4) at the rear of the operator's cab
with hexagonal head bolts (3) (7 pieces) and bolt
(2) (1 piece).
3. Disconnect connectors TM39 (5), TM40 (6), and

TM41 (7) from transmission controller assembly
(9).
a Disconnect connectors TM39 (5), TM40 (6),
and TM41 (7) by using hexagonal wrench (4
mm).
4. Remove bolts (8) (4 pieces), and remove transmis-
sion controller assembly (9).
GD535-5 50-299
(02)
Removal and installation of transmission controller assembly 50 Disassembly and assembly
50-300 GD535-5
(02)
50 Disassembly and assembly Removal and installation of rearview camera

rearview camera 1
Removal
3. Remove bolts (6) (2 pieces), and remove rearview
camera assembly (7).
4. Remove bolts (8) (3 pieces), and remove rearview

2. Remove clip (3), and disconnect connector RL11
camera (9).
(4).
GD535-5 50-301
(02)
Removal and installation of rearview camera 50 Disassembly and assembly
Installation
removal.
a Adjust rear view camera angle
Adjust the rearview camera angle. For details, see
Testing and adjusting, “Adjusting rearview camera
angle”.
50-302 GD535-5
(02)
50 Disassembly and assembly Removal and installation of KOMTRAX terminal assembly
Removal and installation of 5. Remove bolts (8) (4 pieces), and remove

KOMTRAX terminal assembly 1
KOMTRAX terminal assembly (9).
k Place the machine on a level ground, shift the

k Stop the engine, and chock the tires.
OFF position.
Removal
Installation
1. Install KOMTRAX terminal assembly (9) with bolts
(8) (4 pieces).
2. Remove hexagonal head bolts (2) (6 pieces) at the

rear of the operator's cab, and remove cover (3).
2. Connect GPS antenna connector (6) and GPRS
antenna connector (7) to KOMTRAX terminal
assembly (9).
3. Connect connectors L80A (4) and L80B (5) to
3. Disconnect connectors L80A (4) and L80B (5) from

4. Disconnect GPS antenna connector (6) and GPRS
antenna connector (7) from KOMTRAX terminal
assembly (9).
GD535-5 50-303
(02)
Removal and installation of KOMTRAX terminal assembly 50 Disassembly and assembly
4. Install cover (3) at the rear of the operator's cab

with hexagonal head bolt (2) (6 pieces).
50-304 GD535-5
(02)
60 Maintenance standard
GD535-5 60-1
Contents 60 Maintenance standard
Contents 1
Acronyms - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-3
Engine mount and transmission mount - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-8
Cooling system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-9
Cooling fan motor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-10
Power train system- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-12
Torque converter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-12
Transmission - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-14
Main relief valve and torque converter relief valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-23
Front axle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-24
Rear axle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-26
Differential (Non-differential specification) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-27
Differential (Differential lock specification) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-28
Final drive- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-30
Differential lock solenoid valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-31
Tandem drive - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-32
Steering system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-33
Steering cylinder - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-33
Brake system- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-34
Wheel brake - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-34
Parking brake - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-35
Frame and center hinge pin - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-36
Hydraulic tank - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-37
Work equipment pump and steering pump - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-38
Power train pump - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-39
Power train pump and differential lock pump - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-40
Parking brake solenoid valve and lifter lock pin solenoid valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-41
Leaning cylinder - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-42
Articulate cylinder - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-43
Blade lift cylinder - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-44
Drawbar shift cylinder - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-45
Blade side shift cylinder - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-46
Power tilt cylinder - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-47
Scarifier cylinder - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-48
Ripper cylinder - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-49
Work equipment- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-50
Circle and drawbar - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-50
Blade - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-52
Lifter- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-54
Circle rotation gear - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-55
Ripper - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-57
60-2 GD535-5
60 Maintenance standard Acronyms
Acronyms 1
System
Advanced Joystick
ARAC
braking force.
Automatic Retarder
Automatic Spin
Brake Cooling oil
Regulator
used independently.
Closed-center Load
Sensing System
injection timing.
ECU)
GD535-5 60-3
Acronyms 60 Maintenance standard
Electronic Control
Modulation Valve

ECM)
Exhaust Gas
Recirculation
Equipment
Monitoring System
Electromagnetic
Forward-Neutral-
Reverse
Global Positioning
System
Plus) earth

Global Navigation
Satellite System

HSS
Hydro Static
control
Unit
motions.
60-4 GD535-5
KOMATSU Closed
KCSF Engine
KOMATSU Diesel
Oxidation Catalyst
muffler.
Particulate Filter
KOMATSU Traction
LIN
load.
LVDS
sensor.
Service
NC Normally Closed
NO Normally Open
PC Hydraulic system
GD535-5 60-5
Acronyms 60 Maintenance standard
PCCS
Pre-stroke Control
Valve
Control
hydraulic pressure.
Hydraulic system
PTP

Structure
Selective Catalytic
Reduction
VGT Engine

D: Bulldozer
HD: Dump truck
WA: Wheel loader
60-6 GD535-5

A/C Air Conditioner
A/M Air Mix damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
ENG Engine
F.G. Frame Ground
GND Ground
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/M Transmission
GD535-5 60-7
Engine mount and transmission mount 60 Maintenance standard
Engine mount and transmission mount 1
60-8 GD535-5
60 Maintenance standard Cooling system
Cooling system 1
GD535-5 60-9
Cooling fan motor 60 Maintenance standard
Cooling fan motor 1
60-10 GD535-5
60 Maintenance standard Cooling fan motor
Unit: mm
No. Item Judgment criteria Remedy
Standard dimension Repair limit
Free height Load at Load at
Installed Replace the
x outside installed Free height installed
1 Spool return spring height spring (replace
diameter height height
the spring if
58.8 N 47.1 N damaged or
44.84 x 12 33 -
{6 kg} {4.8 kg} deformed)
44.1 N 35.3 N
2 Spool return spring 37 x 8.5 36 -
{4.5 kg} {3.6 kg}
GD535-5 60-11
Torque converter 60 Maintenance standard
Power train system 1
Torque converter 1
60-12 GD535-5
60 Maintenance standard Torque converter
Unit: mm
Standard dimension Tolerance Repair limit
Inside diameter of seal ring sliding surface
1 of hole in pilot +0.025
35 35.1
0
Inside diameter of seal ring sliding surface +0.040
2 of PTO drive gear
120
0
120.1

3 of stator shaft
55
0
55.1
Inside diameter of one-way clutch rolling +0.005

4 contact surface of outer race
88.882
-0.008
88.912
Outside diameter of one-way clutch rolling +0.008

5 contact surface of stator shaft
72.217
-0.005
72.187 Replace
Inside diameter of sliding surface of +0.015

6 bushing
72.32
0
72.4
0
7 Thickness of sliding surface of bushing 5
-0.1
4.5
8 Thickness of clutch disc 5 ±0.1 4.5

0
Width 3.95 3.55
9 Wear of seal ring of stator shaft -0.1
Thickness 4.6 ±0.1 4.14
10 Backlash between input gear and PTO gear 0.160 to 0.418
GD535-5 60-13
Transmission 60 Maintenance standard
Transmission 1
60-14 GD535-5
60 Maintenance standard Transmission
GD535-5 60-15
Unit: mm
Standard Tolerance Standard Allowable
Clearance between input shaft bearing and dimension Shaft Hole clearance clearance
1
front case 0 +0.022 -0.013 to
100 -
-0.015 -0.013 0.037
Clearance between input shaft bearing and 0 +0.028
2 100 0 to 0.043 -
rear case -0.015 0
Clearance between upper shaft bearing and 0 +0.028
3 120 0 to 0.043 -
front case -0.015 0
Clearance between upper shaft bearing and 0 +0.030
4 110 0 to 0.045 -
rear case -0.015 0
Clearance between lower shaft bearing and 0 +0.028
5 110 0 to 0.043 -
front case -0.015 0
Clearance between lower shaft bearing and 0 +0.028
6 120 0 to 0.043 -
rear case -0.015 0
Clearance between output shaft bearing 0 +0.032
7 140 0 to 0.050 -
and front case -0.018 0
Clearance between output shaft bearing 0 +0.032
8 140 0 to 0.050 -
and rear case -0.018 0
Inside diameter of seal ring sliding surface
of input shaft (front) +0.050
55 55.1
9 0
Width of seal ring groove of input shaft +0.076
3.2 3.5
(front) 0
55 55.1
of input shaft (middle) 0
10
3.2 3.5
(middle) 0
Inside diameter of seal ring sliding surface +0.025 Replace
35 35.1
of input shaft (rear) 0
11
2.5 2.7
(rear) +0.10
55 55.1
of upper shaft 0
12
+0.076
Width of seal ring groove of upper shaft 3.2 3.5
0
50 50.1
of lower shaft 0
13
+0.076
Width of seal ring groove of lower shaft 3.2 3.5
0
50 50.1
of output shaft 0
14
+0.076
Width of seal ring groove of output shaft 3.2 3.5
0
Outside diameter of oil seal sliding surface 0
15 80 79.8
of coupling -0.074

Clearance between PTO idler gear A dimension Shaft Hole clearance clearance
16
bearing and rear case
0 +0.004 -0.015 to
80 -
-0.016 -0.015 +0.020
Clearance between PTO idler gear A +0.018 0 -0.030 to
17 50 -
bearing and PTO idler gear A +0.002 -0.012 +0.002
Clearance between PTO driven gear A 0 +0.004 -0.015 to
18 80 -
bearing and rear case -0.016 -0.015 +0.020
Clearance between PTO driven gear A +0.018 0 -0.030 to
19 50 -
bearing and PTO driven gear A +0.002 -0.012 +0.002
60-16 GD535-5
Unit: mm
Clearance between PTO idler gear B dimension Shaft Hole clearance clearance
1 bearing and rear case
0 +0.004 -0.015 to
80 -
-0.016 -0.015 +0.020
Clearance between PTO idler gear B +0.018 0 -0.030 to
2 bearing and PTO idler gear B
50
+0.002 -0.012 +0.002
-
Clearance between PTO driven gear B 0 +0.004 -0.015 to Replace

3 bearing and rear case
80
-0.016 -0.015 +0.020
-
Clearance between PTO driven gear B +0.018 0 -0.030 to

4 bearing and PTO driven gear B
50
+0.002 -0.012 +0.002
-
Clearance between idler gear bearing and R 0 -0.049 -0.073 to -

5 idler gear
100
-0.015 -0.073 0.034
-
Clearance between idler gear bearing and +0.032 0 -0.047 to -

6 front case
70
+0.002 -0.015 0.002
-
GD535-5 60-17
FL and R clutches
Unit: mm
Clearance between input shaft bearing and dimension Shaft Hole clearance clearance
1 input shaft (front)
+0.030 0 -0.045 to
55 -
+0.015 -0.015 -0.015
Clearance between input shaft bearing and +0.030 0 -0.045 to
2 input shaft (rear)
55
+0.015 -0.015 -0.015
-
Standard
- Tolerance Repair limit
dimension
3 Clutch plate
Thickness 1.7 1.5
±0.05
Replace
Strain - 0.05 0.15
Thickness 2.2 ±0.08 1.9
4 Clutch disc
Strain - 0.1 0.25
Wave spring load 1,010 N
5 [Testing height: 2.2 mm] {103 kg}
±101 N {±10.3 kg} 859 N {87.6 kg}
6 Height of thrust washer 3 ±0.1 2.7
7 End play of R clutch gear 0.21 to 1.09
8 End play of FL clutch gear 0.21 to 1.09
60-18 GD535-5
FH and 1st clutches
Unit: mm
Clearance between upper shaft bearing dimension Shaft Hole clearance clearance
1 and upper shaft (front) +0.025 0 -0.037 to
50 -
+0.009 -0.012 -0.009
Clearance between upper shaft bearing +0.035 0 -0.050 to
2 and upper shaft (rear)
55
+0.025 -0.015 -0.025
-
Standard
dimension
3 Clutch plate
Thickness 1.8 1.6
±0.06
Strain - 0.05 0.15
Thickness 2.2 ±0.08 1.9
4 Clutch disc Replace
Strain - 0.1 0.25
Wave spring load 902 N
5 [Testing height: 2.2 mm] {92 kg}
±90 N {±9.2 kg} 767 N {78.2kg}
7 Thickness of thrust washer inside 1st clutch 3 ±0.1 2.7
8 Thickness of thrust washer inside FH clutch 4 ±0.2 3.7

Inside diameter of sliding surface of 1st +0.063
9 gear bushing
63.5
-0.007
63.7
10 End play of 1st clutch gear 0.07 to 0.93
11 End play of FH clutch gear 0.4 to 1.6
GD535-5 60-19
2nd and 3rd clutches
Unit: mm
Clearance between lower shaft bearing and dimension Shaft Hole clearance clearance
1
lower shaft (front) +0.030 0 -0.045 to
55 -
+0.011 -0.015 -0.011
Clearance between lower shaft bearing and +0.034 0 -0.049 to
2 60 -
lower shaft (rear) +0.021 -0.015 -0.021
Standard
dimension
3 3rd clutch plate
Thickness 1.8 ±0.06 1.6
Strain - 0.05 0.15
Replace
Thickness 2.2 ±0.08 1.9
4 3rd clutch disc
Strain - 0.1 0.25
3rd clutch wave spring load [testing height: 902 N ±90 N 767 N
5
2.2 mm] {92 kg} {±9.2 kg} {78.2 kg}
Thickness 1.7 ±0.05 1.5
6 2nd clutch plate
Strain - 0.05 0.15
Thickness 2.2 ±0.08 1.9
7 2nd clutch disc
Strain - 0.10 0.25
2nd clutch wave spring load [testing height: 1,010 N ±101 N 859 N
8
3.8 mm] {103 kg} {±10.3 kg} {87.6 kg}
60-20 GD535-5

Standard
Tolerance Repair limit
9 Thickness of 3rd clutch thrust washer dimension
3 ±0.1 2.7
10 Thickness of 3rd clutch thrust washer 3 ±0.1 2.7
Replace
11 Thickness of 2nd clutch thrust washer 3 ±0.1 3.7
12 Thickness of 2nd clutch thrust washer 3 ±0.1 3.7
13 End play of 2nd clutch gear 0.07 to 0.93
14 End play of 3rd clutch gear 0.07 to 0.93
GD535-5 60-21
4th clutch
Unit: mm
Clearance between output shaft bearing dimension Shaft Hole clearance clearance
1
and output shaft (front)
+0.030 0 -0.045 to
65 -
+0.011 -0.015 -0.011
Clearance between output shaft bearing +0.030 0 -0.045 to
2 65 -
and output shaft (rear) +0.011 -0.015 -0.011
Standard
dimension
3 Clutch plate
Thickness 1.8 ±0.06 1.6
Replace
Strain - 0.05 0.15
Thickness 2.2 ±0.08 1.9
4 Clutch disc
Strain - 0.1 0.25
Wave spring load 902 N
5 ±90 N {±9.2 kg} 767 N {78.2 kg}
[Testing height: 2.2 mm] {92 kg}
8 End play of 4th clutch gear 0.10 to 0.90
60-22 GD535-5
60 Maintenance standard Main relief valve and torque converter relief valve
Main relief valve and torque converter relief valve 1
Unit: mm
Clearance between main relief dimension Shaft Hole clearance clearance
1
valve and valve body
-0.035 +0.013 0.035 to
28 0.078
-0.045 0 0.058
Clearance between torque
-0.035 +0.013 0.035 to
2 converter relief valve and valve 22 0.078
-0.045 0 0.058
body
Load at Load at Replace
Installed
Free height installed Free height installed
3 Main relief valve spring (outside) height
height height
291 N 276 N
108 77.8 104.8
{29.7 kg} {28.2 kg}
347 N 329 N
4 Main relief valve spring (inside) 108 77.8 104.8
{35.4 kg} {33.6 kg}
Torque converter relief valve 162 N 154 N
5 50 41.5 48.5
spring {16.5 kg} {15.7 kg}
GD535-5 60-23
Front axle 60 Maintenance standard
Front axle 1
60-24 GD535-5
60 Maintenance standard Front axle
Unit: mm

dimension Shaft Hole clearance clearance
1 Clearance between center pin and bushing
-0.030 +0.174 0.130 to
55 3.0
-0.076 +0.100 0.250
-0.025 +0.164 0.145 to Replace

2 Clearance between king pin and bushing 45
-0.064 +0.120 0.228
2.0 bushing
Clearance between front axle pin and -0.025 +0.164 0.145 to

3 bushing
45
-0.064 +0.120 0.228
2.0
-0.060 +0.020 0.060 to

4 Clearance between ball joint and bushing 55
-0.090 0 0.110
1.0
5 Preload of hub bearing Starting torque: 98.1 to 137.3 N {10 to 14 kg} ( at hub bolt position) Adjust shims
GD535-5 60-25
Rear axle 60 Maintenance standard
Rear axle 1
60-26 GD535-5
60 Maintenance standard Differential (Non-differential specification)
Differential (Non-differential specification) 1
Unit: mm
1 Preload of bevel pinion and bearing Starting torque: 0.8 to 5.8 Nm {0.08 to 0.59 kgm}
Starting torque: Starting torque stipulated in No. 1 plus 1.7 to
2 Preload of bevel gear and bearing 11.1Nm {0.17 to 1.13 kgm} Adjust by using
(Measure at pinion shaft after gear fits in.) shims
Backlash between bevel pinion and bevel Standard dimension
3
gear 0.20 to 0.28
GD535-5 60-27
Differential (Differential lock specification) 60 Maintenance standard
Differential (Differential lock specification) 1
60-28 GD535-5
60 Maintenance standard Differential (Differential lock specification)
Unit: mm
1 Preload of bevel pinion and bearing Starting torque: 0.8 to 5.8 Nm {0.08 to 0.59 kgm}
Starting torque: Starting torque stipulated in No. 1 plus 0.7 to 5.2 Nm
2 Preload of bevel gear and bearing {0.07 to 0.53 kgm} Adjust by using
(Measure at pinion shaft after gear fits in.) shims
Backlash between bevel pinion and bevel
3 0.20 to 0.28
gear
4 Thickness of disc
2.8 ±0.1 2.65
5 Thickness of plate 1.8 ±0.05 1.65 Replace
6 Thickness of pinion washer 3 ±0.08 2.8
7 Thickness of side gear washer 4 ±0.05 3.8
GD535-5 60-29
Final drive 60 Maintenance standard
Final drive 1
Unit: mm
1 Preload of shaft and bearing Starting torque: 0.8 to 5.0 Nm {0.08 to 0.51 kgm} Adjust by using
2 End play of flange 0 to 0.1 shims
60-30 GD535-5
60 Maintenance standard Differential lock solenoid valve
Differential lock solenoid valve 1
Unit: MPa {kg/cm2}

Differential oil pressure range (with engine Standard Repair limit
speed changing from low idle speed (800
- ±50 rpm) to high idle speed (2,225 ± 50 2.7 to 3.09 Max. 2.7 Adjust
rpm) when differential oil temperature is 50 {27.5 to 31.5} {Max. 27.5}
± 5°C)
GD535-5 60-31
Tandem drive 60 Maintenance standard
Tandem drive 1
Unit: mm
Starting torque: 2.94 to 7.35 Nm {0.3 to 0.75 kgm} Adjust by using
1 Preload of hub bearing
(Torque added to dragging torque) shims
Size Repair limit
2 Elongation of chain (per 10 links) Replace
508.0 515.62
60-32 GD535-5
60 Maintenance standard Steering cylinder
Steering system 1
Steering cylinder 1
Unit: mm
1 Clearance between piston rod and bushing
-0.025 +0.121 0.020 to
35 0.485
-0.064 -0.005 0.185 Replace
Clearance between piston rod support shaft +0.015 +0.030 -0.015 to bushing
2 62 1.0
and bushing -0.010 0 0.040
Clearance between piston bottom support -0.025 0 0.037 to
3 35 1.0
shaft and bushing -0.064 -0.012 0.064
4 Tightening torque of piston nut 245 ± 24.5 Nm {25 ± 2.5 kgm} (width across flats: 30)
Retighten
5 Tightening torque of cylinder head 392 ± 39.0 Nm {40 ± 4.0 kgm}
GD535-5 60-33
Wheel brake 60 Maintenance standard
Brake system 1
Wheel brake 1
Unit: mm
1 Thickness of disc
3.9 ± 0.1 3.6
2 Thickness of plate 2.4 ± 0.1 2.1
Standard dimension Repair limit Replace
Load at installed Load at installed

3 Spring load Installed height
height height
60.5 735 N {75 kg} 662 N {67.5 kg}
60-34 GD535-5
60 Maintenance standard Parking brake
Parking brake 1
Unit: mm
1 Thickness of brake disc
10.4 9.4 Replace
2 Thickness of brake pad 12.5 9.5
GD535-5 60-35
Frame and center hinge pin 60 Maintenance standard
Undercarriage and frame 1
Frame and center hinge pin 1
60-36 GD535-5
60 Maintenance standard Hydraulic tank
Hydraulic system 1
Hydraulic tank 1
GD535-5 60-37
Work equipment pump and steering pump 60 Maintenance standard
Work equipment pump and steering pump 1
Unit: mm
Model Standard clearance Allowable clearance
1 Side clearance SAR (2) 40 0.10 to 0.15 0.19
SAR (2) 20 0.10 to 0.15 0.19
Clearance between inside diameter of plain SAR (2) 40 0.067 to 0.125 0.20
2 Replace
bearing and outside diameter of gear shaft SAR (2) 20 0.067 to 0.125 0.20
Model Standard dimension Tolerance Repair limit
3 Driving depth of pin SAR (2) 40 12 0

-
SAR (2) 20 12 -0.5
4 Splined rotary shaft torque 2.9 to 6.9 Nm {0.3 to 0.7 kgm}
Discharged
Standard Allowable
Revolution pressure
Model discharge discharge
speed (rpm) (MPa -
Discharge, with EO10-CD oil at temperature (l/min) (l/min)
- {kg/cm2})
of 45 to 55°C
SAR (2) 40 3,000 20.6 {210} 111 107
SAR (2) 20 3,000 20.6 {210} 55 53
60-38 GD535-5
60 Maintenance standard Power train pump
Power train pump 1
Unit: mm
Standard clearance Allowable clearance
1 Side clearance
0.10 to 0.15 0.19
Clearance between inside diameter of plain
2 0.067 to 0.125 0.20
bearing and outside diameter of gear shaft
Standard dimension Tolerance
3 Driving depth of pin 0 Replace
12
-0.5
Discharge Standard Allowable
Discharged volume Revolution
pressure discharge discharge
- Oil: EO10-CD speed (rpm)
(MPa {kg/cm2}) (l/min) (l/min)
Temperature: 45 to 55°C
2,300 4.4 {45} 137 124 -
GD535-5 60-39
Power train pump and differential lock pump 60 Maintenance standard
Unit: mm
Model Standard clearance Allowable clearance
1 Side clearance SAR (2) 63 0.10 to 0.15 0.19
SBR (1) 10 0.10 to 0.15 0.19
Clearance between inside diameter of plain SAR (2) 63 0.067 to 0.125 0.20
2 Replace
bearing and outside diameter of gear shaft SBR (1) 10 0.064 to 0.119 0.20
Model Standard dimension Tolerance Repair limit
3 Driving depth of pin SAR (2) 63 12 0

-
SBR (1) 10 10 -0.5
Discharged
Standard Allowable
Revolution pressure
Model discharge discharge
Discharged volume speed (rpm) (MPa -
(l/min) (l/min)
- Oil: EO10-CD {kg/cm2})
Temperature: 45 to 55°C
SAR (2) 63 2,300 4.4 {45} 140.2 124
SBR (1) 10 2,300 4.4 {45} 22.6 18
60-40 GD535-5
60 Maintenance standard Parking brake solenoid valve and lifter lock pin solenoid valve
Parking brake solenoid valve and lifter lock pin solenoid valve 1
GD535-5 60-41
Leaning cylinder 60 Maintenance standard
Leaning cylinder 1
Unit: mm
-0.025 +0.132 0.031 to
40 0.496
-0.064 +0.006 0.196 Replace
bushing
Clearance between piston rod support shaft -0.025 +0.142 0.105 to
2 45 1.0
and bushing -0.064 +0.080 0.206
Clearance between piston bottom support -0.025 +0.142 0.105 to
3 40 1.0
shaft and bushing -0.064 +0.080 0.206
4 Tightening torque of piston nut 785 ± 78.50 Nm {80 ± 8 kgm} (width across flats: 46)
Retighten
5 Tightening torque of cylinder head 569 ± 57 Nm {58 ± 5.8 kgm}
60-42 GD535-5
60 Maintenance standard Articulate cylinder
Articulate cylinder 1
Unit: mm
-0.025 +0.152 0.032 to
45 0.516
-0.064 +0.007 0.216 Replace
Clearance between piston rod support shaft -0.025 +0.142 0.105 to bushing
2 45 1.0
and bushing -0.064 +0.080 0.206
3 45 1.0
4 Tightening torque of piston nut 1,080 ± 110 Nm {110 ± 11 kgm} (width across flats: 50)
Retighten
5 Tightening torque of cylinder head 569 ± 57 Nm {58 ± 5.8 kgm}
GD535-5 60-43
Blade lift cylinder 60 Maintenance standard
Blade lift cylinder 1
Unit: mm
-0.025 +0.164 0.032 to
50 0.528
-0.064 +0.007 0.228 Replace
Clearance between piston rod support shaft bushing
-0.050 +0.100 0.050 to
2 80 1.0
and bushing -0.150 0 0.250
Clearance between cylinder boss and -0.080 +0.062 0.080 to
3 45 1.0
bushing -0.142 0 0.204
4 Tightening torque of piston nut 618 ± 62 Nm {63 ± 6.3 kgm} (width across flats: 41)
Retighten
60-44 GD535-5
60 Maintenance standard Drawbar shift cylinder
Drawbar shift cylinder 1
Unit: mm
-0.025 +0.152 0.032 to
45 0.516
-0.064 +0.007 0.216 Replace
-0.050 +0.100 0.050 to
2 80 1.0
and bushing -0.150 0 0.250
3 80 1.0
shaft and bushing -0.150 0 0.250
Retighten
5 Tightening torque of cylinder head 588±59.0 Nm {60 ± 6.0 kgm}
GD535-5 60-45
Blade side shift cylinder 60 Maintenance standard
Blade side shift cylinder 1
Unit: mm
Clearance between piston rod and dimension Shaft Hole clearance clearance
1
bushing
-0.025 +0.164 0.032 to
50 0.528
-0.064 +0.007 0.228 Replace
bushing
Clearance between piston rod support -0.025 +0.142 0.105 to
2 40 1.0
3 40 1.0
Retighten
60-46 GD535-5
60 Maintenance standard Power tilt cylinder
Power tilt cylinder 1
Unit: mm

-0.025 +0.132 0.031 to
40 0.519
-0.087 +0.006 0.219 Replace
bushing
Clearance between piston rod support shaft -0.025 0 0.013 to
2 40 1.0
and bushing -0.064 -0.012 0.064
Clearance between piston bottom support -0.025 0 0.013 to

3 40 1.0
shaft and bushing -0.064 -0.012 0.064
4 Tightening torque of piston nut 647 ± 64.5 Nm {66 ± 6.6 kgm} (width across flats: 41)
Retighten
GD535-5 60-47
Scarifier cylinder 60 Maintenance standard
Scarifier cylinder 1
Unit: mm
-0.025 +0.164 0.032 to
50 0.528
-0.064 +0.007 0.228 Replace
-0.025 +0.142 0.105 to
2 50 1.0
and bushing -0.064 +0.080 0.206
3 40 1.0
4 Tightening torque of piston nut 1.08 ± 0.11 kNm {110 ± 11 kgm} (width across flats: 50)
Retighten
60-48 GD535-5
60 Maintenance standard Ripper cylinder
Ripper cylinder 1
Unit: mm
-0.025 +0.164 0.032 to
50 0.528
-0.064 +0.007 0.228 Replace
-0.025 +0.142 0.105 to
2 50 1.0
and bushing -0.064 +0.080 0.206
Clearance between cylinder bottom support -0.025 +0.142 0.105 to
3 50 1.0
4 Tightening torque of piston nut 1.42 ± 0.14 kNm {145 ± 14.5 kgm} (width across flats: 55)
Retighten
GD535-5 60-49
Circle and drawbar 60 Maintenance standard
Work equipment 1
Circle and drawbar 1
60-50 GD535-5
60 Maintenance standard Circle and drawbar
Unit: mm
Standard Tolerance Standard Allowable Replace joint or
dimension clearance clearance ball stud if it
Shaft Hole
1 Clearance at ball stud cannot be
-0.050 +0.100 0.050 to adjusted by
S150 -
-0.100 0 0.200 using shims
Standard dimension Repair limit Replace circle
guide if it cannot
2 Clearance between circle and drawbar
1.0 to 2.0 1.0 to 2.0 be adjusted by
using shims
3 Wear of guide plate 6 2 Replace
Replace joint or
ball stud if it
4 Axial play of drawbar 0.65 to 0.95 cannot be
adjusted by
using shims
5 Standard shim pack thickness at ball stud 4 to 4.6
Adjust by using
Standard shim pack thickness at guide shims
6 5.5
mount
GD535-5 60-51
Blade 60 Maintenance standard
Blade 1
Unit: mm
1 Wear of side edge Replace
From blade base: 44 From blade base: 25
60-52 GD535-5
60 Maintenance standard Blade
Unit: mm
2 Wear of cutting edge
From blade base: 74 From blade base: 10
3a Height 368 364
Wear of blade rail Replace
3b Thickness 25 24
4a Height 8 5
Wear of blade rail guide
4b Thickness 25 33
GD535-5 60-53
Lifter 60 Maintenance standard
Lifter 1
Unit: mm
dimension Shaft Hole clearance clearance Replace
1 Clearance between yoke and bushing
bushing
-0.030 +0.174 0.130 to
75 0.6
-0.076 +0.100 0.250
60-54 GD535-5
60 Maintenance standard Circle rotation gear
GD535-5 60-55
Circle rotation gear 60 Maintenance standard
Unit: mm
1 Clearance between shaft and bushing
-0.030 +0.057 0.040 to Replace
80 0.4 bushing
-0.060 +0.010 0.117
+0.035 +0.270 0.026 to
2 Clearance between collar and bushing 90 0.6
0.000 +0.061 0.270
Standard clearance Allowable clearance
3 Backlash between worm and worm wheel Replace
0.3 to 0.4 2.0
Clearance between case lower surface Adjust by using
4 0.1 to 0.5 0.6
plate and pinion shims
5 Wear of pinion Replace
25 20
Starting torque: 2.9 to 7.8 Nm {0.3 to 0.8 kgm}
6 Preload of bearing Adjust
With worm and worm wheel not engaged with each other
7 Standard shim pack thickness (top) 3
-
8 Standard shim pack thickness (bottom) 4.6
60-56 GD535-5
60 Maintenance standard Ripper
Ripper 1
Unit: mm
1 Wear of point Replace
198 123
GD535-5 60-57
Ripper 60 Maintenance standard
Unit: mm
dimension Shaft Hole clearance clearance Replace
1 Clearance between shaft and bushing
-0.025 +0.164 0.145 to bushing
50 0.4
-0.064 +0.120 0.228
Inner diameter of bushing insertion hole of +0.076 +0.046
2 60 -0.076 to 0 0.6
bushing +0.046 0 Repair after
Inner diameter of bushing insertion hole of +0.096 +0.046 -0.096 to build-up welding
3 60 0.6
bushing +0.066 0 -0.020
-0.025 +0.180 0.163 to Replace
4 Clearance between shaft and bushing 50 0.4
-0.064 +0.138 0.244 bushing
60-58 GD535-5
80 Appendix
GD535-5 80-1
(01)
Contents 80 Appendix
Contents 1
Acronyms - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-3
Air conditioner system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-8
Precautions for refrigerant - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-8
Air conditioner component - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-9
Specifications of air conditioner- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-12
Configuration and function of refrigeration cycle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-13
Outline of refrigeration cycle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-14
Component parts of air conditioner system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-16
Air conditioner unit- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-16
Component parts of air conditioner unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-19
Compressor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-21
Condenser - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-22
Receiver drier - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-23
Explanation of procedure for testing and troubleshooting of air conditioner - - - - - - - - - - - - - - - - - - - - - 80-24
Circuit diagram and arrangement of connector pins for air conditioner - - - - - - - - - - - - - - - - - - - - - - - - 80-26
Air conditioner system diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-28
Input and output signals of air conditioner control panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-29
Installation locations of air conditioner parts and arrangement of connectors- - - - - - - - - - - - - - - - - - - - 80-32
Testing air leakage (duct) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-37
Method for testing air leakage (duct) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-37
Testing air conditioner using self-diagnosis function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-39
Check temperature control function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-40
Method for checking temperature control function- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-40
Testing fresh/recirc air changeover- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-41
Method for testing fresh/recirc air changeover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-41
Test evaporator temperature sensor- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-42
Method for checking evaporator temperature sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-42
Test relays - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-43
Method for testing relays - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-43
Check blower AMP- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-44
Method for checking blower AMP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-44
Air conditioner troubleshooting chart 1- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-46
Air conditioner troubleshooting chart 2- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-48
Information described in troubleshooting table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-51
A-1 Troubleshooting for power supply system (air conditioner does not operate) - - - - - - - - - - - - - - - - - 80-52
A-2 Troubleshooting for compressor and refrigerant system (air is not cooled) - - - - - - - - - - - - - - - - - - 80-54
A-3 Troubleshooting for blower motor system (no air comes out or air flow is abnormal) - - - - - - - - - - - 80-57
A-4 Troubleshooting for temperature control function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-60
A-5 Troubleshooting for fresh/recirc air changeover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-63
A-6 Troubleshooting for hot water cut valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-66
Troubleshooting using gauge pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-68
Connection of service tool - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-70
Method for connecting service tool - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-71
Precautions for disconnecting and connecting hoses and tubes in air conditioner pipings- - - - - - - - - - - 80-72
Handle compressor oil - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-74
80-2 GD535-5
(01)
80 Appendix Acronyms
Acronyms 1
Automatic Idling Set-
ting System
Advanced Joystick
Automatic Retarder machine is traveling downhill, this function auto-
ARAC
Accelerator Control (HD series, HM series) matically applies the retarder with a constant brak-
ing force.
machine is traveling downhill, this function auto-
Automatic Retarder
ARSC matically applies the retarder to ensure that the
Automatic Spin Regula-
tor (HD series, HM series) force to drive both wheels.
Brake Cooling oil con-
trol Valve (HD series) load on the hydraulic pump.
A regulator valve which is installed to KCCV venti-
CDR Engine lator. It is written as CDR valve and it is not used
Regulator
independently.
Closed-center Load
Sensing System
injection timing.
Electronic Control Mod- each sensor of the machine and that specifies the
ule optimum operation to the actuators. (Same as
ECU)
GD535-5 80-3
(01)
Acronyms 80 Appendix
Transmission Proportional solenoid valve that reduces the con-
Electronic Control Mod-
ECMV (D series, HD series, WA nection shock by gradually increasing the hydraulic
ulation Valve
series and others) pressure to engage the clutch.
Electronically Con- Traveling This system ensures smooth high-speed travel by

ECSS trolled Suspension Sys- absorbing vibration of machine during travel with
tem (WA series) hydraulic spring effect of accumulator.
ECM)
Exhaust Gas Recircula-
tion
Equipment Manage-
EMMS ment Monitoring Sys- Machine monitor
tem
Electromagnetic proportional control This mecha-
Electromagnetic Pro-
EPC Hydraulic system nism allows actuators to be operated in proportion
portional Control
to the current supplied.
Falling Object Protec- falling objects. (Falling Object Protective Structure)
tive Structure
Forward-Neutral-
Reverse
Global Positioning Sys-
tem
Plus) earth

Global Navigation Sat-
ellite System

HSS
Hydro Static Transmis-
HST and hydraulic motor to shift the speed range step-
sion (D series, WA series) lessly without using gears.
A general term for the engineering and its socially
Information and Com- Communication, electronic
ICT applied technology of information processing and
munication Technology control
communication.
Unit
motions.
80-4 GD535-5
(01)
KOMATSU Closed
KCSF Engine
KOMATSU Diesel Oxi-
dation Catalyst
muffler.
KOMATSU Diesel Par- KDOC (catalyst) and KCSF (filter to capture soot)
ticulate Filter
KOMATSU Traction
KTCS and at the same time activates the inter-axle differ-
Control System (HM series) ential lock when the wheels idle while the machine
travels on the soft ground road.
Light emitting diode It refers to semiconductor ele-
LED Light Emitting Diode Electronic components ment that emits light when the voltage is applied in
forward direction.
Local Interconnect Net- Communication, electronic One of communication standards that is used in the
LIN
work control network on the machine
load.
LVDS
intake airflow sensor may be called the MAF sen-
sor.
Service
NC Normally Closed
NO Normally Open
Open-center Load The hydraulic system that can simultaneously oper-
Sensing System ate multiple actuators regardless of the load.
Pressure Compensa- The function to compensate for the hydraulic pres-
PC Hydraulic system
tion sure.
GD535-5 80-5
(01)
Acronyms 80 Appendix
PCCS
Pre-stroke Control
Valve
Control
hydraulic pressure.
Hydraulic system
PTP

Structure
Selective Catalytic
SCR Urea SCR system harmless nitrogen and water (by reduction reac-
Reduction
tion). It may be called part of the exhaust gas puri-
fying catalyst or the related device name.
Abbreviated for the "International System of Units".
Le SystÐ®me Interna-
SI Unit It is the universal unit system and "A single unit for
tional d‚Äô UnitÐ©s
a single quantity" is the basic principle applied.
Variable Geometry Tur- Turbocharger having the variable geometry of
VGT Engine
bocharger exhaust passage

D: Bulldozer
HD: Dump truck
WA: Wheel loader
80-6 GD535-5
(01)

A/C Air Conditioner
A/M Air Mix damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
ENG Engine
F.G. Frame Ground
GND Ground
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/M Transmission
GD535-5 80-7
(01)
Precautions for refrigerant 80 Appendix
Air conditioner system 1
Precautions for refrigerant 1
k If refrigerant gas (air conditioner gas: R134a) gets in your eyes, you may lose your sight. And if it
touches your skin, you may suffer from frostbite. Put on protective eyeglasses, gloves and working
clothes with long sleeves while collecting the refrigerant or filling the air conditioner circuit with the
refrigerant.
k When replacing the air conditioner unit, air conditioner compressor, condenser or receiver drier,
etc., collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit before discon-
necting the air conditioner hoses.
NOTICE
q Never release the refrigerant (air conditioner gas: R134a) to the atmosphere.
q Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner
gas: R134a).
80-8 GD535-5
(01)
80 Appendix Air conditioner component
Air conditioner component 1
GD535-5 80-9
(01)
Air conditioner component 80 Appendix
1: Air conditioner control panel 8: Receiver drier

2: Air conditioner unit 9: Condenser
3. Hot water return hose 10. Compressor
4. Hot water supply hose 11: Fresh air filter
5: Recirculation air filter 12: Sight glass
6: Dual pressure switch 13: Hot water cut valve
7: Refrigerant hose
80-10 GD535-5
(01)
80 Appendix Air conditioner component
A: Front window glass warm/cool air vent D: Front warm/cool air vent
B: Rear warm/cool air vent E: Recirculation air inlet
C: Side warm/cool air vent F: Fresh air inlet
GD535-5 80-11
(01)
Specifications of air conditioner 80 Appendix
Specifications of air conditioner 1
Refrigerant: R134a
Refrigerant quantity: 1150±50 g
80-12 GD535-5
(01)
80 Appendix Configuration and function of refrigeration cycle
Configuration and function of refrigeration cycle 1
Cycle Compression Condensation Expansion Evaporation

(component) (compressor) (condenser) (Expansion valve) (Evaporator)
Location of compo- Engine compartment Front part of radiator Inside of operator's cab Inside of operator's cab
nent (built in air conditioner (built in air conditioner
unit) unit)
Function Circulates refrigerant Condenses refrigerant to Decreases temperature Absorbs heat from air
and increases tempera- discharge heat absorbed and pressure of refriger- around evaporator to
ture and pressure of gas in evaporator. ant with throttle and con- cool that air by evaporat-
refrigerant so that it is (condensation of refrig- vert it partially into gas ing refrigerant.
liquefied easily in con- erant) so that it is evaporated (Evaporation of refriger-
denser. easily, and controls flow ant)
(Compression of refrig- rate.
erant) (Throttling of refrigerant)
State of refrigerant Gas → gas Gas → liquid Liquid → liquid, gas Liquid, gas → gas
Adiabatic compression Isobaric change Adiabatic expansion Isobaric change
GD535-5 80-13
(01)
Outline of refrigeration cycle 80 Appendix
Outline of refrigeration cycle 1
Regeneration cycles are composed of the following 4 processes. Refrigerant circulates around the system repeat-
edly changing its phase from liquid → gas → liquid.
Compression (Compressor)
q The compressor sucks in the refrigerant which is evaporated in the evaporator and compresses the refriger-
ant until it can be easily liquefied at the ambient temperature.
q The gas refrigerant sucked in the compressor cylinder is compressed to make the pressure higher. When the
refrigerant is cooled at the ambient temperature, it can be easily liquefied.
Condensation (Condenser)
q The condenser cools and liquefies the high-temperature and high-pressure gas refrigerant sent from the com-
pressor at the ambient temperature.
q The heat radiation from the condenser to the atmosphere is called the condensation heat.
q The amount of condensation heat is the sum total of the heat absorbed by the evaporator from the air in the
cab and the quantity of the work applied (the value converted into a heat quantity) by compression of the com-
pressor.
q The refrigerant liquefied in the condenser is sent to the receiver and dewatered.
q In the condensation process, gas refrigerant and liquid refrigerant are mixed.
q The temperature (condensation temperature) and the pressure (condensation pressure) at which the gas-
eous refrigerant is liquefied are proportional to each other.
Reference: The pressure varies depending on the condensation temperature of the refrigerant.
Expansion (Expansion valve)
q The expansion valve reduces the liquid refrigerant pressure to a level where liquid refrigerant can be easily
evaporated by the throttle action (*1).
q The action of reducing the pressure of the liquid refrigerant to a state where it easily evaporates before send-
ing it to the evaporator is called expansion.
q The expansion valve used for expansion reduces the refrigerant pressure and controls the refrigerant flow
simultaneously.
q The quantity of the liquid refrigerant that can be evaporated in the evaporator depends on the amount of heat
(refrigeration load) to be removed under the specific evaporation temperature (evaporation pressure).
q The expansion valve controls the refrigerant supply rate to prevent too much or too little supply of the liquid
refrigerant.
(*1) Throttle action
q If there is a narrow section in the passage through which liquid is flowing at a constant rate, a resistance to the
flow is generated.
When the liquid passes through a narrow section, cross-sectional area suddenly increases. The liquid expan-
sion causes pressure and temperature to decrease.
q No heat is transferred between inside and outside by the throttle action.
Evaporation (Evaporator)
q The evaporator evaporates the liquid refrigerant (superheated vapor).
q The refrigerant evaporates, while absorbing an amount of heat necessary for evaporation (evaporation heat)
from the air around the cooling fins (air in the cab).
q The cooled air is sent into the cab by the blower fan, and it decreases the temperature in the cab.
q In the evaporator, the misty refrigerant sent from the expansion valve and the evaporated gas refrigerant are
mixed together.
q The temperature (evaporation temperature) and the pressure (evaporation pressure) at which the liquid refrig-
erant is evaporated are proportional to each other.
q To evaporate the liquid refrigerant at lower temperature, the pressure in the evaporator must be kept as low
as possible. For this purpose, the compressor sucks in the evaporated refrigerant.
Relation between refrigerant and cooling trouble
q While repeating the refrigeration cycle, the refrigerant circulates in the refrigeration circuit and dissipates the
heat in the cab to the outside of the cab.
q If there is an insufficient quantity of refrigerant, all of it is evaporated while it is passing through the evaporator.
This causes evaporator efficiency to deteriorate, which will result in defective air conditioning.
q If there is excessive refrigerant, not all of it is evaporated and part of it will be sucked into the compressor in
liquid form, which causes the compressor to compress the liquid and may damage the components.
80-14 GD535-5
(01)
80 Appendix Outline of refrigeration cycle
q If water is contained in the refrigerant circuit, it freezes in the small hole of the expansion valve and blocks the
refrigerant flow to cause a cooling trouble.
GD535-5 80-15
(01)
Air conditioner unit 80 Appendix
Component parts of air conditioner system 1
Air conditioner unit 1
Configuration diagram of air conditioner unit
80-16 GD535-5
(01)
80 Appendix Air conditioner unit
A: Refrigerant outlet (to compressor) C: Hot water inlet

B: Refrigerant inlet (from receiver) D: Hot water outlet
1: Evaporator 3: Air mix door (upper)
2: Heater core 4: Air mix door (lower)
GD535-5 80-17
(01)
Air conditioner unit 80 Appendix
5: Expansion valve 10: Evaporator temperature sensor

6: Blower amplifier 11: Blower fan and blower motor
7: Compressor relay 12: FRESH/RECIRC air changeover servomotor
8: Blower-off relay 13: FRESH/RECIRC air changeover door
9: Air mix servomotor 14: Recirculation air filter
REMARK
"Door" may be expressed as "damper".
Function of air conditioner unit
The air conditioner unit consists of evaporator (1) and heater core (2), and it is used to cool down or warm up the
air in the cab.
Temperature control
When the temperature control switch on the air conditioner control panel is operated, the air conditioner control
panel controls air mix servomotor (9) which changes the angles of air mix doors (3) and (4) to adjust the temper-
ature.
Over-cooling (freezing) prevention
q The resistance of evaporator temperature sensor (10) varies in response to the temperature.
q The air conditioner control panel converts the change in resistance of evaporator temperature sensor (10) into
the change in voltage to detect the temperature of evaporator (1).
q The air conditioner control panel operates compressor relay (7) to stop the compressor so that evaporator (1)
does not freeze.
Air flow control
When the air flow control switch on the air conditioner control panel is operated, the air conditioner control panel
controls blower fan and blower motor (11) via blower amplifier (6) and blower-off relay (8) to adjust the air flow.
80-18 GD535-5
(01)
80 Appendix Component parts of air conditioner unit
Component parts of air conditioner unit 1
Function of evaporator as air conditioner unit component

q Evaporator (1) is cooled by the low-pressure and low-temperature refrigerant gas sent from expansion valve
(5).
q Air sent from blower motor (11) is cooled and dried when it passes through the fins of evaporator (1).
Function of heater core as air conditioner unit component
q Heater core (2) is heated with the hot water (engine coolant) sent from the engine.
q Air sent by blower motor (11) is heated when it passes through the fins of heater core (2).
Function of air mix servo motor as air conditioner unit component
q When the switch on the air conditioner control panel is operated, the motor drive power (12 V) is supplied to
the servomotor terminals.
q The rotating direction of the motor changes according to the polarity of the received power.
q A variable resistor is built into the servomotor, and its resistance value changes as the motor rotates.
q A voltage (5 V) is supplied to both ends of the variable resistor from the air conditioner control panel, and the
air conditioner control panel detects the motor rotation angle from the voltage of variable resistor.
q When a target temperature is set by using the temperature control switch on the air conditioner control panel,
the control panel determines the rotating direction of motor by reading the voltage of variable resistor.
q When the air mix door reaches the position specified by the air conditioner control panel, the air conditioner
control panel stops the current output to the servomotor to stop the air mix door.
q Rotation of the motor also stops when the contact point (limiter) which moves linked with motor is detached.
Function of blower fan and blower motor as air conditioner unit component
Blower fan and blower motor (11) rotates the blower fan to suck the air and send it to evaporator (1) and heater
core (2).
Function of fresh/recirc air changeover servo motor as air conditioner unit component
q FRESH/RECIRC air changeover servomotor (12) receives the drive current from the air conditioner control
panel, and opens or closes the FRESH/RECIRC air changeover door to make a switch between the fresh air
and recirculated air settings.
q When the switch on the air conditioner control panel is operated, the motor drive power (12 V) is supplied to
the servomotor terminals.
q The rotating direction of the motor changes according to the polarity of the received power.
q The direction of rotation of the motor is determined based on the operation of the FRESH/RECIRC air selec-
tor switch on the air conditioner control panel.
q Rotation of the motor stops when the contact point (limiter) which moves linked with motor is detached, or
when the drive current from the air conditioner control panel is turned “OFF”.
Function of evaporator temperature sensor as air conditioner unit component
To prevent evaporator (1) from freezing, the resistance of evaporator temperature sensor (10) varies with the
evaporator temperature, and the temperature is monitored on the air conditioner control panel.
Function of expansion valve as air conditioner unit component
q Expansion valve (5) converts the high-pressure and high-temperature liquid refrigerant sent from the receiver
drier into low-pressure and low-temperature misty refrigerant by throttle action.
q It controls the flow rate of refrigerant by changing the level of throttling corresponding to the temperature in
the cab.
q The temperature of the air blown out of the air vent is adjusted corresponding to the volume of refrigerant cir-
culating in evaporator (1).
GD535-5 80-19
(01)
Component parts of air conditioner unit 80 Appendix
Function of dual pressure switch

The dual pressure switch is located before the relay on the air
conditioner piping.
LA or lower: Abnormally low pressure
HA or higher: Abnormally high pressure
LA: 0.20 MPa {2 kg/cm2}
LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}
q The dual pressure switch turns "OFF" when it detects abnormally low refrigerant pressure or abnormally high
refrigerant pressure in circulation line of refrigerant
q When the dual pressure switch turns "OFF", the compressor relay also turns "OFF". Thus, the magnetic
clutch of the compressor is disengaged and air conditioner components are protected.
80-20 GD535-5
(01)
80 Appendix Compressor
Compressor 1
Structure of compressor
General view
A: Refrigerant inlet (from air conditioner unit) B: Refrigerant outlet (to condenser)
Specifications of compressor
Number of cylinders - Cylinder bore x Stroke: 7 - 29.3 x 32.8 mm
Discharged volume: 154.9 cc/rev
Allowable max. speed: 4000 rpm
Compressor oil to be used: SANDEN SP-10 (for R134a)
Compressor oil refill capacity: 240 cc
Function of compressor
q The compressor circulates the refrigerant and compresses the gaseous refrigerant from the evaporator into a
misty refrigerant at high pressure and high temperature so that it is easily regenerated (liquefied) at the nor-
mal temperature.
q The built-in magnetic clutch is engaged or disengaged in accordance with the evaporator temperature and
refrigerant pressure.
q When the clutch is engaged, the power of the engine rotates the compressor shaft to drive the compressor.
GD535-5 80-21
(01)
Condenser 80 Appendix
Condenser 1
Structure of condenser
General view
A: Refrigerant inlet (from compressor) B: Refrigerant outlet (to receiver drier)

Specifications of condenser
Fin pitch: 1.5 mm
Total heat dissipation area: 6.55 m2
Max. operating pressure: 3.6 MPa {36 kg/cm2}
Function of condenser
Condenser cools and liquefies the high-temperature and high-pressure misty refrigerant sent from the compres-
sor.
NOTICE
If the cooling fins are crushed or clogged with dirt, etc., the heat exchanged efficiency decreases and the
refrigerant cannot be completely liquefied.
If the heat exchange efficiency decreases, the circuit pressure in the refrigerant cycle increases resulting
in unnecessary load on the engine and poor cooling effect. Be careful not to crush the fins in handling
and daily maintenance of the condenser.
80-22 GD535-5
(01)
80 Appendix Receiver drier
Receiver drier 1
Structure of receiver drier

General view and sectional view
A: Refrigerant inlet (from condenser)
B: Refrigerant outlet (to air conditioner unit)
1: Sight glass
Specifications of receiver drier

Effective capacity: : 578 cm3
Weight of desiccating agent: : 300 g
Function of receiver drier
q The receiver drier temporarily stores the high-pressure and high-temperature liquid refrigerant from the con-
denser so that it can be supplied to the evaporator in accordance with the cooling demand.
q It sends the stored refrigerant from its bottom to the evaporator, allowing the refrigerant to be liquefied com-
pletely even when it contains bubbles due to the heat dissipation condition of the condenser.
q The built-in filter and desiccating agent remove foreign material in the circulation circuit and moisture con-
tained in the refrigerant.
q The flow of refrigerant can be seen through sight glass (1) to check the flow rate of refrigerant.
GD535-5 80-23
(01)
Explanation of procedure for testing and troubleshooting of air conditioner 80 Appendix
Explanation of procedure for testing and troubleshooting of air conditioner 1
Air conditioner has self-diagnosis function in order to check its main components. Operation of sensor, servo mo-
tor, and motor valve can be checked.
After finding failure component, check of each part is required.
1. After basic checks are performed, narrowing down of failure place is performed based on trouble on air condi-
tioner.
2. Self-diagnosis function is used to narrow down of failure place. (See “EXPLANATION FOR TESTING AIR
CONDITIONER USING SELF-DIAGNOSIS FUNCTION”.)
However, if air conditioner unit does not operate at all, check whether power supply to air conditioner control
panel is normal or not.
When any part of air conditioner unit operates, power supply to air conditioner control panel is normal.
3. After narrowing down, check the corresponding component parts and find out the failure place, and repair it.
Basic flow of testing and troubleshooting
*1 Display the abnormality on the air conditioner control panel.

q Flashing of set temperature display on LCD
q Flashing of FRESH/RECIRC selector symbol on LCD
q Flashing of working symbol (A/C) of air conditioner on LCD
q Simultaneous flashing of HOT and COOL on LCD
*2 See “Simple check of refrigerant volume through sight glass”.
*3 If refrigerant leaks, compressor oil which circulates air conditioner circuit also leaks at the same place.
In such case, retighten the pipe joints. For details, see tightening torque table in “PRECAUTIONS FOR DISCON-
NECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS”.
*4: Start the engine, turn on the air conditioner switch, and check.
80-24 GD535-5
(01)
80 Appendix Explanation of procedure for testing and troubleshooting of air conditioner
Simple check of refrigerant volume through sight glass

Start the engine, turn on air conditioner switch, wait for 5 minutes, and then check.
S: Condition viewed through sight glass LR: Liquid refrigerant

R: Condition inside receiver drier
A: When bubbles are continuously seen, the quantity of refrigerant is insufficient.
B: When bubbles are seen intermittently, the quantity of refrigerant is proper.
C: When no bubble is seen (i.e., the liquid is clear), the system has too much refrigerant or no refrigerant.
Use the above as a guideline since there are exceptions.
See “TROUBLESHOOTING BY GAUGE PRESSURE”, and judge by using gauge pressure.
GD535-5 80-25
(01)
Circuit diagram and arrangement of connector pins for air conditioner 80 Appendix
Circuit diagram and arrangement of connector pins for air conditioner 1
80-26 GD535-5
(01)
80 Appendix Circuit diagram and arrangement of connector pins for air conditioner
GD535-5 80-27
(01)
Air conditioner system diagram 80 Appendix
Air conditioner system diagram 1
This air conditioner has manual temperature control only. (It is not an automatic temperature control.)
80-28 GD535-5
(01)
80 Appendix Input and output signals of air conditioner control panel
Input and output signals of air conditioner control panel 1
Connector AC5: AMP 040-20 (T-adapter: 799-601-7220)

Pin No. Symbol Signal name Input/Output
1 - NC -
2 - NC -
3 - NC -
Air mix door
4 Am out 1 Output
Servomotor output 1
Air mix door
5 Am out 2 Output
Servomotor output 2
6 Valve out 1 Motor valve output 1 Output
7 Valve out 2 Motor valve output 2 Output
FRESH/RECIRC air changeover door
8 R/F out 1 Output
Servomotor output 1
FRESH/RECIRC air changeover door
9 R/F out 2 Output
Servomotor output 2
10 DC 24 V 24 V power supply Input
11 - NC -
12 - NC -
13 EVA Evaporator temperature sensor Input
14 - NC -
15 - NC -
16 Pot 5 V Potentiometer 5 V power supply Output
17 - NC -
18 Pot GND Potentiometer ground Input
19 EVA GND Evaporator temperature sensor GND Input
20 GND GND Input
Connector AC6: AMP 040-16 (T-adapter: 799-601-7210)

1 - NC -
2 - NC -
3 - NC -
4 - NC -
Air mix
5 Am pot Input
Potentiometer voltage
Motor valve
6 Valve pot Input
FRESH/RECIRC air changeover
7 R/F pot Input
8 Blow F/B Blower amplifier feedback signal Input
9 BL off RL Blower-off relay Output
10 COMP RL Compressor relay Output
GD535-5 80-29
(01)
Input and output signals of air conditioner control panel 80 Appendix

11 Blow gate Blower amplifier gate Output
12 - NC -
13 - NC -
14 - NC -
15 - NC -
16 - NC -
NC: No contact
Note: Never connect with “NC” pins, otherwise malfunctions or failures may occur.
Structure of air conditioner control panel
Switches
No. Name Function Operation

RECIRC
1 FRESH/RECIRC air selector switch Switch to select recirculated or fresh air ↑↓
FRESH
OFF
Switch to turn cooling, drying, and heating function
2 Air conditioner switch
on or off. ↑↓
ON
OFF
Switch to turn the main power of air conditioner on or
3 Main power switch
off. ↑↓
ON
Low temperature
Switch for adjusting the output air temperature (8
4 Temperature control switch
level settings) ↑↓
High temperature
Lo
Switch to adjust the air flow of fan
5 Fan switch
(6 level settings - Lo, M1, M2, M3, M4, and Hi) ↑↓
Hi
q The air conditioner control panel contains a CPU (Central Processing Unit) that processes the input signals
from each sensor and the control signals from each switch on panel, and displays the signals on the panel
and outputs them to the servomotors and relays.
q For details of input/ output signals and operation, see “AIR CONDITIONER SYSTEM DIAGRAM”.
80-30 GD535-5
(01)
80 Appendix Input and output signals of air conditioner control panel
Function of air conditioner control panel

q Control panel controls air conditioner unit by turning on each switch.
q Control panel performs temperature control (air mix) by controlling the air mix servomotor.
q Control panel switches FRESF/RECIRC air by controlling FRESH/RECIRC air changeover servomotor.
q Control panel turns on blower-off relay to drive blower motor, and rotates the fan to send the air.
q Control panel controls the air flow by using blower amplifier.
q Control panel detects evaporator temperature by using evaporator temperature sensor.
q Control panel turns on/off the compressor relay to control the compressor so that the evaporator does not
freeze.
q Control panel performs self-diagnosis against air mix servomotor, FRESH/RECIRC air changeover servomo-
tor, and evaporator temperature sensor, and informs abnormality on control panel (flashing) if any.
(“EXPLANATION FOR TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION”)
GD535-5 80-31
(01)
Installation locations of air conditioner parts and arrangement of connectors 80 Appendix
Installation locations of air conditioner parts and arrangement of connectors1

Connector of air conditioner unit
REMARK
The number of unlabeled connector is shown in [ ].
80-32 GD535-5
(01)
80 Appendix Installation locations of air conditioner parts and arrangement of connectors
1: Air mix door 6: FRESH/RECIRC air changeover servomotor

2: FRESH/RECIRC air changeover door 7: Compressor relay
3: Recirculation air filter 8: Blower-off relay
4: Expansion valve 9: Blower amplifier
5: Air mix servomotor
GD535-5 80-33
(01)
A: Air inlet B: Air outlet

AC1: Connector of power supply and compressor AC3: Intermediate connector of control panel
AC2: Connector of hot water cut valve
[3]: Connector of evaporator temperature sensor [6]: Connector of FRESH/RECIRC air changeover
[4]: Connector of temperature control (air mix) servo- servomotor
motor [8]: Connector of blower-off relay
[5]: Connector of compressor relay [12]: Connector of blower amplifier
REMARK
For [7] and [11], see “Parts and connectors layout”.
Location of evaporator temperature sensor
TS: Evaporator temperature sensor X: Evaporator temperature sensor is installed on 10th

H: Holder 　row.
Parts and connectors layout

80-34 GD535-5
(01)
80 Appendix Installation locations of air conditioner parts and arrangement of connectors
q Fuse No.1 in fuse box FB2, 20 A: For blower motor power

supply
q Fuse No.8 in fuse box FB2, 5 A: For air conditioner com-
pressor power supply
q Fuse No.11 in fuse box FB2, 5 A: For primary power sup-
ply of air conditioner control panel and each relay
2. Remove covers (2) and (3).
3. Remove operator's seat (4) and cover (5).

A/C Unit: Air conditioner unit
BL OFF RL: Blower-off relay
COMP RL: Compressor relay
A/M: Air mix servomotor
BL AMP: Blower amplifier
PRSW: Dual pressure switch
[3]: Connector of evaporator temperature sensor
[4]: Connector of air mix servomotor
[5]: Connector of compressor relay
[7]: Connector of dual pressure switch
[8]: Connector of blower-off relay
[12]: Connector of blower amplifier
AC1: Connector of air conditioner unit for 24 V power supply
and compressor
AC2: Connector of hot water cut valve
AC3, AC4: Connectors between air conditioner unit and con-
trol panel
GD535-5 80-35
(01)
R/FA: FRESH/RECIRC air changeover servomotor

[6]: Connector of FRESH/RECIRC air changeover servomotor
4. Remove the recirculation air filter.

[11]: Connector of blower motor
6. Pull air conditioner control panel (7) toward you, and remove it.
AC5, AC6: Connectors of air conditioner control panel
80-36 GD535-5
(01)
80 Appendix Method for testing air leakage (duct)
Testing air leakage (duct) 1
k Place the machine on a level ground, set parking brake to “PARK” position, stop the engine, and
chock the tires.
k Check that the system operating lamp is off, and then turn the battery disconnect switch to OFF
position, and remove the starting switch key.
(When the battery disconnect switch is not installed, disconnect the cable from the battery negative
(-) terminal.)
REMARK
Write down the connector numbers and installed positions before disconnecting wiring harnesses and hoses.
Method for testing air leakage (duct) 1
1. Remove covers (1) to (2).
2. Check whether face ducts (3) and (4) are partially discon-
nected.
3. Remove covers (5) and (6), and operator's seat (7).
4. Check whether face duct (8) is partially disconnected.
GD535-5 80-37
(01)
Method for testing air leakage (duct) 80 Appendix
5. Remove cover (9) on both of right and left.

6. Remove rear cover (10).
7. Check fresh air duct (11) for disconnection.
8. Check defroster duct (12) for disconnection.
80-38 GD535-5
(01)
80 Appendix Testing air conditioner using self-diagnosis function
Testing air conditioner using self-diagnosis function 1
This function performs self-diagnosis for following 4 failures, and indicates failed part by flashing the display of air
conditioner control panel (1).
NOTICE
Once a failure is detected, the failure condition is not canceled even if the failed part returns to normal.
To cancel the failure condition (stop flashing of display), the starting switch must be turned to OFF posi-
tion.
1. Failure in potentiometer circuit for air mix servomotor controlling temperature (i.e., open circuit or short circuit)
or failure of air mix servomotor controlling temperature not to reach target value of opening/closing position
(i.e., door lock is detected due to low input voltage from the potentiometer.)
Display of self-diagnosis: Flashing of set temperature display
q Action of control panel: Stop of output to the air mix servomotor
q Symptom: Temperature control switch (4) does not work.
q Even when the link is disconnected and door does not turn, self-diagnosis determines that the condition is
normal if the air mix servomotor rotates normally.
q See “CHECK TEMPERATURE CONTROL FUNCTION”.
2. Failure of the FRESH/RECIRC air changeover door not to reach the target value of opening/closing position
(i.e., door lock is detected due to low input voltage from the potentiometer.)
Display of self-diagnosis: Flashing of FRESH/RECIRC selector symbol on display
q Action of control panel: Stop of output to the FRESH/RECIRC air changeover servomotor
q Symptom: FRESH/RECIRC air selector switch (2) does not work.
q Even when the lever is disconnected and door does not turn, self-diagnosis determines that the condition
is normal if the FRESH/RECIRC air changeover servomotor rotates normally.
q See “TEST FRESH/RECIRC AIR CHANGEOVER”.
3. Failure in input circuit for evaporator temperature sensor (i.e., open circuit or short circuit)
Display of self-diagnosis: Flashing of working symbol of air conditioner on display
q Symptom: Air conditioner does not work.
q Reset of control panel: Turn the starting switch to OFF position.
q See “METHOD FOR CHECKING EVAPORATOR TEMPERATURE SENSOR”.
4. Failure in hot water cut valve circuit (i.e., open circuit or short circuit)
Display of self-diagnosis: Simultaneous flashing of HOT and COOL on display
q Symptom: When temperature setting indicates COOL MAX, hot water cut valve does not close. Or, when
temperature setting indicates other than COOL MAX, hot water cut valve does not open.
q Symptom: Since the hot water to heater core cannot be blocked, hot water may flow into heater core.
q Or, since hot water is blocked, air temperature does not rise during heating.
q See “TROUBLESHOOTING FOR HOT WATER CUT VALVE”.
GD535-5 80-39
(01)
Method for checking temperature control function 80 Appendix
Check temperature control function 1
k Place the machine on a level ground, set parking brake switch to PARK position, stop the engine,
REMARK
Check the connector numbers and installed positions before disconnecting wiring harnesses and hoses, and re-
cord them.
Method for checking temperature control function 1
The angle of the door (or damper) in the air conditioner unit is adjusted by the air mix servomotor so that the tem-
perature can be controlled by changing the mixing ratio of hot air from the heater and cold air from the evaporator.
REMARK
The starting switch must be turned to OFF position in order to cancel the self-diagnosis function (to stop LED
flashing). (When the LED is flashing, nothing is output to the air mix servomotor due to the detection of a failure
by self-diagnosis.)
1. Remove covers (1) and (2), operator's seat (3), and cover (4).
2. Check levers (L1) and (L2), and bar (2) for disconnection.
3. Check contact of the connector of the air mix servomotor.
(Check whether the connector is partially disconnected.)
4. Start the engine and turn on the air conditioner.
Set the temperature to the minimum COOL MAX and
maximum HOT MAX on the control panel and check visually
that levers (L1), (L2) move smoothly between C1 and H1, and
between C2 and H2, respectively, as shown in the figures.
In the case of electrical failure, see “TROUBLESHOOTING
FOR TEMPERATURE CONTROL FUNCTION”
80-40 GD535-5
(01)
80 Appendix Method for testing fresh/recirc air changeover
Testing fresh/recirc air changeover 1
k Place the machine on a level ground, set parking brake switch to “PARK” position, stop the engine,
REMARK
Check the connector numbers and installed positions before disconnecting wiring harnesses and hoses, and re-
cord them.
Method for testing fresh/recirc air changeover 1
The FRESH/RECIRC air changeover servomotor switches the fresh air and recirculation air by changing the angle
of the FRESH/RECIRC air changeover door (damper) through the lever and bar. Visually check the operation of
this lever.
REMARK
q Check motor locking, open circuit, and short circuit in self-diagnosis.
q The starting switch must be turned off in order to cancel the self-diagnosis function (to stop LED flashing).
(When the LED is flashing, nothing is output to the FRESH/RECIRC air changeover servomotor due to the
detection of a failure by self-diagnosis.)
1. Remove the cover and seat.
2. Check the condition of contact at connector [6] for FRESH/
RECIRC air changeover servomotor (1).
3. Check levers (L1) and (L2), and bar (2) for disconnection.
4. Start the engine and turn on the power supply of air condi-
tioner.
5. Press the FRESH/RECIRC air selector switch on the control
panel, and visually check whether levers (L1) and (L2) move
between FRESH and RECIRC as shown in the figures.
F1, F2: FRESH positions
R1, F2: RECIRC positions
B: Fresh air inlet
In the case of electrical failure, see “TROUBLESHOOTING
FOR FRESH/RECIRC AIR CHANGEOVER”.
GD535-5 80-41
(01)
Method for checking evaporator temperature sensor 80 Appendix
Test evaporator temperature sensor 1
k Place the machine on a level ground, set parking brake to “PARKING” position, stop the engine, and
chock the tires.
(-) terminal.)
REMARK
q Check the connector numbers and installed positions before disconnecting wiring harnesses and hoses, and
record them.
q Perform the inspection, if an error is found in self-diagnosis.
q To cancel the self-diagnosis system (detection of abnormality), the starting switch must be turned to OFF
position.
Method for checking evaporator temperature sensor 1
2. Check connector [3] for poor connection.

3. Turn the starting switch to OFF position, and disconnect
connector [3].
4. Measure the resistance between the terminals of connector
[3] (evaporator temperature sensor side).
Standard value
: 7.2 kΩ (at 0 °C)
: 2.2 kΩ (at 25 °C)
If there is an abnormality, remove the air conditioner unit (see
DISASSEMBLY AND ASSEMBLY, “METHOD FOR REMOV-
ING AIR CONDITIONER UNIT ASSEMBLY”), and replace
the evaporator temperature sensor (see “CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT”).
REMARK
Precautions for replacement of the evaporator temperature sensor
For mounting position of the evaporator temperature sensor, see “INSTALLATION LOCATIONS OF AIR
CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS”.
5. Turn the starting switch to OFF position, and disconnect connector AC5 from control panel. (See “CIRCUIT
DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER”.)
Between connector AC5 (13) (Lg/R) and (19) (R/B)
Standard value
: 7.2 kΩ (at 0 °C)
: 2.2 kΩ (at 25 °C)
If the preceding step 5 indicates a normal condition, the control panel is defective. If it indicates an abnormal
condition, the wiring harness is defective.
80-42 GD535-5
(01)
80 Appendix Method for testing relays
Test relays 1
chock the tires.
(-) terminal.)
REMARK
q Record the connector numbers and installed positions before disconnecting wiring harnesses and hoses.
q If the air conditioner compressor is normal and air comes out, this check can be omitted.
q Listen closely to the relay to check its operation sound.
Method for testing relays 1
There are 2 relays as follows.

q Blower-off relay: ON/OFF of fan motor
q Compressor relay: ON/OFF of air conditioner compressor (clutch)
2. Turn the starting switch to ON position, and turn on the main
power switch of air conditioner, and blower-off relay is turned
on if it is normal. Check that a click is heard.
3. Turn the air conditioner switch to ON position, and compressor
relay is turned on if it is normal. Check that a click is heard.
REMARK
q Control panel does not turn on the compressor clutch
relay in the following conditions.
q When the evaporator temperature is 5 °C and below (by
the evaporator temperature sensor)
q When the dual pressure switch detects abnormality (relay is OFF)
q If the fan sound is so large that you cannot hear the operation sound of the compressor relay, proceed as
follows.
1) Turn off the main power supply of air conditioner, and disconnect the ground cable from the battery.
2) Disconnect connector [8].
3) Perform preceding step 2 and 3 after connecting the ground cable to the battery.
4. If you suspect that one of the relays is defective, proceed as
follows to investigate.
1) Turn off the main power supply of air conditioner, and
disconnect the ground cable from the battery.
2) Replace the blower-off relay with compressor relay.
3) Connect the ground cable to the battery, repeat preceding
steps 2 and 3, and check whether the symptom is
reversed.
COMP RL: Compressor relay
BL OFF RL: Blower-off relay
[5]: Connector of compressor relay
[8]: Connector of blower-off relay
Check of relay unit
q The coil resistance between terminals (1) and (2) is
approximately 320 Ω.
q When voltage (DC 20 to 30 V) is not applied over termi-
nals (1) and (2), terminals (3) and (4) have no continuity.
q When voltage (DC 20 to 30 V) is applied over terminals (1)
and (2), terminals (3) and (4) have continuity.
GD535-5 80-43
(01)
Method for checking blower AMP 80 Appendix
Check blower AMP 1
chock the tires.
position, and remove the key.
(-) terminal.)
REMARK
q If air blows out and flow can be adjusted, this check is not required.
q Turn on main power supply switch of air conditioner, if air does not blow out (to check for built-in temperature
fuse, etc.), perform this check.
q Troubleshooting for electronic circuit inside cannot be performed. Accordingly, when air flow cannot be
adjusted even if air blows out, replace blower amplifier.
Method for checking blower AMP 1
2. Check connector [12] for poor contact.
3. Turn the starting switch to OFF position, and disconnect connector [12].
BL AMP: Blower amplifier
[12]: Connector of blower amplifier
80-44 GD535-5
(01)
80 Appendix Method for checking blower AMP
Check of the blower amplifier unit (fuse and diodes only)

q The resistance between terminals (1) and (3) is approxi-
mately 4.7 kΩ.
q Set the multimeter to diode range.
q There is continuity between terminals (1) (+) and (2) (-).
(Sound is heard.)
q There is no continuity between terminals (1) (+) and (2) (-).
GD535-5 80-45
(01)
Air conditioner troubleshooting chart 1 80 Appendix
Air conditioner troubleshooting chart 1 1
Cooling trouble
80-46 GD535-5
(01)
80 Appendix Air conditioner troubleshooting chart 1
Heating trouble
GD535-5 80-47
(01)
Air conditioner troubleshooting chart 2 1
Blower fan motor does not operate or rotation speed does not match the air flow setting
during cooling.
See “Troubleshooting of blower motor system (air does not come out or air flow is abnormal)”.
Probable cause Check method Remedy
Defective blower-off relay See “TEST RELAYS”. Replace
Check for disconnection of connector.
Breakage of wire or defective Repair the open circuit.
See “INSTALLATION LOCATIONS OF AIR CONDITIONER
connection Connect it correctly.
PARTS AND ARRANGEMENT OF CONNECTORS”.
See “Troubleshooting of blower motor system” and
Defective blower fan motor “INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS Replace
AND ARRANGEMENT OF CONNECTORS”.
Operate fan switches in order and check that fan turns.
Defective blower amplifier See “CHECK BLOWER AMP” and “Troubleshooting of Replace
blower motor system”.
Blower fan motor is normal but air flow is insufficient during cooling.
Ventilation resistance is high. Check filter for clogging and duct for crushing or clogging. Repair
Air leakage through connecting Check connecting part of duct.
Repair
part of duct Check duct seal for defect and duct for disconnection
Obstacles on suction side of Remove obstacle and
Check evaporator for dirt and obstruction.
evaporator clean evaporator
Defective evaporator tempera- Evaporator is frozen.
ture sensor, defective contact of Check sensor fixing clip, check sensor for dirt and dust.
Replace or repair
evaporator temperature sensor, Check if air conditioner hose near pressure switch is frosted
or defective expansion valve *1 (when freezing has advanced even further).
*1: Evaporator temperature sensor and expansion valve are located inside air conditioner unit.
Pressure is abnormal during cooling (low/high pressure)
Repair leaking part and
Insufficient refrigerant refill with proper volume
Check regrigerant volume through sight glass. of refrigerant again.
To be accurate, check with the gauge manifold connected. Collect refrigerant, then
Over-filling with refrigerant refill with proper volume
of refrigerant again.
Normal refrigerant pressure range
q Low-pressure: Approximately 0.13 to 0.2 MPa {1.3 to 2.0 kg/
cm2} See "TROUBLESHOOT-
Judgment by pressure at outlet
q High-pressure: Approximately 1.5 to 1.7 MPa {15 to 17 kg/ ING BY GAUGE PRES-
and inlet of compressor
cm2} SURE".
q Temperature inside cab: 30 to 35 °C
q Engine speed: Approximately 1500 rpm
80-48 GD535-5
(01)
80 Appendix Air conditioner troubleshooting chart 2
Compressor does not operate at all or does not operate easily during cooling.
See “Troubleshooting of compressor system (Air is not cooled)”.
Failed part Probable cause Check method Remedy
Compressor belt Loose belt Belt deflection is large. Adjust tension
Internal defect of compres-
Slip of belt Repair or replace
sor
Compressor
Insufficient compressor oil See “HANDLE COM-
Overheat of compressor
Seized compressor PRESSOR OIL”.
Low battery voltage Slip during rotation Charge battery
Open circuit or short circuit
Check with multimeter (10 to 20 Ω). Replace
in coil
Magnetic clutch
Check ground cable and connecting part
Open circuit in wiring or
See “TROUBLESHOOTING OF COM-
defective connection of Repair
PRESSOR SYSTEM (AIR IS NOT
ground cable
COOLED)”.
Defective compressor clutch
Relay See “TEST RELAYS”. Replace
relay
See
Abnormal pressure See “TROUBLESHOOTING BY
Refrigerant pressure “TROUBLESHOOTING BY
(pressure switch is actuated) GAUGE PRESSURE”.
GAUGE PRESSURE”.
See “TROUBLESHOOTING OF COM-
Pressure switch Defective pressure switch PRESSOR SYSTEM (AIR IS NOT Replace
COOLED)”.
Blower fan motor is normal but air flow is insufficient during cooling.
Ventilation resistance is high. Check filter for clogging and duct for crushing or clogging. Repair
Air leakage through connecting Check duct connecting part. Check duct seal for defect and
Repair
part of duct duct for disconnection.
Clogging of heater core fins Check heater core fins for clogging. Clean
Engine coolant temperature or quantity is abnormal during cooling or heating.

Low engine coolant tempera- Check engine coolant temperature after warm-up opera-
Investigate the cause
ture tion.
Low engine coolant level Check coolant level in radiator. Add coolant
Low circulation rate of engine Check engine coolant piping for clogging (hose, pipe,
Bleed air, correct.
coolant core).
Inverted connection of heater
Check destinations of heater hoses. Repair
hoses between IN and OUT
Fan speed is abnormal during cooling.

See shop manual, chapter 30, TESTING AND ADJUSTING,
Low fan speed Repair
“TEST COOLING FAN SPEED”.
GD535-5 80-49
(01)
Other abnormalities
Abnormality and probable cause Check method Remedy
See “CHECK TEMPERATURE CONTROL FUNCTION” and
Temperature cannot be con-
“TROUBLESHOOTING FOR TEMPERATURE CONTROL
trolled.
FUNCTION”. Common to cooling and
See “TEST FRESH/RECIRC AIR CHANGEOVER” and heating
Fresh air and recirculation air
“TROUBLESHOOTING FOR FRESH/RECIRC AIR
cannot be changed over.
CHANGEOVER”.
Defective cooling (excessive
See “HANDLE COMPRESSOR OIL”.
compressor oil) Cooling only
Water leakage into cab Clogging of drain hole
80-50 GD535-5
(01)
80 Appendix Information described in troubleshooting table
Information described in troubleshooting table 1
The following types of information are described in the troubleshooting table and related circuit diagram. Fully un-
derstand the description and perform troubleshooting.
Failure Problem on machine

Related information Information related to the occurred failure and its troubleshooting

1 Probable causes for [Details]
trouble q Procedure
2 q Measuring point
"Between A and B" denotes measuring values such as voltage and resistance, etc. between
A and B.
q Criteria to judge probable causes (standard value), remarks
[Precautions for troubleshooting]
(1) Connector number description sequence and tester lead handling
For troubleshooting, connect the positive (+) and negative (-) leads of a multimeter as shown
3 Defective ---
below unless otherwise specified.
q Connect the positive (+) lead to pin or wiring harness indicated in the front.
q Connect the negative (-) lead to a pin or wiring harness indicated in the rear.
(2) Example of troubleshooting by check of multiple items
q Normal in 1 but abnormal in 2
At that time, the description is made as "Defective ---" as shown on the left.
[Failures in wiring harness]

q Open circuit
Connection of connector is defective or wiring harness is broken.
q Ground fault
A wiring harness not to be connected to the GND (ground) circuit comes to contact with the GND (ground) cir-
cuit or chassis.
q Hot short circuit
A wiring harness not to be connected to the power supply circuit comes to contact with the power supply cir-
cuit.
q Short circuit
An independent wire in the wiring harness abnormally comes into contact with one of other wires. (Defective
insulation in connector, etc.)
Related circuit diagram

This is the excerpted circuit diagram related to troubleshooting
q Connector numbers and pin numbers are shown.
q Size of wire is shown. When there is a number in front of color, it shows size.
W: White, B: Black, R: Red, G: Green, Y: Yellow, L: Blue, V: Purple, P: Pink, O: Orange, Br: Brown, Gr:
Gray, Sb: Sky blue, Lg: Light green, Dg: Dark green, Ch: Dark brown
q When there are two colors
Example) WY: Yellow line on white background
q When there is a number in front of color, it shows size.
q NC: Normally closed (Normally ON)
q [1] and [2] are numbers of unlabeled connectors.
q Arrow (←→): Roughly indicates their mounting place on the machine.
GD535-5 80-51
(01)
A-1 Troubleshooting for power supply system (air conditioner does not operate) 80 Appendix
A-1 Troubleshooting for power supply system (air conditioner does not
operate) 1
Failure Air conditioner does not operate because of power supply system failure.
Phenomenon
Even if the air conditioner switch is turned on, the LCD does not light up.
on machine
q Ground cable of air conditioner is connected in machine wiring harness together with other electrical com-
ponents.
q Turn the starting switch to ON position, and turn on the air conditioner main switch. At this time, if LCD on
air conditioner control panel lights up for a moment and the fuse is blown out immediately, see
“TROUBLESHOOTING OF COMPRESSOR SYSTEM (AIR IS NOT COOLED)” and
“TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS
ABNORMAL)”.
Related
q For each connector and fuse, see “INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND
information
ARRANGEMENT OF CONNECTORS”.
q For arrangement of each connector pin, see “CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNEC-
TOR PINS FOR AIR CONDITIONER”.
q T-adapter for connector AC1: 799-601-7310, T-adapter for connector AC5: 799-601-7220, T-adapter for
connector AC6: 799-601-7210
REMARK
T-adapter is not available for connectors of types other than the above, DT, and SWP.
No. Cause Procedure, measuring location, criteria and remarks

1 Defective fuse If fuse No.1 in fuse box FB2 is blown out, circuit probably has ground fault.
Defective wiring harness 2. Disconnect connector AC5, and connect T-adapter to female side.
2
(ground cable)
Resistance Between AC5 (female) (20) and ground (chassis ground) Max. 1 Ω
If a fuse is blown out, replace it.
Defective air conditioner 2. Disconnect connector AC5, and connect T-adapter to female side.
3 wiring harness, defective 3. Turn the starting switch to ON position.
machine wiring harness If the fuse is blown out again, perform the check on cause 4 and after, and then determine
which wiring harness is defective.
Voltage Between AC5 (female) (10) and (20) 20 to 30 V
When abnormality is found in troubleshooting for “Defective air conditioner wiring har-
ness, Defective machine wiring harness”, perform the following.
2. Disconnect connector AC1, and connect T-adapter to female side.
Defective machine wiring 3. Turn the starting switch to ON position.
4
harness
If the fuse is blown out again, or the result of following check is abnormal, machine wiring
harness is defective.
Between AC1 (female) (10) and (4) 20 to 30 V
Voltage
Between AC1 (female) (1) and (4) 20 to 30 V
If a fuse is blown out in troubleshooting for “Defective air conditioner wiring harness,
Defective machine wiring harness”, and result of preceding check for “Defective
machine wiring harness” is normal, perform the following.
Defective air conditioner 1. Turn the starting switch to OFF position.
5
wiring harness 1 2. Disconnect connector AC3.
3. Disconnect connectors [7], [8], and [12].
Voltage Between AC3 (male) (3) and (2) 20 to 30 V
80-52 GD535-5
(01)
80 Appendix A-1 Troubleshooting for power supply system (air conditioner does not operate)

When result of check for “Defective air conditioner wiring harness 1” is normal, perform
the following.
2. Disconnect connector AC3 and connect T-adapter to female side.
Voltage Between AC3 (male) (3) and (2) 20 to 30 V
Defective air conditioner q When abnormality is found in troubleshooting for “Defective air conditioner wiring har-
6 ness, Defective machine wiring harness”, and result of check for “Defective air condi-
wiring harness 2
tioner wiring harness 2” is normal, the wiring harness between AC3 and AC5 is
defective.
q When abnormality is found in troubleshooting for “Defective air conditioner wiring har-
ness, Defective machine wiring harness”, and result of check for “Defective air condi-
tioner wiring harness 1” is normal, and result of check for “Defective air conditioner
wiring harness 2” is abnormal, perform “TROUBLESHOOTING OF COMPRESSOR
SYSTEM (AIR IS NOT COOLED)” and “TROUBLESHOOTING FOR BLOWER MO-
TOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)”.
Open circuit in wiring har-
7 ness (air conditioner con- If a fuse is not blown out, check by referring to circuit diagram.
trol panel side)
Defective air conditioner
8 If no failure is found by preceding checks, air conditioner control panel is defective.
control panel
Circuit diagram related to air conditioner power supply
GD535-5 80-53
(01)
A-2 Troubleshooting for compressor and refrigerant system (air is not cooled) 80 Appendix
A-2 Troubleshooting for compressor and refrigerant system (air is not

cooled) 1
Failure Air is not cooled due to compressor or refrigerant system failure

Phenomenon q When engine is started and air conditioner switch is pressed, air is not cooled.
on machine q Compressor does not operate.
q If the refrigerant pressure is abnormal, the compressor is not turned on, and air is not cooled.
REMARK
An abnormal refrigerant pressure refers to that the dual pressure switch is turned off.
q When temperature is 5 °C and below, control panel does not turn on compressor relay in order to pre-
vent evaporator from freezing (normal condition).
Related
information
REMARK

to OFF position.
3. Disconnect connector [7] of the dual pressure switch.
In some case, the dual pressure switch is OFF even if it operates normally. If the check
Defective dual pressure
2 result below is abnormal (switch OFF), install the pressure gauge to the air conditioner
switch system
compressor and check the pressure of refrigerant. (See “TROUBLESHOOTING BY
GAUGE PRESSURE”.)
Resistance [7] Between terminals (switch side terminal) Max. 1 Ω
k Before replacing dual pressure switch, always collect refrigerant. See
chapter 80 T HE OTHER INFORMATION, “PRECAUTIONS FOR
REFRIGERANT”.
Check the connection of ground cable (FT77) of the air conditioner compressor. (See
“INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT
OF CONNECTORS”.)
Defective air conditioner 2. Disconnect connector ET88 from the air conditioner compressor, and connect T-
3 adapter to male side.
compressor
Between ET88 (male) (1) and (2) (Coil resistance of air Approx. 15
Resistance conditioner compressor) Ω
Between ET88 (male) (1) and ground Min. 1 MΩ
Defective compressor
4 clutch relay (it is not Referring to “METHOD FOR TESTING RELAYS”, check compressor clutch relay.
turned ON)
Defective evaporator tem- Perform troubleshooting. For details, see “METHOD FOR CHECKING EVAPORATOR
5
perature sensor TEMPERATURE SENSOR”.
80-54 GD535-5
(01)
80 Appendix A-2 Troubleshooting for compressor and refrigerant system (air is not cooled)

Check in advance that the check result on cause 2 is normal (Dual pressure switch
is ON.), and check result on cause 3 is normal (Air conditioner compressor is normal.).
2. Disconnect connectors AC5 and AC6, and connect T-adapter to each female side.
Approx. 320
Resistance Between AC5 (female) (10) and AC6 (female) (10)
Ω
ness
2. Disconnect connector [5] and fuse No.8 in fuse box FB2.
Between fuse No.8 in fuse box FB2 and [5] (wiring harness
side) (red line on white background) Max. 1 Ω
Resistance Between [5] (wiring harness side) (white line on green

background) and machine ground (coil resistance of air Approx. 15 Ω
conditioner compressor)
Replace fuse if it is blown out.
2. Remove fuses No.8 and 11 in fuse box FB2,
Ground fault in wiring har- 3. Disconnect connectors ET88, AC5, AC6, [7], and [8], and connect T-adapter to female
7 ness (contact with ground sides of ET88 and AC6.
circuit) Between ET88 (female) (1) and ground Min. 1 MΩ
Resistance Between fuse No.8 in fuse box FB2 and ground Min. 1 MΩ
Between fuse No.11 in fuse box FB2 and ground Min. 1 MΩ
Short circuit in wiring har- 2. Disconnect connectors [5], AC5, and AC6, and connect T-adapter to female sides of
8 AC5 and AC6.
ness
Resistance Between AC5 (female) (10) and AC6 (female) (10) Min. 1 MΩ
2. Insert T-adapter into connectors AC5 and AC6.
Defective air conditioner 3. Turn the starting switch to ON position.
9
control panel 4. Operate the air conditioner control panel, and press the air conditioner switch.
Voltage Between AC6 (10) and AC5 (20) Max. 1 V
GD535-5 80-55
(01)
A-2 Troubleshooting for compressor and refrigerant system (air is not cooled) 80 Appendix
Circuit diagram related to compressor and refrigerant system
80-56 GD535-5
(01)
80 Appendix A-3 Troubleshooting for blower motor system (no air comes out or air flow is abnormal)
A-3 Troubleshooting for blower motor system (no air comes out or air flow
is abnormal) 1
Failure Air does not come out or air flow is abnormal due to failure in blower motor system.
Phenomenon
Air does not come out or air flow is abnormal due to failure in blower motor system.
on machine
q If the air flow does not change regardless of air flow setting, replace the blower amplifier.
q If air flow decreases (air does not come out) after a while during cooling, the evaporator may be frozen.
The probable causes for this failure are as follows.
q Defective compressor relay (stays ON) (See “TEST RELAYS”.)
q Coming-off of mounting holder of evaporator temperature sensor (Replace air conditioner
unit and disassemble it.)
q Defective adjustment of expansion valve (Collect the refrigerant and replace the expan-
Related sion valve.)
information q For each connector and fuse, see “INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND
REMARK

2 Defective blower motor 2. Disconnect connector [11].
Continuity [11] (Blower motor side) terminal Continuity
Referring to Check of relay, check the sound of blower-off relay when it is turned ON.
Clicking sound is heard.
If “no sound is heard” in above check, perform this.
3 Defective blower-off relay. 1. Turn the starting switch to OFF position.
2. Replace the blower-off relay with compressor relay.
4. Turn on the main power switch of air conditioner.
If air comes out, original blower-off relay is defective.
4 Defective blower amplifier Referring to “TEST BLOWER AMP”, check the blower amplifier.
GD535-5 80-57
(01)
A-3 Troubleshooting for blower motor system (no air comes out or air flow is abnormal) 80 Appendix

2. Remove fuses No.1 and 11 in fuse box FB2.
3. Disconnect connectors AC5 and AC6, and connect T-adapter to each wiring harness
side.
Between AC6 (female) (9) and AC5 (female) (10) (coil Approx. 320
resistance of relay) Ω
Resistance
Between AC6 (female) (11) and AC5 (female) (20) (internal Approx. 4.7
resistance of blower amplifier) kΩ
ness or defective blower 1. Turn the starting switch to OFF position.
5
motor (replace air condi- 2. Disconnect connectors AC5, AC6, [8], and [12], and connect T-adapter to female sides
tioner unit) of AC5 and AC6.
Between AC6 (female) (8) and [12] (wiring harness side)
Resistance
(white line on black background) Max. 1 Ω
Includes blower motor resistance.

Continuity Between AC6 (female) (8) and [8] (wiring harness side) Continuity
(red line on white background)
Between fuse No.1 in fuse box FB2 and [8] (wiring harness
Resistance
side) (red) Max. 1 Ω
Replace fuse if it is blown out.

2. Remove fuses No.1 and 11 in fuse box FB2.
Ground fault in wiring har- 3. Disconnect connectors AC5, AC6, [8], [11], and [12], and connect T-adapter to female
6 ness (contact with ground sides of AC5 and AC6.
circuit) Between fuse No.1 in fuse box FB2 and ground Min. 1 MΩ
Resistance Between AC6 (female) (8) and ground Min. 1 MΩ
Between AC6 (female) (11) and ground Min. 1 MΩ
2. Disconnect connectors AC5 and AC6, and insert T-adapter into them.
Defective air conditioner 5. Press the fan switch on air conditioner control panel (for any air flow rate).
7
control panel Between AC6 (9) and AC5 (20) Max. 1 V
Between AC6 (11) and AC5 (20) Approx. 10 V
Voltage
Varies within
Between AC6 (8) and AC5 (20)
Max. 10 V.
Defective blower amplifier If no failure is found in preceding checks, and air flow does not change or air does not
8
(defect of amplifier part) come out even if air flow switch is operated, blower amplifier is defective.
80-58 GD535-5
(01)
80 Appendix A-3 Troubleshooting for blower motor system (no air comes out or air flow is abnormal)
Circuit diagram related to blower motor system
GD535-5 80-59
(01)
A-4 Troubleshooting for temperature control function 80 Appendix
A-4 Troubleshooting for temperature control function 1
Failure Temperature cannot be controlled.

Phenomenon
Even if the temperature control switch is operated, the temperature does not change.
on machine
q Temperature control refers to the action of mixing warm air and cold air by changing the angle of a door
(or damper).
q When a failure is detected by self-diagnosis function and the main power switch on the air conditioner
control panel is turned on, the temperature setting display on the air conditioner control panel flashes.
q Each time the main power switch is turned on, self-diagnosis checks the open circuit and short circuit in
air mix servomotor, the contacts (or LIMIT terminals) in the air mix servomotor.
q Even when the link is disconnected (see “CHECK TEMPERATURE CONTROL FUNCTION”), self-diag-
nosis determines that the condition is normal if the air mix servomotor rotates in response to operation of
the switch.
Related q Check connector [4] for interference, mechanical failure (disconnection of link, interference of lever, etc.).
information For details, see “CHECK TEMPERATURE CONTROL FUNCTION”.
q The link must be removed in order to replace the air mix servomotor. (See “CONFIGURATION DIA-
GRAM OF AIR CONDITIONER UNIT” or parts book.)
q T-adapter for connector AC5: 799-601-7220, T-adapter for connector AC6: 799-601-7210
REMARK

Defective air mix door Operate the temperature control switch to check if air mix door (damper) has mechanical
1
(damper) system failure (coming off of lever or interference, etc.).
2. Disconnect connector [4], and then perform troubleshooting with starting switch stayed
in OFF position.
[4] (Servomotor side) between (light green) and (green line Approx. 110
Defective air mix servo on white background) Ω
2
motor (unit test)
[4] (Servomotor side) between (red line on brown back-
Resistance Approx. 4 kΩ
ground) and (black line on green background)
[4] (Servomotor side) between (blue line on yellow back- Approx. 500
ground) and (black line on blue background) Ω to 3.5 kΩ
80-60 GD535-5
(01)
80 Appendix A-4 Troubleshooting for temperature control function

q When LCD does not flash in self-diagnosis, controller does not stop driving servo motor,
so following checks can be performed.
q When temperature setting display flashes in self-diagnosis, skip check on causes 3 and
4, and proceed to check on causes 5 and 6.
5. Set the temperature to the minimum by using temperature control switch on air condi-
tioner control panel.
Defective air mix servo 6. Press the temperature control switch to increase the temperature, and perform trouble-
motor, defective air condi-
shooting.
3 tioner wiring harness,
7. Set the temperature to the maximum by using temperature control switch on air condi-
defective air conditioner tioner control panel.
controller
8. Press the temperature control switch to decrease the temperature, and perform trou-
bleshooting.
REMARK
The voltage is applied for only approximately 1 second (only while door is moving), and its
polarity is contrary between pressing raising button and lowering button of temperature
control switch. When raising button is pressed, polarity of AC5 (5) pin becomes positive
(+).
Between voltage AC5 (16) and (18) 5V
Voltage
Between AC5 (4) and (5) 12 V or -12 V
qWhen LCD does not flash in self-diagnosis, controller does not stop driving servo motor,
so checks can be performed.
q When temperature setting display flashes in self-diagnosis, skip check on causes 3 and
4, and proceed to check on causes 5 and 6.
q When air mix servomotor does not operate even if it is normal in preceding check (the
following is abnormal), air mix servomotor is defective.
5. Set the temperature to the minimum by using temperature control switch on air condi-
Defective air mix servomo- tioner control panel.
4
tor (internal defect) 6. Press the temperature control switch to increase the temperature, and perform trouble-
shooting.
7. Set the temperature to the maximum by using temperature control switch on air condi-
tioner control panel.
8. Press the temperature control switch to decrease the temperature, and perform trou-
bleshooting.
REMARK
Voltage varies for only approximately 1 second (only while door is moving). (When door
stops, the voltage becomes constant.)
Varies within
Voltage Between AC6 (5) and AC5 (18)
Max. 5 V.
Open circuit in wiring har- If no failure is found by check on causes 1 to 4, this check is not required. Check by refer-
5
ness ring to circuit diagram.
GD535-5 80-61
(01)
A-4 Troubleshooting for temperature control function 80 Appendix

If no failure is found by check on causes 1 to 4, this check is not required.
2. Disconnect connectors AC2, AC5, AC6, [4], and [6], and connect T-adapter to female
sides of AC5 and AC6.
Short circuit in wiring har- Between AC5 (4) and each pin other than (4) No continuity
6
ness Between AC5 (5) and each pin other than (5) No continuity
Continuity Between AC5 (16) and each pin other than (16) No continuity
Between AC5 (18) and each pin other than (18) No continuity
Defective air mix servomo- When temperature setting display flashes in self-diagnosis,, and check results on causes
7
tor 1, 2, 5, and 6 are normal, air mix servomotor is defective.
Defective air conditioner When test result for cause 2 is normal and that for cause 3 is abnormal and that for
8
control panel causes 5 and 6 is normal, air conditioner control panel is defective.
Circuit diagram related to temperature control function
80-62 GD535-5
(01)
80 Appendix A-5 Troubleshooting for fresh/recirc air changeover
A-5 Troubleshooting for fresh/recirc air changeover 1
Failure Fresh air and recirculation air cannot be changed over.

Even if FRESH/RECIRC air changeover switch on air conditioner control panel is operated, the air does not
Phenomenon
switch between FRESH and RECIRC.
on machine
(FRESH/RECIRC air changeover door (damper) does not rotate.)
q When a failure is detected by self-diagnosis function and the main power switch is turned on, FRESH/RE-
CIRC air changeover symbol on the air conditioner control panel (LCD) flashes.
q Each time the main power switch is turned on, self-diagnosis checks the contacts (or LIMIT terminals) in
the FRESH/RECIRC air changeover servomotor.
q Self-diagnosis does not check for short circuits and open circuits in the FRESH/RECIRC air changeover
servomotor, and therefore, flashing of the LCD by self-diagnosis does not necessarily mean that all the
probable servomotor failures are checked.
q Operate FRESH/RECIRC air selector switch to check if FRESH/RECIRC air changeover door has me-
Related
chanical failure (disconnection of link, interference of lever, etc.). For details, see “TEST FRESH/RECIRC
information
AIR CHANGEOVER”.
REMARK

Defective FRESH/
Operate the FRESH/RECIRC air selector switch to check if FRESH/RECIRC air change-
1 RECIRC air changeover
over door (damper) has mechanical failure (coming off of lever or interference, etc.).
door (damper) system
2. Disconnect connector [6], and then perform troubleshooting with starting switch stayed
in OFF position.
Defective FRESH/ [6] (Servomotor side) between (green line on yellow back- Approx. 110
2 RECIRC air changeover ground) and (black line on yellow background) Ω
servomotor (unit test) [6] (Servomotor side) between (red line on brown back-
Resistance Approx. 4 kΩ
ground) and (black line on blue background)
[6] (Servomotor side) between (white line on blue back- 500 Ω to 3.5
ground) and (black line on blue background) kΩ
q When FRESH/RECIRC selector symbol flashes in self-diagnosis, skip check on causes
3 and 4, and proceed to check on causes 5 and 6.
Defective FRESH/ 3. Turn the starting switch to ON position.
RECIRC air changeover 4. Turn on the main power switch of air conditioner.
servomotor, defective air 5. Set FRESH/RECIRC air selector switch to RECIRC position on the air conditioner
3
conditioner wiring har- control panel, and be ready for check.
ness, defective air condi- 6. Set FRESH/RECIRC air selector switch to FRESH position on the air conditioner
tioner controller control panel.
REMARK
Voltage is applied only for approximately 3 seconds (time for door to move toward FRESH
or RECIRC position), and its polarity is contrary between FRESH and RECIRC.
Between AC5 (16) and (18) 5V
Voltage
Between AC5 (8) and (9) 12 V or -12 V
GD535-5 80-63
(01)
A-5 Troubleshooting for fresh/recirc air changeover 80 Appendix

q When FRESH/RECIRC selector symbol flashes in self-diagnosis, skip check on causes
3 and 4, and proceed to check on causes 5 and 6.
q When FRESH/RECIRC air changeover servomotor does not operate even if it is normal
in preceding check (the following is abnormal), FRESH/RECIRC air changeover servo-
motor is defective.
Defective FRESH/ 2. Disconnect connectors AC5 and AC6, and insert T-adapter into them.
RECIRC air changeover 3. Turn the starting switch to ON position.
4 4. Turn on the main power switch of air conditioner.
servomotor (internal
defect) 5. Set FRESH/RECIRC air selector switch to RECIRC position on the air conditioner
control panel, and be ready for check.
6. Set FRESH/RECIRC air selector switch to FRESH position on the air conditioner
control panel.
REMARK
Voltage varies only for approximately 3 seconds (time for door to move toward FRESH or
RECIRC position). (When door stops, the voltage becomes constant.)
Varies within
Voltage Between AC6 (7) and AC5 (18)
Max. 5 V.
ness (wire breakage or If no failure is found by check on causes 1 to 4, this check is not required.
5
defective contact of con- Check by referring to circuit diagram.
nector)
If no failure is found by check on causes 1 to 4, this check is not required.
6
Defective FRESH/ When FRESH/RECIRC selector symbol on LCD flashes in self-diagnosis, and check
7 RECIRC air changeover results on causes 1, 2, 5, and 6 are normal, FRESH/RECIRC air changeover servomotor
servomotor is defective.
Defective air conditioner When test result for cause 2 is normal and that for cause 3 is abnormal and that for
8
control panel causes 5 and 6 is normal, air conditioner control panel is defective.
80-64 GD535-5
(01)
80 Appendix A-5 Troubleshooting for fresh/recirc air changeover
Circuit diagram related to fresh/recirc air changeover
GD535-5 80-65
(01)
A-6 Troubleshooting for hot water cut valve 80 Appendix
A-6 Troubleshooting for hot water cut valve 1
When temperature setting indicates COOL MAX, hot water cut valve does not close. Or, when temperature
Failure
setting indicates other than COOL MAX, hot water cut valve does not open.
Phenomenon Since the hot water to heater core cannot be blocked, hot water may flow into heater core. Or, since
on machine hot water is blocked, air temperature does not rise during heating.
q HOT and COOL flashes simultaneously in self-diagnosis.
q Since the command from air conditioner control panel cannot be detected by multimeter, check the open/
close of hot water cut valve by measuring potentiometer voltage. (When the voltage between AC2 (3) and
(5) is approx. 5 V, valve is open, when it is approx. 0 V, valve is closed.)
Related
q For each connector, etc., see “INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND AR-
information
RANGEMENT OF CONNECTORS”.
REMARK

2. Disconnect connector AC2, and then perform troubleshooting with starting switch
stayed in OFF position.
Defective hot water cut Between AC2 (servomotor side) (green line on blue back- Approx. 2.8
1 ground) and (light green) kΩ
valve (unit test)
Resistance Between AC2 (servomotor side) (white line on red back-
ground) and (white) Approx. 5 kΩ
Between AC2 (servomotor side) (orange) and (white) 0.2 to 4.8 kΩ

q When LCD does not flash in self-diagnosis, controller does not stop driving valve, so
checks can be performed.
q When HOT and COOL display flashes simultaneously in self-diagnosis, skip check on
cause 2, and proceed to check on cause 3.
2. Disconnect connector AC3, and insert T-adapter into it.
3. Start the engine
Defective hot water cut 4. Turn on the main power switch of air conditioner.
valve, defective air condi-
5. Operate the temperature control switch on air conditioner control panel, and set it to
2 tioner wiring harness,
other than COOL MAX.
defective air conditioner 6. Operate the temperature control switch on air conditioner control panel, and set it to
control panel
COOL MAX.
REMARK
ON/OFF command to hot water cut valve from air conditioner control panel cannot be
checked by using multimeter.
Other than COOL MAX Approx. 5 V
Voltage Between AC3 (14) and (1)
COOL MAX Approx. 0 V
Open circuit in wiring har- If no failure is found by check on causes 1 and 2, this check is not required. Check by
3
ness referring to circuit diagram.
If no failure is found by check on causes 1 and 2, this check is not required.
4
80-66 GD535-5
(01)
80 Appendix A-6 Troubleshooting for hot water cut valve

q When HOT and COOL display flashes simultaneously in self-diagnosis, and check re-
sult on causes 3 and 4 are normal, hot water cut valve is defective.
Defective hot water cut
5 q When HOT and COOL displays do not flash simultaneously in self-diagnosis, and check
valve
result on causes 1, 3 and 4 are normal, and check result on cause 2 is abnormal, hot
water cut valve is defective.
Defective air conditioner
6 If no failure is found by preceding checks, air conditioner control panel is defective.
control panel
Circuit diagram related to hot water cut valve
GD535-5 80-67
(01)
Troubleshooting using gauge pressure 80 Appendix
Troubleshooting using gauge pressure 1
Connect the service tool referring to “METHOD FOR CONNECTING SERVICE TOOL”, perform troubleshooting
by reading the gauge pressures of the high-pressure and low-pressure lines in the freezing cycle.
q For the cause, checking method, and remedy corresponding to the gauge pressure, see the indicated gauge
pressure table.
q The gauge pressure varies with the weather condition and operating condition of the machine. Check the
gauge pressure under the pressure measurement conditions.
q Pressure measurement condition
Outside air temperature: 25 to 50 °C
Engine speed: 1500 rpm
Air conditioner switch: ON
Fan switch: HI
Set temperature: COOL MAX
q Pressure measurement standard value
High in high-pressure side: Approx. 2.5 MPa {25 kg/cm2} and above
Low in high-pressure side: Approx. 1 MPa {10 kg/cm2} and below
High in low-pressure side: Approx. 0.3 MPa {3 kg/cm2} and above
Low in low-pressure side: Approx. 0.05 MPa {0.5 kg/cm2} and below
q Dual pressure switch turns "OFF" to protect the air conditioner circuit if the pressure of the high-pressure or
low-pressure line is abnormally high or low.
Dual pressure switch is normally turned "ON" and is turned "OFF"
when it detects abnormal pressure in compressor operation.
LA: 0.20 MPa {2 kg/cm2}
LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}
Indicated gauge pressure table
Indicated gauge pressure Cause Check method Remedy

Air conditioner cycle is operating normally.
If there is any failure (defective cooling), there is another
Pressure is normal cause. -
High-pressure: Approx. 1.5 to 1.7 MPa {15 to 17 kg/cm2}
Low-pressure: Approx. 0.13 to 0.2 MPa {1.3 to 2.0 kg/cm2}
80-68 GD535-5
(01)
80 Appendix Troubleshooting using gauge pressure
Indicated gauge pressure Cause Check method Remedy

Collect refrigerant, then refill
Bubbles are seen through
Insufficient refrigerant with proper volume of refriger-
sight glass.*1 *3
ant again.*2
There is a temperature differ-
ence between inlet and outlet
Clogging of receiver drier Replace*2
pipes of receiver drier. Tank is
frosted.
Clogging of expansion valve Expansion valve is frosted. Clean or replace *2
Gas leakage at heat sensing Low-pressure gauge indicates
Both pressures in highpres- Replace *2
tube of expansion valve negative pressure.
sure and low-pressure side
are low (Low-pressure side Evaporator is frozen.
Repair or replace
becomes vacuum) Defective evaporator temper- Air flow is decreased by freez-
Replace receiver drier
ature sensor or defective con- ing.
tact of sensor (coming off of (If temperature is set to COOL
with proper volume of refriger-
fixing clip) MAX and fan speed is set to
ant again.*2
HI, air does not get cold later.)
Piping between receiver drier
and compressor is clogged or
crushed.
Clogged or crushed piping Clean or replace *2
If it is clogged completely,
low-pressure gauge indicates
negative pressure.
Overfilling of refrigerant Connect gauge manifold. with proper volume of refriger-
ant again.*2
Dirty condenser, clogging or Clean condenser, repair fins,
Defective cooling of con-
crushing of fins, or defective or repair or replace cooling
Both pressures in highpres- denser
rotation of cooling fan fan *2
sure and low-pressure side
are high Incorrect adjustment of
expansion valve (valve is Replace *2
sight glass. *3
opened too wide)
Evacuate, then refill with
Air mixed in refrigerant circuit proper volume of refrigerant
sight glass. *3
again. *2
There is a remarkable temper-
Pressure in high-pressure Clogged or crushed refriger-
ature difference around Clean inside of refrigerant cir-
side is high, and that in low- ant circuit between compres-
clogged part in refrigerant circuit or replace. *2
pressure side is low sor and condenser
cuit.
Both pressures in highpres-
sure side and low-pressure
Pressure in high-pressure Defective compressor (defec-
side becomes same while
side is low, and that in low- tive compression of compres- Replace *2
compressor is in operation.
pressure side is high sor)
Compressor has seizure and
is extremely hot.
*1: If refrigerant leaks, compressor oil in the air conditioner circuit always leaks as well. Accordingly, perform the
check mainly on pipe joints and dirty parts with oil.
*2: When replacing cooling cycle parts, see “PRECAUTIONS FOR REFRIGERANT” and collect refrigerant. After
replacing it, fill up the air conditioner circuit with refrigerant again.
*3: Sight glass is on the receiver drier.
GD535-5 80-69
(01)
Troubleshooting using gauge pressure 80 Appendix
Connection of service tool 1
k Place the machine on a level ground, set parking brake to “PARK” position, stop the engine, and
chock the tires.
position, and remove the key.
(-) terminal.)
Use the following service tool kit for R134a.
- 799-703-1200 Service tool kit
Service tool kit

(1): Gauge manifold (4): Large diameter quick joint (for high-pressure line)
(2): Red high-pressure line charging hose (5): Small diameter quick joint (for low-pressure line)
(3): Blue low-pressure line charging hose
REMARK
(a): Note that the threads are coarse and the hoses are relatively easy to loosen.
80-70 GD535-5
(01)
80 Appendix Method for connecting service tool
Method for connecting service tool 1
1. Close high-pressure line valve (6) and low-pressure line valve (7) of gauge manifold (1).
2. Connect red high-pressure line charging hose (2) to the gauge manifold (1) (HI side) .
3. Connect blue low-pressure line charging hose (3) to the gauge manifold (1) (LO side).
4. Connect quick joints (4) and (5) to each hose.
5. Connect quick joint (4) to service valve (8) of high-pressure piping.
6. Connect quick joint (5) to service valve (9) of low-pressure piping.
GD535-5 80-71
(01)
Precautions for disconnecting and connecting hoses and tubes in air conditioner pipings 80 Appendix
Precautions for disconnecting and connecting hoses and tubes in air

conditioner pipings 1
Precautions for disconnection

k When replacing the air conditioner unit, air conditioner compressor, condenser or receiver drier,
etc., collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit before discon-
necting the air conditioner hoses.
k If refrigerant gas (air conditioner gas: R134a) gets in your eyes, you may lose your sight. And if it
touches your skin, you may suffer from frostbite. Put on protective eyeglasses, gloves and working
clothes with long sleeves while collecting the refrigerant or filling the air conditioner circuit with the
refrigerant.
NOTICE
q Never release the refrigerant (R134a) to the atmosphere.
q Ask a qualified person for collecting, adding and filling operations of the refrigerant (R134a).
1: Engine 4: Receiver drier

2. Compressor 5: Air conditioner unit
3: Condenser
q When loosening the air conditioner hose nut after collecting the refrigerant, be sure to use 2 wrenches. Use
one wrench to fix one nut and the other wrench to loosen the other nut.
q When working on the air conditioner piping, take measures to prevent the entry of dirt, dust, water, etc. into
the hoses.
80-72 GD535-5
(01)
80 Appendix Precautions for disconnecting and connecting hoses and tubes in air conditioner pipings
Precautions for connection

q When connecting the pipes, apply compressor oil(SP-10) for
R134a to prevent O-ring from damage and twisting.
Do not apply oil to threaded portion of bolt, nut and union.
REMARK
An O-ring is fitted to every joint of the air conditioner piping.
q Once an O-ring is used, it is deformed and deteriorated.
Accordingly, do not reuse it. When removing it, use a soft tool
(such as a toothpick) so that the piping will not be damaged.
q When connecting a pipe, push it into the end and fully finger-
tighten the bolt or nut.
q Be sure to use 2 wrenches to tighten each nut. Use one
wrench to fix one nut and the other wrench (torque wrench) to
tighten the other nut to the specified torque.
Table of tightening torque for refrigerant pipe joint.

Thread size Tightening torque
M6 7.8 to 11.8 Nm {0.8 to 1.2 kgm}
M8 20 to 25 Nm {2.0 to 2.6 kgm}
M18 Unit 9.8 to 12 Nm {1.0 to 1.2 kgm}
M16 12 to 15 Nm {1.2 to 1.5 kgm}
M22 20 to 25 Nm {2.0 to 2.6 kgm}
M24 30 to 35 Nm {3.0 to 3.5 kgm}
GD535-5 80-73
(01)
Handle compressor oil 80 Appendix
Handle compressor oil 1
Management of compressor oil (SANDEN: SP-10 for R134a)

The compressor oil does not need to be checked or refilled as frequently as the engine oil. However, if its level is
low or too high, it can cause the following troubles. Accordingly, charge the compressor oil by the specified quan-
tity, similarly to the refrigerant.
Condition Content
Lack of oil Defective lubrication and seizure of compressor
Defective cooling (Excess oil sticks to each part and decreases heat exchanged effi-
Excess of oil
ciency.)
Filling of compressor oil

k Refrigerant is potentially hazardous to health and environment. Before disconnecting air conditioner
hoses, collect refrigerant. For details, see “PRECAUTIONS FOR DISCONNECTING AND CONNECT-
ING HOSES AND TUBES IN AIR CONDITIONER PIPINGS”.
k If you use the oil for CFC-12 (R-12), lubrication trouble will occur and the compressor may be broken
or seized.
Be sure to use oil for R134a (SANDEN: SP-10).
k Oil for R134a is extremely hygroscopic, and therefore, put the cap immediately after using the oil in
order to block them from the air.
Store the oil container in a dry and well ventilated place.
k Since the compressor oil may dissolve the plastic and painting surface, do not allow the oil to con-
tact with them.
Check oil level and add oil in the following cases.
q The large quantity of leakage of refrigerant occurs and refrig-
erant is discharged abruptly.
q The compressor has a trouble and it is replaced
(See “The quantity of compressor oil level when the compres-
sor is replaced”.)
q Cycle parts such as the condenser, receiver drier, evaporator
unit, etc. are replaced.
q Quantity of oil to be added when cycle parts are replaced.
Air conditioner component Quantity to be added

Air conditioner unit, evaporator Approx. 40 cc
Condenser Approx. 40 cc
Receiver drier Approx. 20 cc
Hose (compressor to cab) Approx. 25 cc
Hose (compressor to condenser) Approx. 10 cc
Hose (cab to receiver drier) Approx. 15 cc
The quantity of compressor oil when the compressor is replaced

The following is the explanation when the compressor is broken due to seizure, etc. and in other cases.
q When compressor is broken due to seizure, etc.
Metal chips circulate through the air conditioner circuit and contaminate the compressor oil extremely.
In such case, clean the air conditioner circuit and replace the compressor and receiver drier.
Since all of the compressor oil is removed from the air conditioner circuit by cleaning the circuit, install the
new compressor with the oil of the specified quantity (240 cc) filled in it.
80-74 GD535-5
(01)
80 Appendix Handle compressor oil
q Other cases
New compressor contains compressor oil of 240 cc in it.
1. Prepare a container to catch the oil, and drain the oil from
the removed compressor.
2. Measure the quantity of the drained oil with a measuring
cylinder, and write it down.
3. Drain the oil from the new compressor by the following
quantity.
Quantity to be drained = 240 cc - “Quantity recorded”
Example: If the quantity of the oil drained from the removed
compressor is 30 cc, the quantity of the oil to
be drained from the new compressor is 240 cc - 30 cc =
210 cc.
GD535-5 80-75
(01)
Handle compressor oil 80 Appendix
80-76 GD535-5
(01)
90 Diagrams and drawings
GD535-5 90-1
Contents 90 Diagrams and drawings
Contents 1
Acronyms - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90-3
Hydraulic diagrams and drawings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90-8
Symbols used in hydraulic circuit diagrams - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90-8
Hydraulic circuit diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90-11
Power train hydraulic circuit diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90-15
Electrical diagrams and drawings- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90-17
Symbols used in electric circuit diagrams- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90-17
Chassis electric circuit diagram- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90-21
Floor electric circuit diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90-31
90-2 GD535-5
90 Diagrams and drawings Acronyms
Acronyms 1
System
Advanced Joystick
ARAC
braking force.
Automatic Retarder
Automatic Spin
Brake Cooling oil
Regulator
used independently.
Closed-center Load
Sensing System
injection timing.
ECU)
GD535-5 90-3
Acronyms 90 Diagrams and drawings
Electronic Control
Modulation Valve

ECM)
Exhaust Gas
Recirculation
Equipment
Monitoring System
Electromagnetic
Forward-Neutral-
Reverse
Global Positioning
System
Plus) earth

Global Navigation
Satellite System

HSS
Hydro Static
control
Unit
motions.
90-4 GD535-5
KOMATSU Closed
KCSF Engine
KOMATSU Diesel
Oxidation Catalyst
muffler.
Particulate Filter
KOMATSU Traction
LIN
load.
LVDS
sensor.
Service
NC Normally Closed
NO Normally Open
PC Hydraulic system
GD535-5 90-5
Acronyms 90 Diagrams and drawings
PCCS
Pre-stroke Control
Valve
Control
hydraulic pressure.
Hydraulic system
PTP

Structure
Selective Catalytic
Reduction
VGT Engine

D: Bulldozer
HD: Dump truck
WA: Wheel loader
90-6 GD535-5

A/C Air Conditioner
A/M Air Mix damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
ENG Engine
F.G. Frame Ground
GND Ground
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/M Transmission
GD535-5 90-7
Symbols used in hydraulic circuit diagrams 90 Diagrams and drawings
Hydraulic diagrams and drawings 1
Symbols used in hydraulic circuit diagrams 1
Symbol Substance
Main piping line
Pilot or drain line
Flexible pipe (hose, etc.)
Lines intersecting without joining
Lines joining (junction with a round black mark)
Direction of flow
Throttle in passage.
Variable
Electricity
Spring
Take-off port
Take-off port and pressure gauge
Check valves
Suction (with strainer)
Tank and return pipe
Filter
Oil cooler
Stop valve
Drive shaft䋨unidirectional䋩
Drive shaft䋨bidirectional䋩
90-8 GD535-5
90 Diagrams and drawings Symbols used in hydraulic circuit diagrams
Symbol Substance
Pump
Note : Black triangle shows outlet port䋩
Variable capacity hydraulic pump
Hydraulic motor (The figure shows bidirectional type.)

Note䋺Two black triangles in the figure show direction of oil entering hydraulic motor
㩷㩷㩷㩷㩷㩷㩷㩷㩷depending on the oil entry port, the direction of rotation is reversed.
Servo piston
PPC valve
Control valve
Single-acting solenoid
Hydraulic pilot valve
Hydraulic two-stage pilot valve
Lock valve
Drain valve
Pressure regulator valve/ Safety valve/ Abnormal pressure prevention valve
Pressure regulator valve/Safety valve/ Abnormal pressure prevention valve

䋨When the figure shows air pressure, being released to atmosphere.䋩
Bypass valve
Accumulator
Cylinder
Component group
GD535-5 90-9
Symbols used in hydraulic circuit diagrams 90 Diagrams and drawings
90-10 GD535-5
Hydraulic circuit diagram (1/2)
Hydraulic circuit diagram (1/2) GD535-5
GD535-5
a This figure covers the equipment and devices that are unavailabole as optional items some areas.
GD535-5 90-11
Hydraulic circuit diagram (2/2)
Hydraulic circuit diagram (2/2) GD535-5
GD535-5
GD535-5 90-13
90 Diagrams and drawings Power train hydraulic circuit diagram
Power train hydraulic circuit diagram

GD535-5
GD535-5 90-15
90 Diagrams and drawings Symbols used in electric circuit diagrams
Electrical diagrams and drawings 1
Symbols used in electric circuit diagrams 1
Symbol Substance
Electric wire
Electric wire 䋨Wires intersecting without connecting䋩
Electric wire 䋨Wires intersecting and connecting (junction) with a round

black mark 䋩
Electric wire (Bundled drawing style)
Terminal
Chassis ground
Chassis ground using terminal
Contact
Switch
Push-button type switch (N.O. type)

*N.O.: Normally Open
Push-button type switch (N.C. type)

*N.C.: Normally Close
Pull-button type switch (N.O. type)

Pull-button type switch (N.C. type)

Variable
Resistance (resistor)
Variable resistance (variable resistor)
GD535-5 90-17
Symbols used in electric circuit diagrams 90 Diagrams and drawings
Symbol Substance
Diode
Light emitting diode (LED)
Photo diode
Constant voltage diode (Zener diode)
Transistor (PNP type)
Transistor (NPN type)
Coil
Battery
Fuse
Connector
䋨Note䋩
䊶Convex side of connecting portion (right in figure): male
䊶Concave side of connecting portion (left in figure): female
*Figure shows a line disconnection status.
Plug and receptacle type connector (left: male, right: female)

Note: Figure shows a line connection status.
Solenoid
Motor
90-18 GD535-5
90 Diagrams and drawings Symbols used in electric circuit diagrams
Symbol Substance
Lamp
Pressure switch (N.O. type)

Pressure switch (N.C. type)

Potentiometer
Fuel dial
Temperature sensor
Starting switch
Backup alarm
Horn
Buzzer
Antenna
GD535-5 90-19
Symbols used in electric circuit diagrams 90 Diagrams and drawings
90-20 GD535-5
Chassis electric circuit diagram (1/5)
Chassis electric circuit diagram (1/5) GD535-5 1
GD535-5
GD535-5 90-21
GD535-5
GD535-5 90-23
GD535-5
GD535-5 90-25
GD535-5
GD535-5 90-27
GD535-5
GD535-5 90-29
Floor electric circuit diagram (1/7)
Floor electric circuit diagram (1/7) GD535-5 1
GD535-5
GD535-5 90-31
GD535-5
GD535-5 90-33
GD535-5
GD535-5 90-35
GD535-5
GD535-5 90-37
GD535-5
GD535-5 90-39
GD535-5
GD535-5 90-41
GD535-5
GD535-5 90-43
Index
Index 1
Configuration and function of refrigeration cycle.... 80-13
Connection of service tool...................................... 80-70
Connector list and layout ....................................... 40-49
A Connector pin layout .............................................. 40-63
A-1 Troubleshooting for power supply system Control valve ........................................................ 10-110
(air conditioner does not operate) .....................80-52 Conversion table .................................................... 00-51
A-2 Troubleshooting for compressor and refrigerant Cooling fan control system................................... 10-182
system (air is not cooled) .................................. 80-54 Cooling fan motor........................................ 10-11, 60-10
A-3 Troubleshooting for blower motor system Cooling system ............................................... 10-9, 60-9
(no air comes out or air flow is abnormal) .........80-57
A-4 Troubleshooting for temperature
control function.................................................. 80-60 D
A-5 Troubleshooting for fresh/recirc Diagnosis of open harness in pressure sensor
air changeover .................................................. 80-63 system .............................................................. 40-47
A-6 Troubleshooting for hot water cut valve ...........80-66 Differential (Differential lock specification) .. 10-61, 60-28
Acronyms ............................................................................ Differential (Non-differential specification) .. 10-59, 60-27
00-12, 01-3, 10-4, 20-3, 30-4, 40-8, 50-4, 60-3, 80-3, 90-3 Differential lock solenoid valve.................... 10-64, 60-31
Adjusting drawbar ball joint clearance .................. 30-106 Disassembly and assembly of
Adjusting rearview camera angle.......................... 30-167 circle rotation gear assembl ........................... 50-252
Adjusting transmission speed sensor ..................... 30-68 Disassembly and assembly of
Adjusting valve clearance ....................................... 30-24 differential assembly....................................... 50-181
Air conditioner component ........................................ 80-9 Disassembly and assembly of
Air conditioner system .............................................. 80-8 final drive assembly........................................ 50-194
Air conditioner system diagram .............................. 80-28 Disassembly and assembly of
Air conditioner troubleshooting chart 1 ................... 80-46 hydraulic cylinder assembly ........................... 50-243
Air conditioner troubleshooting chart 2 ................... 80-48 Disassembly and assembly of
Air conditioner unit .................................................. 80-16 tandem drive assembly .................................. 50-175
Articulate cylinder ................................................... 60-43 Disassembly and assembly of
Automatic gear shift control system...................... 10-151 torque converter assembly ............................. 50-126
transmission assembly ................................... 50-137
B Disassembly and assembly of
Battery disconnect switch ..................................... 10-139 wheel brake assembly.................................... 50-208
Blade......................................................... 10-126, 60-52 Disconnection and connection of engine, transmission,
Blade lift cylinder..................................................... 60-44 and torque converter assembly ...................... 50-124
Blade side shift cylinder .......................................... 60-46 Drawbar shift cylinder ............................................ 60-45
Bleeding air from brake circuit ................................ 30-87
Bleeding air from fuel circuit ................................... 30-34
Bleeding air from steering circuit ............................ 30-82 E
Bleeding air from work equipment circuit.............. 30-105 E-1 Engine does not start
Brake and cooling fan pump ................................. 10-109 (Starting motor does not rotate). .................... 40-421
Brake circuit accumulator ....................................... 10-88 E-2 Manual preheating system does not work..... 40-425
Brake circuit accumulator charge valve .................. 10-89 E-3 When starting switch is turned ON,
Brake system ...................... 10-82, 30-83, 50-208, 60-34 machine monitor displays nothing. ................. 40-431
Brake valve ............................................................. 10-83 E-4 LCD panel backlight of machine monitor fails
(goes out or flickers)....................................... 40-434
E-5 LCD display failure of machine monitor......... 40-435
C E-6 The switch of machine monitor switch panel
Cab and its attachments ......................... 10-135, 50-257 does not work. ................................................ 40-436
Charging brake accumulator with gas .................... 30-93 E-7 Two-switch operation of switch panel on machine
Chassis electric circuit diagram .............................. 90-21 monitor does not function. .............................. 40-437
Check blower AMP ................................................. 80-44 E-8 Machine monitor buzzer does not sound. ..... 40-438
Check temperature control function........................ 80-40 E-9 Some gauges or caution lamps of
Checking and replacing alternator belt ................... 30-49 machine monitor do not work normally........... 40-439
Checking and replacing auto-tensioner .................. 30-51 E-10 Rearview monitor does not light up or
Checks before troubleshooting ............................... 40-15 backlight flickers. ............................................ 40-440
Circle and drawbar.................................... 10-124, 60-50 E-11 Rearview monitor images are not displayed
Circle rotation gear ................................... 10-132, 60-55 clearly ............................................................. 40-442
Circle rotation motor ............................................. 10-130 E-12 Rearview monitor brightness cannot be
Circuit diagram and arrangement of connector pins for air adjusted.......................................................... 40-444
conditioner......................................................... 80-26 E-13 Night lighting lamp of rearview monitor is
Coating materials list .............................................. 50-11 abnormal ........................................................ 40-447
Component parts of air conditioner system ............ 80-16 E-14 Speedometer or engine speed display is
Component parts of air conditioner unit.................. 80-19 abnormal. ....................................................... 40-449
Compressor ............................................................ 80-21
Condenser .............................................................. 80-22
GD535-5 1
(02)
Index
E-15 Engine coolant temperature is displayed Failure code [15L0MW] Failure of Clutch System
abnormally. ..................................................... 40-450 (2nd)................................................................ 40-112
E-16 Articulated meter display is abnormal. ......... 40-452 Failure code [15M0MW] Failure of Clutch System
E-17 Torque converter oil temperature is displayed (3rd) ................................................................ 40-113
abnormally. ..................................................... 40-454 Failure code [15N0MW] Failure of Clutch System
E-18 Fuel gauge is displayed abnormally............. 40-456 (4th)................................................................. 40-114
E-19 Centralized warning lamps do not light or Failure code [15SBL1] Release Trouble of ECMV
do not go out................................................... 40-458 (R) ................................................................... 40-115
E-20 Alarm buzzer does not sound or does not stop Failure code [15SBMA] Malfunction of ECMV
sounding. ........................................................ 40-459 (R) ................................................................... 40-117
E-21 Transmission mode cannot be switched...... 40-461 Failure code [15SCL1] Release Trouble of ECMV
E-22 Engine mode cannot be switched. ............... 40-463 (FH)................................................................. 40-119
E-23 Differential gear lock function does not operate or is not Failure code [15SCMA] Malfunction of ECMV
canceled (for differential gear lock model)...... 40-465 (FH)................................................................. 40-121
E-24 Cannot be locked or canceled Failure code [15SDL1] Release Trouble of ECMV
by the lifter lock pin. ........................................ 40-467 (FL) ................................................................. 40-123
E-25 Horn does not sound or Failure code [15SDMA] Malfunction of ECMV
does not stop sounding................................... 40-469 (FL) ................................................................. 40-125
E-26 Backup alarm does not sound or does not stop Failure code [15SEL1] Release Trouble of ECMV
sounding. ........................................................ 40-471 (1st)................................................................. 40-127
E-27 Headlamps, clearance lamps, and tail lamps do not Failure code [15SEMA] Malfunction of ECMV
light up or go out. ............................................ 40-474 (1st)................................................................. 40-129
E-28 Working lamps do not light up or go out. ..... 40-482 Failure code [15SFL1] Release Trouble of ECMV
E-29 Turn indicator light or emergency flashing light (2nd)................................................................ 40-131
does not flash. ................................................ 40-487 Failure code [15SFMA] Malfunction of ECMV
E-30 Stop lamp does not light up or (2nd)................................................................ 40-133
does not go out. .............................................. 40-496 Failure code [15SGL1] Release Trouble of ECMV
E-31 Backup lamp does not light up or (3rd) ................................................................ 40-135
does not go out ............................................... 40-498 Failure code [15SGMA] Malfunction of ECMV
E-32 All wipers do not operate ............................. 40-500 (3rd) ................................................................ 40-137
E-33 Front wiper does not operate ....................... 40-502 Failure code [15SHL1] Release Trouble of ECMV
E-34 Rear wiper does not operate ....................... 40-506 (4th)................................................................. 40-139
E-35 Left and right door wiper does not operate .. 40-509 Failure code [15SHMA] Malfunction of ECMV
E-36 Left door wiper does not operate ................. 40-512 (4th)................................................................. 40-141
E-37 Right door wiper does not operate............... 40-514 Failure code [15SJMA] Malfunction of ECMV
E-38 Front or door washer does not operate........ 40-516 (L/U) ................................................................ 40-143
E-39 Rear washer does not operate .................... 40-518 Failure code [15U0NT] Overload of
E-40 KOMTRAX system does not operate Inching Clutch ................................................. 40-144
normally. ......................................................... 40-520 Failure code [2G42ZG] Accumulator Oil Pressure Low
ECMV ..................................................................... 10-46 (Front) ............................................................. 40-145
Electrical diagrams and drawings........................... 90-17 Failure code [2G43ZG] Accumulator Oil Pressure Low
Electrical system ........................ 10-136, 30-111, 50-296 (Rear).............................................................. 40-147
Engine and cooling system ...... 10-9, 30-16, 50-51, 60-8 Failure code [989L00] Engine Controller Lock
Engine controller .................................................. 10-159 Caution 1......................................................... 40-149
Engine mount and transmission mount .................... 60-8 Failure code [989M00] Engine Controller Lock
Engine power mode selector circuit...................... 10-181 Caution 2......................................................... 40-150
Engine starting circuit ........................................... 10-168 Failure code [989N00] Engine Controller Lock
Engine stop circuit ................................................ 10-170 Caution 3......................................................... 40-151
Explanation of procedure for testing and Failure code [AB00KE] Charge Voltage Low........ 40-152
troubleshooting of air conditioner...................... 80-24 Failure code [AB00KY] Hot Short of
Explanation of terms for maintenance standard ..... 00-24 Alternator R Terminal...................................... 40-153
Failure code [B@BAZG] Derating in speed due to
F engine oil pressure drop ................................. 40-154
Failure code [1500L0] Double Engagement of T/M Failure code [B@BCNS] Engine Overheat ........... 40-155
Clutches.......................................................... 40-107 Failure code [B@CENS] T/C Oil Temp.
Failure code [15G0MW] Failure of R-Clutch Overheat ......................................................... 40-156
System............................................................ 40-108 Failure code [B@CKNS] DIFF Oil Temp.
Failure code [15H0MW] Failure of Clutch System Overheat ......................................................... 40-157
(FH)................................................................. 40-109 Failure code [B@HANS] HYD Oil Temp.
Failure code [15J0MW] Failure of Clutch System Overheat ......................................................... 40-159
(FL) ................................................................. 40-110 Failure code [CA111] Engine NE, controller
Failure code [15K0MW] Failure of Clutch System internal error.................................................... 40-161
(1st)................................................................. 40-111 Failure code [CA115] Engine NE, Bkup speed
sensor error..................................................... 40-162
2 GD535-5
(02)
Index
Failure code [CA122] Charge pressure sensor Failure code [CA431] Idle validation switch
high error......................................................... 40-163 error................................................................ 40-215
Failure code [CA123] Charge pressure sensor Failure code [CA432] Idle validation action
low error .......................................................... 40-165 error................................................................ 40-219
Failure code [CA131] Throttle sensor high error... 40-167 Failure code [CA435] Engine oil pressure
Failure code [CA132] Throttle sensor low error .... 40-169 switch error..................................................... 40-222
Failure code [CA144] Coolant sensor high error .. 40-172 Failure code [CA441] Power supply voltage
Failure code [CA145] Coolant sensor low error.... 40-174 low error ......................................................... 40-223
Failure code [CA153] Charge temperature sensor Failure code [CA442] Power supply voltage
high error......................................................... 40-176 high error ........................................................ 40-225
Failure code [CA154] Charge temperature sensor Failure code [CA449] Common rail pressure
low error .......................................................... 40-178 high error 2 ..................................................... 40-226
Failure code [CA155] Speed derating error by high charge Failure code [CA451] Common rail pressure
temperature..................................................... 40-180 sensor high error ............................................ 40-227
Failure code [CA1633] KOMNET (CAN communication) Failure code [CA452] Common rail pressure
error................................................................. 40-244 sensor low error.............................................. 40-229
Failure code [CA187] Sensor power supply 2 Failure code [CA488] Torque derating error by
low error .......................................................... 40-181 high charge temperature ................................ 40-231
Failure code [CA2185] Throttle sensor power supply high Failure code [CA553] Common rail pressure
error................................................................. 40-248 high error 1 ..................................................... 40-232
Failure code [CA2186] Throttle sensor power supply low Failure code [CA559] Supply pump pressure
error................................................................. 40-250 low error 1 ...................................................... 40-233
Failure code [CA221] Atmospheric pressure sensor high Failure code [CA689] Engine Ne speed
error................................................................. 40-183 sensor error .................................................... 40-235
Failure code [CA222] Atmospheric pressure sensor low Failure code [CA731] Engine Bkup speed
error................................................................. 40-185 sensor phase error ......................................... 40-237
Failure code [CA2249] Supply pump pressure Failure code [CA757] All continuous data
low error 2 ....................................................... 40-252 lost error ......................................................... 40-239
Failure code [CA227] Sensor power supply 2 Failure code [CA778] Engine Bkup speed
high error......................................................... 40-187 sensor error .................................................... 40-240
Failure code [CA2311] Abnormality in IMV (IMA) Failure code [D160KA] Disconnection of
solenoid........................................................... 40-253 Backup Light Relay ........................................ 40-258
Failure code [CA234] Engine overspeed .............. 40-188 Failure code [D160KB] Ground Fault of
Failure code [CA238] Ne speed sensor Backup Light Relay ........................................ 40-260
power supply error .......................................... 40-189 Failure code [D160KY] Hot Short of Back Lamp Relay
Failure code [CA2555] Intake heater relay Output............................................................. 40-262
open circuit...................................................... 40-254 Failure code [D19JKZ] Personal Code Relay
Failure code [CA2556] Intake heater relay Abnormality .................................................... 40-264
short circuit...................................................... 40-256 Failure code [D19KKZ] Failure of
Failure code [CA271] IMV short-circuit error ........ 40-190 Diff Control Relay ........................................... 40-266
Failure code [CA272] IMV open circuit ................. 40-192 Failure code [D1EHKA] Disconnection of
Failure code [CA322] Injector #1 (L/B #1) Engine Start Relay ......................................... 40-268
open/short ....................................................... 40-194 Failure code [D1EHKB] Ground Fault of
open/short ....................................................... 40-196 Failure code [D1EHKY] Hot Short of
open/short ....................................................... 40-198 Failure code [D1FBKB] Ground Fault of Sol.
Failure code [CA325] Injector #6 (L/B #6) Self-Holding Relay.......................................... 40-271
open/short ....................................................... 40-200 Failure code [D8AQK4] CAN2 Discon
Failure code [CA331] Injector #2 (L/B #2) (KOMTRAX) 2 ................................................ 40-273
open/short ....................................................... 40-202 Failure code [D8AQKR] CAN2 Discon
Failure code [CA332] Injector #4 (L/B #4) (KOMTRAX) ................................................... 40-274
open/short ....................................................... 40-204 Failure code [DAF0KT] Abnormality of Non-volatile Memory
Failure code [CA342] Data compatibility error in engine (MON)............................................................. 40-276
controller ......................................................... 40-206 Failure code [DAF0MB] Monitor ROM Abnormality 40-277
Failure code [CA351] Injector drive circuit error ... 40-207 Failure code [DAF0MC] Monitor Error ................. 40-278
Failure code [CA352] Sensor power supply 1 Failure code [DAF3KK] Controller Power Source Low
low error .......................................................... 40-208 (MON)............................................................. 40-279
Failure code [CA386] Sensor power supply 1 Failure code [DAFLKA] Op Lamp Open Cir
high error......................................................... 40-210 (Mon) .............................................................. 40-281
Failure code [CA428] Water-in-fuel sensor Failure code [DAFLKB] Op Lamp Shrt Cir
high error......................................................... 40-211 (Mon) .............................................................. 40-283
Failure code [CA429] Water-in-fuel sensor Failure code [DAQ0KK] Controller Power Source Low
low error .......................................................... 40-213 (T/M)............................................................... 40-285
GD535-5 3
(02)
Index
Failure code [DAQ0KT] Abnormality of Non-volatile Memory Failure code [DLF1LC] Failure of T/M Input
(T/M) ............................................................... 40-287 Speed Sensor ................................................. 40-343
Failure code [DAQ0MC] T/M Con Error................ 40-288 Failure code [DLF2KA] Disconnection of T/M Inter.
Failure code [DAQ1KA] Disconnection of Speed Sensor ................................................. 40-345
Key SW ACC .................................................. 40-289 Failure code [DLF2LC] Failure of T/M Intermediate
Failure code [DAQ2KK] Solenoid Power Source Low Speed Sensor ................................................. 40-347
(T/M) ............................................................... 40-291 Failure code [DLM3KA] Rad Fan Spd Sen
Failure code [DAQ9KQ] Inconsistency of Model Selection Opn/Shrt Cir .................................................... 40-349
(T/M) ............................................................... 40-293 Failure code [DLM3LC] Rad Fan Spd Sen Sig
Failure code [DAQLKA] Op Lamp Open Cir Error ................................................................ 40-351
(T/M Cont)....................................................... 40-294 Failure code [DLM3MB] Rad Fan Spd Sen
Failure code [DAQLKB] Op Lamp Shrt Cir Error ................................................................ 40-352
(T/M Cont)....................................................... 40-296 Failure code [DLT3KA] Disconnection of T/M
Failure code [DAQQKR] CAN2 Discon output Speed Sensor ...................................... 40-353
(Transmission Con) ........................................ 40-298 Failure code [DW4BKA] Disconnection of Parking Brake
Failure code [DAQRMA] Inconsistency of Option Selection Valve ............................................................... 40-355
(T/M) ............................................................... 40-299 Failure code [DW4BKB] Ground Fault of Parking Brake
Failure code [DB2QKR] CAN2 Discon Valve ............................................................... 40-357
(Engine Con)................................................... 40-300 Failure code [DW4BKY] Hot Short of Parking Brake
Failure code [DD1PKB] Abnormality of Solenoid .......................................................... 40-359
RPM Switch .................................................... 40-304 Failure code [DW7BKA] Rad Fan R Sol
Failure code [DD1QKB] Abnormality of Opn Cir............................................................ 40-361
RPM Set Mode Switch.................................... 40-306 Failure code [DW7BKB] Rad Fan R Sol
Failure code [DDB6L4] Parking brake Gnd Flt ............................................................ 40-363
signal error...................................................... 40-308 Failure code [DW7BKY] Rad Fan R Sol
Failure code [DDTHKA] Disconnection of Fill Switch Shrt Cir............................................................ 40-365
(FH)................................................................. 40-310 Failure code [DX16KA] Rad Fan Pump EPC Sol
Failure code [DDTJKA] Disconnection of Fill Switch Opn Cir............................................................ 40-367
(FL) ................................................................. 40-311 Failure code [DX16KB] Rad Fan Pump EPC Sol
Failure code [DDTKKA] Disconnection of Fill Switch Gnd Flt ............................................................ 40-369
(1st)................................................................. 40-312 Failure code [DX16KY] Rad Fan Pmp EPC Sol
Failure code [DDTLKA] Disconnection of Fill Switch Shrt Cir............................................................ 40-371
(2nd) ............................................................... 40-313 Failure code [DXH1KA] Disconnection of ECMV Solenoid
Failure code [DDTMKA] Disconnection of Fill Switch (Lockup) .......................................................... 40-373
(3rd) ................................................................ 40-314 Failure code [DXH1KB] Ground Fault of ECMV Solenoid
Failure code [DDTNKA] Disconnection of Fill Switch (Lockup) .......................................................... 40-375
(R)................................................................... 40-315 Failure code [DXH1KY] Hot Short of ECMV Solenoid
Failure code [DDTPKA] Disconnection of Fill Switch (Lockup) .......................................................... 40-377
(4th) ................................................................ 40-316 Failure code [DXH2KA] Disconnection of ECMV Solenoid
Failure code [DF10KA] Disconnection of (High) .............................................................. 40-379
Shift Lever Input.............................................. 40-317 Failure code [DXH2KB] Ground Fault of ECMV Solenoid
Failure code [DF10L4] Gear Speed/Travel Direction (High) .............................................................. 40-381
Signal Error..................................................... 40-321 Failure code [DXH2KY] Hot Short of ECMV Solenoid
Failure code [DGF1KX] Out of Range of T/M Oil Temp. (High) .............................................................. 40-383
Sensor ............................................................ 40-324 Failure code [DXH3KA] Disconnection of ECMV Solenoid
Failure code [DGH2KB] Ground Fault of Hydraulic (Low) ............................................................... 40-385
Oil Temp. S..................................................... 40-326 Failure code [DXH3KB] Ground Fault of ECMV Solenoid
Failure code [DGT1KX] Out of Range of T/C Oil Temp. (Low) ............................................................... 40-387
Sensor ............................................................ 40-328 Failure code [DXH3KY] Hot Short of ECMV Solenoid
Failure code [DGT7KB] Ground Fault of Diff Oil Temp. (Low) ............................................................... 40-389
S.(C) ............................................................... 40-330 Failure code [DXH4KA] Disconnection of ECMV Solenoid
Failure code [DHT5KX] Out of Range of T/C Input Pressure (1st)................................................................. 40-391
Sensor ............................................................ 40-331 Failure code [DXH4KB] Ground Fault of ECMV Solenoid
Failure code [DHT5L6] Failure of T/C Oil (1st)................................................................. 40-393
Press Sensor .................................................. 40-333 Failure code [DXH4KY] Hot Short of ECMV Solenoid
Failure code [DJF1KA] Disconnection of (1st)................................................................. 40-395
Fuel Level Sensor........................................... 40-335 Failure code [DXH5KA] Disconnection of ECMV Solenoid
Failure code [DK70KX] Out of Range of (2nd)................................................................ 40-397
Inching Potentio. ............................................. 40-337 Failure code [DXH5KB] Ground Fault of ECMV Solenoid
Failure code [DKD0KX] Out of Range of Articulated Angle (2nd)................................................................ 40-399
Sensor ............................................................ 40-339 Failure code [DXH5KY] Hot Short of ECMV Solenoid
Failure code [DLF1KA] Disconnection of T/M Input Speed (2nd)................................................................ 40-401
Sensor ............................................................ 40-341 Failure code [DXH6KA] Disconnection of ECMV Solenoid
(3rd) ................................................................ 40-403
4 GD535-5
(02)
Index
Failure code [DXH6KB] Ground Fault of ECMV Solenoid H-28 Fan revolution is abnormal (Fan sound/vibration is
(3rd)................................................................. 40-405 abnormally large or engine overheats)........... 40-561
Failure code [DXH6KY] Hot Short of ECMV Solenoid Handle battery disconnect switch ........................ 30-169
(3rd)................................................................. 40-407 Handle compressor oil ........................................... 80-74
Failure code [DXH7KA] Disconnection of ECMV Solenoid Handling cylinder cutout mode operation............... 30-36
(Reverse) ........................................................ 40-409 Handling fuel system devices ................................ 30-31
Failure code [DXH7KB] Ground Fault of ECMV Solenoid Handling high-voltage circuit of engine controller 30-162
(Reverse) ........................................................ 40-411 Handling no-injection cranking operation............... 30-37
Failure code [DXH7KY] Hot Short of ECMV Solenoid Handling of connectors newly used for engines .... 00-35
(Reverse) ........................................................ 40-413 Handling of electric equipment and
Failure code [DXHHKA] Disconnection of ECMV Solenoid hydraulic component ........................................ 00-26
(4th)................................................................. 40-415 Handling voltage circuit of engine controller .......... 30-38
Failure code [DXHHKB] Ground Fault of ECMV Solenoid How to proceed in troubleshooting ........................ 40-14
(4th)................................................................. 40-417 How to read electric wire code............................... 00-38
Failure code [DXHHKY] Hot Short of ECMV Solenoid How to read matrix............................................... 40-563
(4th)................................................................. 40-419 How to read the shop manual ................................ 00-22
Failure code list....................................................... 40-34 How to read this manual .......................................... 50-9
Final drive ................................................... 10-65, 60-30 How to use troubleshooting table......................... 40-522
Floor electric circuit diagram................................... 90-31 Hydraulic circuit diagram........................................ 90-11
Flushing procedure for torque converter and transmission Hydraulic cylinder................................................. 10-113
circuits ............................................................... 30-74 Hydraulic diagrams and drawings............................ 90-8
Foreword and general information.......................... 00-17 Hydraulic piping drawing of brake system ............. 10-82
Frame ..................................................................... 10-98 Hydraulic piping drawing of work equipment ....... 10-102
Frame and center hinge pin.................................... 60-36 Hydraulic system............... 10-100, 30-95, 50-227, 60-37
Front axle.................................................... 10-55, 60-24 Hydraulic tank ........................................... 10-105, 60-37
Functions and valve operations ............................ 10-112
I
H Information described in
H-1 Engine speed drops significantly or troubleshooting table ............................. 40-45, 80-51
engine stalls .................................................... 40-528 Information related to troubleshooting ................... 40-13
H-2 Machine does not move off............................ 40-529 Input and output signals of air conditioner
H-3 Gear speed does not shift.............................. 40-530 control panel..................................................... 80-29
H-4 Travel speed or power is low. ........................ 40-531 Inspection procedure before troubleshooting......... 40-17
H-5 Torque converter lockup does not operate or is not Installation locations of air conditioner parts and
canceled.......................................................... 40-534 arrangement of connectors .............................. 80-32
H-6 Machine starts or gear speed shifts with
long time lag.................................................... 40-535 K
H-7 Torque converter oil temperature is high. ...... 40-538 KOMTRAX system............................................... 10-162
H-8 Differential gear lock function does not operate or KOMTRAX terminal ............................................. 10-163
is not canceled. ............................................... 40-541 KOMTRAX terminal start-up procedure ............... 30-163
H-9 Steering speed or power is insufficient. ......... 40-542
H-10 Steering wheel does not move..................... 40-543
H-11 Wheel brakes do not work or are weak........ 40-544 L
H-12 Wheel brakes are not released or drag........ 40-545 Layout drawing of electrical system ..................... 10-136
H-13 Parking brake does not work or it is weak ... 40-546 Leaning cylinder..................................................... 60-42
H-14 Parking brake (including emergency release system) Lifter .......................................................... 10-128, 60-54
is not released or drags................................... 40-547 Locations of fuses ................................................ 40-104
H-15 All work equipment operates slowly or
lacks power ..................................................... 40-548 M
H-16 Work equipment does not operate............... 40-549 Machine monitor .................................................. 10-140
H-17 Unusual noise is heard from around Main relief valve and torque converter
hydraulic pump................................................ 40-550 relief valve ............................................. 10-53, 60-23
H-18 Blade lift speed or power is low. .................. 40-551 Method for checking blower AMP .......................... 80-44
H-19 Hydraulic drift of lifted blade is large. ........... 40-552 Method for checking evaporator temperature
H-20 Drawbar side shift speed or power is low .... 40-553 sensor............................................................... 80-42
H-21 Blade side shift speed or power is low......... 40-554 Method for checking temperature control function. 80-40
H-22 Power tilt speed or power is low. ................. 40-555 Method for connecting service tool ........................ 80-71
H-23 Articulate speed or power is low. ................. 40-556 Method for testing air leakage (duct) ..................... 80-37
H-24 Leaning speed or power is insufficient......... 40-557 Method for testing fresh/recirc air changeover....... 80-41
H-25 Hydraulic drift (tilting) of leaning is large. ..... 40-558 Method for testing relays........................................ 80-43
H-26 Blade does not rotate................................... 40-559 Method of disassembling and connecting push-pull type
H-27 Lifter lock pin is not locked or coupler.............................................................. 00-44
is not canceled. ............................................... 40-560
GD535-5 5
(02)
Index
O Removal and installation of engine controller

Outline of refrigeration cycle................................... 80-14 assembly......................................................... 50-296
Removal and installation of engine front oil seal .... 50-85
Removal and installation of engine hood
P
assembly......................................................... 50-112
Parking brake .............................................. 10-97, 60-35
Removal and installation of engine rear oil seal ..... 50-88
Parking brake solenoid valve and lifter lock pin solenoid
Removal and installation of engine, transmission,
valve ...................................................... 10-96, 60-41
and torque converter assembly....................... 50-116
Pilot check valve................................................... 10-115
Removal and installation of floor frame assembly 50-276
Pm Clinic .............................................................. 30-172
Removal and installation of fuel tank assembly.... 50-108
Points to remember when troubleshooting ............. 40-13
Removal and installation of hydraulic tank
Power tilt cylinder ................................................... 60-47
assembly......................................................... 50-234
Power train ................................................ 30-54, 50-116
Removal and installation of hydraulic tank, battery, and
Power train hydraulic circuit diagram...................... 90-15
frame assembly............................................... 50-227
Power train piping drawing ..................................... 10-20
Removal and installation of injector assembly........ 50-55
Power train pump ...................................... 10-107, 60-39
Removal and installation of KOMTRAX terminal
Power train pump and
assembly......................................................... 50-303
differential lock pump........................... 10-108, 60-40
Removal and installation of machine monitor
Power train system ...................................... 10-19, 60-12
assembly......................................................... 50-298
Power train system drawing ................................... 10-19
Removal and installation of operator cab glass
Precautions for disconnecting and connecting hoses and
(adhered glass) ............................................... 50-266
tubes in air conditioner pipings ......................... 80-72
Removal and installation of operator's cab and floor frame
Precautions for refrigerant ........................................ 80-8
assembly......................................................... 50-280
Precautions when carrying out work....................... 00-41
Removal and installation of operator's cab
Preheating circuit.................................................. 10-171
assembly......................................................... 50-257
Preparatory work for troubleshooting of electrical system
Removal and installation of Orbitrol valve
failure .............................................................. 30-170
assembly......................................................... 50-203
Priority valve ........................................................... 10-70
Removal and installation of power train oil cooler
Procedure for testing diodes ................................ 30-111
assembly......................................................... 50-105
Removal and installation of radiator assembly ....... 50-97
R Removal and installation of rearview camera ....... 50-301
Rear axle ..................................................... 10-58, 60-26 Removal and installation of supply pump
Rearview camera ................................................. 10-167 assembly........................................................... 50-51
Rearview monitor ................................................. 10-166 Removal and installation of tandem drive and final drive
Rearview monitor system ..................................... 10-165 assembly......................................................... 50-172
Receiver drier ......................................................... 80-23 Removal and installation of transmission controller
Related information on disassembly and assembly......................................................... 50-299
assembly............................................................. 50-9 Removal and installation operator's seat.............. 50-293
Releasing parking brake manually ......................... 30-92 Removal and installation seat belt ........................ 50-294
Releasing remaining pressure from brake circuit ... 30-83 Retrieval of disabled machine due to transmission valve
Releasing remaining pressure from fuel system .... 30-32 failure ................................................................ 30-71
Removal and installation of aftercooler Ripper ........................................................ 10-134, 60-57
assembly......................................................... 50-101 Ripper cylinder........................................................ 60-49
Removal and installation of air conditioner compressor ROPS cab............................................................. 10-135
assembly......................................................... 50-114
Removal and installation of air conditioner compressor S
belt .................................................................... 50-82
S-1 Engine startability is poor. .............................. 40-566
Removal and installation of air conditioner
S-2 Engine does not start. .................................... 40-567
unit assembly.................................................. 50-287
S-3 Engine does not pick-up smoothly. ................ 40-570
Removal and installation of alternator belt ............. 50-83
S-4 Engine stops during operation. ...................... 40-571
Removal and installation of blade assembly ........ 50-247
S-5 Engine runs rough or is unstable. .................. 40-572
Removal and installation of center hinge pin........ 50-216
S-6 Engine lacks power. ....................................... 40-573
Removal and installation of circle drawbar
S-7 Exhaust smoke is black
assembly......................................................... 50-248
(Incomplete combustion)................................. 40-574
Removal and installation of circle rotation gear
S-8 Large oil consumption
assembly......................................................... 50-250
(or blue exhaust gas) ...................................... 40-575
Removal and installation of control valve
S-9 Oil becomes contaminated early.................... 40-576
assembly......................................................... 50-238
S-10 Fuel consumption is excessive. ................... 40-577
Removal and installation of cooling fan and fan motor
S-11 Oil is in coolant (or coolant spurts back or
assembly........................................................... 50-93
coolant level goes down) ................................ 40-578
Removal and installation of cooling fan pump
S-12 Oil pressure drops........................................ 40-579
assembly........................................................... 50-91
S-13 Oil amount increases
Removal and installation of cylinder head
(due to water or fuel mixing). .......................... 40-580
assembly........................................................... 50-64
6 GD535-5
(02)
Index
S-14 Coolant temperature rises too high Testing muffler (main body) and stacked muffler for
(overheating). .................................................. 40-581 looseness and damage .................................... 30-39
S-15 Unusual noise is heard................................. 40-582 Testing muffler function.......................................... 30-40
S-16 Vibration is excessive................................... 40-583 Testing of engine piping for damage and
Safety notice ........................................................... 00-17 looseness ......................................................... 30-42
Scarifier cylinder ..................................................... 60-48 Testing oil leakage of steering cylinder.................. 30-81
Sensors................................................................. 10-172 Testing oil leakage of work equipment cylinder ... 30-102
Sketches of special tools ........................................ 50-23 Testing power train oil pressure............................. 30-54
Special functions of machine monitor ................... 30-113 Testing wear of wheel brake disc........................... 30-88
Special tool list........................................................ 50-15 Testing work equipment oil pressure ..................... 30-95
Specification drawing.................................................01-8 Tire......................................................................... 10-99
Specifications................................................ 01-8, 01-10 Tools for testing, adjusting, and troubleshooting ..... 30-9
Specifications of air conditioner .............................. 80-12 Torque converter......................................... 10-22, 60-12
Standard tightening torque table............................. 00-47 Transmission............................................... 10-25, 60-14
Standard value table................................................. 20-8 Transmission control.............................................. 10-21
Standard value table for engine................................ 20-8 Transmission control valve .................................... 10-44
Standard value table for machine ........................... 20-10 Transmission controller........................................ 10-156
Steering cylinder ..................................................... 60-33 Troubleshooting by failure code
Steering piping drawing .......................................... 10-69 (display of code) ............................................. 40-107
Steering system .................. 10-69, 30-80, 50-203, 60-33 Troubleshooting of electrical system (E-mode).... 40-421
Steering valve ......................................................... 10-75 Troubleshooting of engine (S-mode) ................... 40-563
Swivel joint............................................................ 10-114 Troubleshooting of hydraulic and mechanical system
Symbols used in electric circuit diagrams ............... 90-17 (H-mode) ........................................................ 40-522
Symbols used in hydraulic circuit diagrams.............. 90-8 Troubleshooting using gauge pressure.................. 80-68
Symptoms and troubleshooting numbers ............... 40-42
System operating lamp system............................. 10-138 U
Undercarriage and frame ............... 10-98, 50-216, 60-36
T
Table of contents ...................................................... 00-2 W
Table of fuel, coolant, and lubricants ...................... 01-17 Weight table ........................................................... 01-16
Tandem drive.............................................. 10-67, 60-32 Wheel brake................................................ 10-95, 60-34
T-box and T-adapter list.......................................... 40-99 Work equipment........................... 30-106, 50-247, 60-50
Test evaporator temperature sensor ...................... 80-42 Work equipment control ....................................... 10-104
Test relays .............................................................. 80-43 Work equipment pump and
Testing air conditioner using self-diagnosis steering pump...................................... 10-106, 60-38
function.............................................................. 80-39
Testing air leakage (duct) ....................................... 80-37
Testing and adjusting air conditioner compressor belt
tension............................................................... 30-47
Testing and adjusting brake oil pressure ................ 30-84
Testing and adjusting circle guide clearance........ 30-107
Testing and adjusting differential lock oil pressure
(differential lock specification) ........................... 30-78
Testing and adjusting parking brake pad................ 30-89
Testing and adjusting slip clutch type circle drive. 30-109
Testing and adjusting steering oil pressure ............ 30-80
Testing and adjusting toe-in.................................... 30-76
Testing blowby pressure......................................... 30-29
Testing boost pressure ........................................... 30-18
Testing compression pressure................................ 30-26
Testing cooling fan circuit oil pressure.................. 30-100
Testing cooling fan speed....................................... 30-99
Testing engine oil pressure..................................... 30-30
Testing engine speed ............................................. 30-16
Testing exhaust gas color....................................... 30-22
Testing exhaust gas temperature ........................... 30-20
Testing fresh/recirc air changeover ........................ 80-41
Testing fuel circuit for leakage ................................ 30-35
Testing fuel discharge, return rate, and leakage .... 30-43
Testing fuel pressure .............................................. 30-33
Testing installed condition of cylinder heads and
manifolds........................................................... 30-41
Testing lifter lock pin circuit pressure...................... 30-97
GD535-5 7
(02)
GD535-5 MOTOR GRADER
Form No. SEN06650-02
©2017 KOMATSU
All Rights Reserved
Printed in Japan 11-17 (01)

Serviços 02 Ingles Sen06650-02

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SEN06650-02

MOTOR GRADER GD535 -5

SERIAL NUMBERS 1001 and up

() Page to be deleted Discard

List of revised pages

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10 Structure and function

Undercarriage and frame .......................................................................................................................... 10-98

20 Standard value table

30 Testing and adjusting

Testing exhaust gas temperature........................................................................................................... 30-20

Preparatory work for troubleshooting of electrical system failure ........................................................ 30-170

E-36 Left door wiper does not operate................................................................................................. 40-512

50 Disassembly and assembly

Special tool list ....................................................................................................................................... 50-15

90 Diagrams and drawings

Electronically Traveling This system ensures smooth high-speed travel by

Communication Global navigation satellite system A general term

Steering This function uses a combination of hydraulic motor

The structure to protect the operator (fastened with

*1: Applicable model codes

Abbreviations used in circuit diagrams 1

Foreword and general information 1

2. Preparation work 7) When removing components, be careful not to

4. Precautions for sling work and making signals

If the load is unstable or the wire rope or

8. Precautions for disconnecting and connecting

a For tightening torque, see the precau-

How to read the shop manual

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

60. Maintenance standard

Revision and distribution

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

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

Explanation of terms for maintenance standard

1. Standard size and tolerance

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

2. Standard clearance and standard value 5. Clearance limit

4. Repair limit and allowable value or allowable

Handling of electric equipment and hydraulic components

Points to remember when handling electric equip-

2) Defective crimping or soldering of connectors

4) High-pressure water entering connector

3. Removing, installing, and drying connectors

2] When removing from clips

q When removing a connector from a clip,

3] Action to take after removing connectors

2] Fix the connector securely.

3) DT connector (DT 8-pole, 12-pole)

4) Drying wiring harness

2] Dry the inside of the connector with a dryer.

3] Carry out a continuity test on the connector.